IMPROVEMENT IN CONDENSATE RECOVERY FOR ENERGY CONSERVATION USING SIX SIGMA METHODOLOGY IN A TEXTILE INDUSTRY /

Abstract

The hot byproduct of steam, called condensate, still retains 25% of the energy from the original steam. Rather than draining it, it makes more sense to return it to the boiler. In today's world, energy is a precious resource and we are facing an energy crisis. Pakistan is currently experiencing one of the worst energy crises in its history. As a result, the textile industry is struggling due to high production costs compared to other global markets. However, condensate has now become a valuable resource that can significantly reduce operating costs. Every day, approximately 840 m3 of water is fed into the coal-fired steam boiler, which generates 820 tons of steam. 300 tons of steam are supplied to Processing Div. II, with 80 tons used directly on machines and the remaining steam used indirectly through heat exchangers. This leaves about 154 m3 of condensate at 80-90 ℃ that can either be wasted or returned to the system for reuse. This report serves as an optimized tool for conducting a cost-benefit analysis of condensate recovery systems. Advanced techniques were used to identify the root causes of condensate wastage. A detailed audit of the Processing Div. II was conducted, data was collected and analyzed, and potential improvements were identified. Some repair and maintenance activities were completed and others are currently in progress. Ultimately, a model will be designed to find potential savings by upgrading the current condensate recovery system. This report promotes a zero-drain approach in the textile industry, contributing to a sustainable environment and reducing fabric costs.