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Overall performance of steam system used in garment industries in Bangladesh: a case study–based approach

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Abstract

The fabric or garments production activities starting from raw material preparation to the finishing process are energy-intensive. Steam generation and distribution system is part of all the major processes involved here. Therefore, this study aims to assess the overall performance of the steam system used in the textile or garment industry in Bangladesh. The quantity of heat loss through different sources both at steam generation and distribution unit was computed. The amount of in-process heat energy consumption was also determined. Current practices in steam system management were investigated, and opportunity for improvement was addressed. Finally, the genetic algorithm approach was used to optimize the process parameters of steam generation unit thermodynamically. The average efficiency of the steam generation units used in the fifteen studied factories was found 76%. The dyeing and ironing processes were found as the most heat energy–intensive process. Among the sources of heat losses, maximum loss was found occurring through the dry flue gas during steam generation. At distribution unit, most heat is lost through the steam line and in-process distribution. Based on the analysis, daily 694 GJ heat passes away through a steam system resulting in 13 tons and 31 tons of fuel wastage and greenhouse gas emission, respectively. Considering the occurring losses, the remedial measures were focused on excess air and stack temperature control, improvement in boiler operating condition, steam leakage and trap maintenance, insulation enhancement, etc. Moreover, by optimizing the thermodynamic process parameters, it is possible to increase energy efficiency by almost 3.0%.

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Abbreviations

\( \dot{m} \) :

Mass flow rate (kg/h)

∆θ :

Temperature difference (°C)

AAS:

Actual sir supply (kg/kg of fuel)

B ex :

Excess blowdown rate (kg/h)

BL:

Heat loss in boiler blowdown (%)

C :

Specific heat (kJ/kg °C)

E :

Steam generation rate (kg/h)

EGB:

Exhaust gas boiler

ETP:

Effluent treatment plant

FL:

Heat loss in dry flue gas (%)

GA:

Genetic algorithm

GCV:

Gross calorific value of fuel (kJ/kg)

GHG:

Greenhouse gas

h :

Enthalpy (kJ/kg)

IL:

Heat loss for incomplete combustion (%)

m :

mass (kg)

M a L :

Heat loss for moisture presence in air (%)

Max.:

Maximum

M f L :

Heat loss for moisture presence in fuel (%)

ML:

Miscellaneous loss (kJ/h)

mm:

Mass of moisture per kg of fuel (kg)

P cw :

Amount of condensate water in RC

P fs :

Amount of flash steam in RC

PM:

Polynomial mutation

Q :

Heat consumption amount (kJ)

RC:

Recoverable condensate

S :

Amount of total dissolved solid (ppm)

SBX:

Simulated binary crossover

T :

Max. permissible concentration of TDS (ppm)

TDS:

Total dissolved solid

UCL:

Heat loss in unrecovered condensate

WL:

Heal loss in wet flue gas (%)

a :

Air

bc :

Blowdown condition

c :

Combustion

cp :

Combustible product

fg :

Dry flue gas

ew :

Water entering economizer

f :

Fuel

fs :

Flash steam

fw :

Feed water

rh :

Reheated steam

s :

Steam

sh :

Superheated steam

w :

Water

w1 :

Water entering economizer

cw :

Condensate water

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Acknowledgments

The authors sincerely acknowledge the University Research Center, Shahjalal University of Science and Technology for providing the financial support to their project titled Optimization of Energy Utilization in Steam Generation Unit Used in Textile and Apparel Industry. The authors are also thankful to the authorities of the concerning garment industries for their administrative support during data collection.

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Authors and Affiliations

  1. Department of Industrial and Production Engineering, Shahjalal University of Science and Technology, Sylhet, 3114, Bangladesh

    S. Saha, M. M. A. Khan & P. K. Biswas

  2. Department of Industrial and Production Engineering, National Institute of Textile Engineering and Research, Dhaka, Bangladesh

    N. A. Sayem

Authors
  1. S. Saha
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  2. N. A. Sayem
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  3. M. M. A. Khan
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  4. P. K. Biswas
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Contributions

M.M.A. Khan and S. Saha contributed to the study conception and design. Material preparation and data collection were performed by N.A. Sayem and P.K. Biswas. M.M.A. Khan and S. Saha analyzed the data. S. Saha wrote the first draft of the manuscript. All authors commented on previous versions of the manuscript. All authors also read and approved the final manuscript.

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Correspondence to M. M. A. Khan.

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Saha, S., Sayem, N.A., Khan, M.M.A. et al. Overall performance of steam system used in garment industries in Bangladesh: a case study–based approach. Energy Efficiency 14, 17 (2021). https://doi.org/10.1007/s12053-021-09929-0

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