Todays Headlines

Industrial Techno-vation Challenge

15th April, 2013

Problem Statement
Study energy shortages of textile industry and suggest how this problem can be addresses in a cost effective way

Energy Shortages- Pakistan

Natural Gas - Supply: 5.8 bcfd - Demand: 7.1 bcfd Electricity -Supply: 1,3500 MW -Demand: 1,8000 MW
(Source: Pakistan Energy Yearbook-2011)

Textile Industry (Brief intro)

Pakistan holds the distinction of being: - worlds 4th largest producer of cotton - worlds 3rd largest consumer in the world Textile industry economic contribution: Exports 60%, Manufacturing 46%, Employment 30%
(Source: Economic Survey of Pakistan)

Pakistan is among top 10 textile exporters of the world. China $55 billion, Hong Kong $38 billion, Korea $35 billion Taiwan $16 billion, Indonesia $11billion , India $11billion Bangladesh $11billion, Pakistan $11billion
(Source: Pakistan Textile Journal)

Trend of Textile Industry during last 10 years

YEARS 2001-02
GROWTH

4.10%

2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11

State Bank of Pakistan

5.20% 20% 24.50% 11.23% 8.40% 4.05% -0.70% -1.78% 1%

Source: Economic Survey of Pakistan

Energy Shortages Textile Sector

In 2011-12 energy crisis lead to decline in exports by 25-30 percent. This quantity worth $1.9 billion is not being exported, due to the fact that this quantity was never produced
(Said by: Gohar Ejaz, the former Chairman of APTMA, Reported in Pakistan Textile Journal- May 2012 Edition)

Total demand of textile industry is not more than 500 mmcfd out of 4000 mmcfd gas totally available in the country, which is 12.5%.
(Said by Chairman APTMA Punjab Shahzad Ali Khan, Reported in The Nation)

Textile industry was denied gas for 77 days in 2008-09, followed by 100 days in 2009-10 and 157 days in 2010-11
(Adviser to Prime Minister on Petroleum Dr Asim Hussain, Reported in The Nation)

Energy Shortages Textile Sector

Energy supply disruption is causing a loss of Rs1 billion per day, rendering 70 per cent daily-wagers jobless.
(Said by: PTEA Chairman Asghar Ali, Reported in The Nation)

350 megawatts (MW) power is required for the textile sector to enable the industry to get rid of power load shedding.
(Source: Daily Times)

Proposed Solutions
Use of Solar Heaters in Textile industry Implementing Energy Efficiency Program in Textile industries Cut-off gas connection to captive power units Bio-CNG concept

Use of Solar Heaters in Textile Industry

Solar Technology in Textile Industry Textile manufacturing process can be broadly divided into Spinning, Weaving and Finishing. Table illustrates the typical temperature requirements :
Industrial Applications Yarn Conditioning Sizing Desizing Scouring Bleaching Mercerizing Dyeing Finishing Application Media Steam Hot Water Hot Water Steam Hot Water Hot Water Hot Water Hot Water Temp Requirement ( Deg. C) 55-60 80-85 60-90 90-110 90-93 60-70 48-80 90-93

Benefits of Solar Installation

Direct Benefits Cost benefit analysis of installation of solar water heating systems after replacing the electrical heaters is expected to give energy saving ranging from 30-37 %.

Indirect Benefits With an impressive payback period of 1-2 year, solar technology applied on yarn-conditioning operation alone can save up to 16,500 kWh/ annum of energy.

Case Study on Solar Heaters

Researcher: Dr. Muhammad Asif Research published: Dawn News (6/9/2004) Industry: Paramount textile industry(medium scale) Given: - 120000 liters of water at 85C / day - Solar initial cost: Rs. 100/ liter So we will base our Calculations on the above mentioned case study

Calculations Total Energy requirement: = In Summer the inlet temperature =20C and outlet Temperature is 85C. So Putting values for Water: 120000 998 4.18 85 20 = 1000 = 30035808

 Now we will find the amount of Natural Gas required for the Heating Purpose. As = 4 = 55.50 103 (/) Assuming Combustion Efficiency of 90% So 55.50 103 = 0.9 30035808 = 487.067 As 1 kg of 4 = 1 MMBTU 19.05 So = 25.5678

Price Calculations
= . 488.23/ /12 = 25.5678 488.23 9 30 /12 = . 4493868.12

Solar Water Heating For setting up a solar water heating Unit the initial Cost is estimated to depend on its capacity in our case capacity is 120,000 litres So using Estimated rate of Rs. 100/ litre as initial cost of venture then total Initial Cost is given as: Total Initial Cost= Rs. 100x120000=Rs.12,000,000

 We Can Find the Pay back time by: =

4

= =

12000000 4493868.12

Total Payback time= 2years & 6month Total Life of Solar Water Heating System is approx. 30 years. So it is a safe and quite wise investment

Implementing Energy Efficiency Program in Textile industries..

