Textile Industry Experts Exchange Energy Saving And Emission Reduction Technologies

　　 Eight areas to enhance energy saving space

Zhengzhou Hongda spinning new technology consulting Co., Ltd. Wang Weimin

Core view: at present, the entire textile industry is facing environmental pressure. The government is facing pressure of indicators, and enterprises are facing pressure from capital, technology and cost. The development of printing and dyeing industry will be affected by environmental protection, which will affect the entire textile industry. The pressure of emission reduction is far greater than that of energy conservation. Therefore, enterprises must pay attention to the ecological problems in every link of the production process, and speed up the work of energy conservation and emission reduction.

Since 2011, experts from the China Textile Federation and the Jiangsu environmental protection and Development Commission have successively conducted energy saving "voluntary consultation" for 8 enterprises of Dasheng Group Co., Ltd., Wuxi first cotton mill, Anhui Huamao Group Co., Ltd., Huarun Textile Group Co., Ltd., mutual Textiles Holdings Limited, cheerful home textiles, Jiangsu sunshine group, Yaguang home textiles, etc. Through voluntary consultation, we believe that enterprises should transform from labor-intensive to technology intensive, such as Wuxi one cotton, which has high quality, low energy consumption, less employment, and 25 workers employing ten thousand ingots. To gather from scattered to the park, the park has high resource allocation and low cost; from low level expansion to industrial chain integration, high-end products and industrial chain should be extended; from high energy consumption to low carbon ecology, because this can directly reduce costs.

In terms of energy saving in building systems, it is proposed to revise the energy conservation design standard for cotton textile factories, and balance the utilization of surplus heat (hot air) in the workshop. The photoelectric design and photothermal load should be reserved for roofing design, and the rainwater collection and reuse system should be reserved for water supply and drainage design, considering the design of multi-storey factory buildings.

In terms of energy saving in air-conditioning system, it is recommended to standardize the air conditioning design standards for cotton textile factories, set up regional design standards, standardize the catalogue of technical equipment for textile air-conditioners, spray, refrigeration and heating, adopt efficient motor and function control, and strengthen the utilization of surplus heat (hot air) in winter, and adopt a variety of cooling and cooling methods in summer.

In terms of energy saving in motor system, it is suggested that YE3 (two level), YE2 and YX3 can be selected according to the rational load of motor and the replacement of high efficiency motors, and the frequency conversion motor should be selected reasonably to replace the economic analysis of the motor.

In terms of energy saving in the boiler system, clean fuels such as natural gas, biomass fuel, condensate water reuse, and efficient insulation measures should be adopted to reduce heat loss.

In terms of clean power quality, a single machine with larger current and larger power can be used to filter out harmonics. A single machine with small current and small power can be controlled remotely by multiple computers. It is suggested to use active power filter and increase series reactors to reduce the amplification of harmonics by the capacitor, and build an online monitoring system for power quality so as to find out the hidden harm of harmonics to the system in time.

In terms of air pressure system, it is suggested to install expert control system for air compressor cluster, auxiliary system for air compressor energy saving, desiccant, water pump, gas storage tank, cooling water circulation monitoring system, electricity metering, gas flow metering management system, gas supply pipeline detection system; according to the technology, reasonable selection of compressed air pressure, gas tank capacity, pipe diameter and process should be rationally selected; the location of air compressor station should be selected rationally, and the air pressure hot air and hot water recovery can be effectively utilized to configure the number of centrifuges and screw machines to meet the optimal matching of energy consumption, and the power frequency machine and frequency converter should be equipped to adapt to the fluctuation of gas consumption.

Energy management system, the enterprise energy consumption online monitoring and management platform can better solve the problems of manual meter reading report, data analysis seriously lagged behind, data randomness, and can not feedback in time. The construction of energy online monitoring management system and production network management and control system can reduce the operation cost of energy system, improve labor productivity, increase the response speed of emergency, optimize power scheduling and balance power consumption, and save energy consumption.

