Insulation of dyeing machines

Insulation of dyeing machines reduced thermal energy consumption by over 50%, resulting in 20.93 MWh saved and 2.3 million PLN in avoided costs.

The challenge

In a textile plant, significant thermal energy losses were identified on process machines (dyeing machines). Lack of insulation caused:

high thermal energy consumption during heating and temperature stabilization,
heat radiation to the surroundings,
the need for greater cooling energy later in the process.

The objective of the work was to reduce thermal energy losses and improve the efficiency of the entire dyeing process.

Our approach

DB Energy engineers designed and implemented modernization consisting of:

application of insulation on dyeing machines using synthetic rubber with aluminum covering,
measurements of thermal power and cooling water parameters for insulated and non-insulated machines,
comparison of results for comparable processes to assess investment profitability.

DB Energy engineers during project implementation

Solution

Insulation reduced thermal energy losses during heating and stabilization of process water temperature. Although insulation increased the demand for cooling (due to reduced heat loss to the surroundings), clean cooling water could be reused in the process as process water.

The investment cost was 213.9 thousand PLN.

Results

Actions undertaken by DB Energy resulted in:

reduction of thermal energy consumption by over 50%,
annual energy savings: 20.93 MWh,
avoided costs: 2.3 million PLN,
possibility to reuse cooling water as process water,
improved efficiency of the entire dyeing process.

reduction of thermal energy losses and improvement of the entire dyeing process efficiency — Reduction of thermal energy losses and improvement of the entire dyeing process efficiency

Conclusions

Insulation of process equipment, even with relatively simple technologies, allows significant reduction of energy losses. An additional benefit is the possibility of utilizing cooling water, which enhances the energy and economic effect of the modernization.

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