Potential:
According to Small and Medium Enterprises Development Authority (SMEDA) and GIZ, a Germany-based organization: Amount Rs.150 million per annum can be saved by textile industry by implementing major Energy Efficiency System in industries. All Pakistan Textile Mills Association (APTMA) : Energy up to 40 million kilowatts hour (kWh) per year, can be saved by implementing major Energy Efficiency System in industries.
(according to report published in DAWN on 2nd November, 2012)

Some of the Energy Efficiency processes are as:

Thermal Energy
Waste heat recovery Recovery of heat from flue gas, engine cooling water and engine exhausts can considerably reduce overall Energy consumption of an industry. Efficient removal of water using heavy squeezing enables 15-20% reduction in energy requirement for drying. Cogeneration: During less busy or idle hours cogeneration should be used.

Energy Efficiency processes (cont'd)

Use smooth, well-rounded air inlet cones for fans/blowers air intakes. Use energy-efficient motors where economical. Avoid poor flow distribution at the fan inlet. Minimize blower speed as current requirement decreases. Compressed Air: Turn off the back-up air compressor until it is needed. Cooling Tower: Turn off unnecessary cooling tower fans when loads are reduced.

Energy Efficiency processes (cont'd)

Insulate exposed heated oil tanks. Burn wastes if permitted. Recycle steam condensate. Use waste steam for water heating. Preheat boiler feed-water. Repair damaged thermal insulation
NITRA has developed a user friendly software that performs energy balance on any machine in a textile mill.

Stop providing gas to Inefficient captive power plants.

Captive Power Plants

Inefficient captive power plants installed at industrial units running on natural gas are causing a loss of Rs70 billion per annum. Efficiency of captive power plants is only 27%. These plants are getting 454mmcfd gas per day, of which 327mmcfd is being lost due to inefficiency. The generation capacity of these plants is 900 MW of electricity by consuming 300 mmcfd gas. The efficient use of 300 mmcfd gas could produce 1,800 MW.
The Planning Commission and Ministry of Water and Power had already termed captive power plants a drain on national resources.
(Said by: Ministry of Petroleum and Natural Resources, Reported by: Business Recorder on 11th April, 2013)

Recommendations:
Stop giving gas to captive power plant and divert this gas to independent power plants which are running on higher efficiency. Support captive power plant owners to lift plants efficiency to minimum 40%. Waste Heat Recovery system should be implemented at each power plant present in the country.

Bio-CNG

CNG Sector
Demand of gas from CNG sector is 325 mmcfd while supply is around 265 mmcfd. But textile sector suffers most due to this ill distribution of gas amongst different sectors of economy. For instance out of 3000 CNG stations, even if 1/3rd are shutdown, total labour force that may become unemployed would be around 15,000 but 100 mmcfd could run a large number of big textile units that employ thousands of workers.
(Source: APTMA & Govt Officials: Reported by Business Recorder)

Our Aim: Feed CNG Stations with Bio-Gas rather than buying gas direcly from gas distribution companies

Bio-gas Pakistans Potential

According to Livestock census 2002-03, there are : Animals (Buffaloes, Cows, Bullocks) in Pakistan= 48 million Average (daily dung dropping) of these animals = 15Kg/animal Total dung dropping =720 million Kg. Assuming 50% collect-ability , Availability of fresh dung = 360 million Kg/ per day

Thus, 18.0 Million M3 biogas @0.05M3/Kg dung can be daily produced by anaerobic fermentation of dung

What CNG Station Owners to do ???

Establish a Biogas Plant near CNG station and produce their own gas (Methane) Instead of Buying it from gas distribution companies.

What Govt. to do ???

Import/develop Technology : 01: To upgrade methane content in Biogas from 50% to 90%. 02: To clean the biogas by removing hydrogen sulfide and carbon dioxide
This has been achieved successfully, technically and commercially recently.
(Source: Newsletter- Bio Master)

Bio-CNG system is acceptable for use in CNG engines ???

Bio-CNG fuel was compared to: - Standards issued by the Society of Automotive Engineers (SAE) - Recommended Practices for Compressed Natural Gas Vehicle Fuel (Cummins Westport fuel specifications) - Pipeline natural gas. The test showed that the Bio-CNG fuel meets or exceeds the specifications.
(Source: Analysis Report published by company called Bio-CNG, LLC-USA)

Thanks for your patience listening