In terms of process management system, reasonable design method drafting and distributing process; under the premise of satisfying quality, reasonably modulate and use cotton, increase production rate and reduce unit consumption; ensure equipment condition, rationally select equipment, improve equipment yield and reduce energy consumption; rationally deploy air-conditioning system to meet the best temperature and humidity in spinning and weaving process; and weaving system to rationally allocate yarn quality and sizing quality.

　　 Five key points to achieve cleaner production

Guangzhou Hong Yu Environmental Protection Technology Co., Ltd. Yang Aimin

The core point is that cleaner production is a new thing, a way of thinking and a way of thinking. We need to correctly understand and apply the principles and methods of cleaner production, fully mobilize the leadership and staff of enterprises, improve the management and change the thinking with the reality of enterprises, constantly find the space of energy conservation and consumption reduction, and find ways to reduce production costs and find ways to reduce the production and discharge of pollutants. Cleaner production is a continuous work. Continuous process requires long-term adherence of enterprises.

After years of clean production practice, we summarize the following five key points:

First, pay attention to source control, material and energy consumption, pollutant emissions and accidents and problems are the three sources of cleaner production of textile and dyeing enterprises. Specifically, controlling the source of material and energy consumption is to control costs. This is what most enterprises attach importance to. The source of controlling pollutants is to reduce unnecessary pollution. The source of controlling accidents and problems is to control costs. This requires a series of systematic work to achieve the goal, such as controlling the success rate of technology.

The two is to carry out energy saving and water saving work systematically. After years of publicity and guidance, energy saving and water saving technologies and technologies have been taken seriously by most enterprises. However, in concrete practice, no specific or systematic analysis of water-saving and energy saving will be made, and the efficiency will be greatly reduced, which may cause unnecessary losses. The correct way should be systematic analysis of water consumption and energy consumption, and the implementation plan and measures should be determined on the basis of systematic analysis. For example, in the process of fabric washing, enterprises can reduce the energy consumption by lowering the water temperature. But if the waste heat recovery work is done well and there are more hot water, then we can use the method of raising the washing temperature and reducing the washing times to save water.

Three is the bold use of new technology and new equipment. At present, the enthusiasm of enterprises to use new equipment and new technology has been greatly improved than before. However, some enterprises are limited to inertial thinking in the process of using new equipment and new technologies. For example, in batch dyeing, we are willing to accept the low bath ratio dyeing technology such as air flow dyeing machine, but are less willing to accept cold pad dyeing technology. This is not only restricted by the lack of skilled personnel, but also related to the consciousness of the responsible person.

Four is to improve management means and strengthen management ability. It is necessary to invest funds in purchasing equipment and implement water-saving, energy saving and cleaner production projects, which can greatly improve the level of cleaner production of enterprises. However, it is unrealistic to put all the hope of improving the level of cleaner production in the investment of equipment, and it should also be realized through management. On the contrary, under the existing conditions, the level of cleaner production can be improved by strengthening management. With the continuous development of various technologies, management means should also be improved. Therefore, in terms of management, we should not only strengthen, but also innovate the system to adapt to the development of the new situation.

Five, efforts should be made to overcome some problems existing in the printing and dyeing industry. Such as heavy branches, light systems, heavy equipment, light management, heavy investment, light maintenance, heavy hardware, light talent and so on.

　 Solar thermal utilization technology has broad prospects for development.

Beijing Zhongke Xi Yuan energy saving Technology Co., Ltd. Miao Jingyi

The core point of view is to combine the demand for energy in China's industrial field, and develop a feasible and efficient unit solar energy medium temperature conversion and utilization device according to the requirements of low cost and large-scale utilization of solar energy, and promote the industrialization and large-scale utilization of solar energy medium temperature collector. It is of great significance to improve the efficiency and reliability of the solar energy energy conversion device and promote the application of solar energy in many fields such as industrial heating.

Due to the poor utilization of solar energy and the lack of communication between industrial and energy industries, the application of solar thermal technology in China's industrial field is relatively slow. Apart from Changshu Kaida printing and dyeing factory, Foshan Jia Lida textile printing and dyeing mill and Zhejiang Daly printing and dyeing mill, few other companies use solar energy medium temperature heat utilization technology. Foreign research on the application of solar thermal technology in the industrial field began in the late 70s of last century. 12 countries in Europe and the United States have investigated and studied the hot grade in the industrial field. The International Energy Agency launched the solar heating and cooling plan (IEASHC) in 1976. In 1977, the solar thermal power and solar energy chemical energy system plan (SolarPACESProgram) was launched by the 7 countries of the United States, Russia, Germany, Australia, Israel, Switzerland and Spain as the Executive Committee. The current situation of solar energy technology and its application in the industrial thermal process were also studied.

The industrial sector is the largest consumer of energy in China. According to statistics, the total energy consumed by industrial production accounts for 70% of the total energy consumption of the whole country, of which 50% to 70% is the heat for industrial processing. For different industrial sectors, the heat load distribution is also different, but the temperature generally does not exceed 250 degrees, and the pressure is below 9 atmospheric pressure. According to the thermal demand of industrial thermal process, nine industries, such as tobacco, textile, medicine, food, paper and building materials, were selected to analyze the heating potential of solar energy industry. These industries account for 22.5% of the gross industrial product, and the total energy consumption of the research industry accounts for more than 22.7% of the total industrial energy consumption.

{page_break}

In China, because of their different production processes, the above industries differ greatly in their thermal energy consumption. According to the data of 2007, the higher value of thermal energy consumption is chemical industry, paper making industry, food processing industry and textile industry. In the future development, paper industry, food industry and textile industry have great potential to apply solar thermal technology. It is estimated that if 10% of the heating energy in different industries is supplied by solar energy, the required collector area will reach 1 billion 100 million square meters. The industry studied has 10% thermal energy substitution, the annual energy can reach 26 million 630 thousand tons, and the emission reduction of carbon dioxide is 93 million 340 thousand tons. The required collector area is 273 million 330 thousand square meters, much larger than the collector area of the existing solar water heater. According to the current solar hot water system, the installed area of hot water is installed at 150 million square meters and the annual output value is 65 billion yuan. The industrial heating of solar energy is widely applied in the industries analyzed. The thermal energy consumption is 10%. The solar energy is replaced by the medium temperature heating. The annual output value reaches at least 100 billion yuan, corresponding to the annual coal consumption of about 1 million tons. The simple calculation corresponds to the emission reduction of 3.2 billion tons of carbon dioxide. According to China's emission of carbon dioxide in 2006, the emission reduction is about 5%.

　　 Three levels of implementation Digitalization of printing and dyeing

Gu Ren, Changzhou Hongda Technology Group

The core point is: the successful application of intelligent management and control system of textile printing and dyeing greatly improves the automation of the production process of textile printing and dyeing enterprises. By realizing the digital management of the production process, it provides strong support for the upgrading of enterprises, guarantees the optimization of production process, improves product quality, improves the production conditions of workers, and fundamentally changes the production mode of enterprises, thus greatly reducing production and management costs, and saving raw material consumption and reducing pollution.

According to the actual situation of the existing equipment and printing and dyeing enterprises in China, Changzhou Hongda achieves the digital control of printing and dyeing through the popularization and application of the following three levels, enhancing the automation level of printing and dyeing industry and the level of intelligent information.

First, the on-line inspection and automatic control of the key process parameters of the existing production process are realized: the main point is to realize the automatic control of a single key point or several key process parameters of a certain processing technology. It includes on-line measurement and control of concentrated alkali concentration, pH value, moisture content, moisture content, fabric width, fabric seam head and hydrogen peroxide concentration.

Second realizing automatic control and digitalization management of single station: by quantifying the process parameters of single station, overcoming the errors caused by human factors, and achieving good reproducibility through memory and storage process menu, greatly improving the success rate. The main products are: digester and bleaching machine integrated intelligent digital information integration solution, dyeing machine intelligent digital information integration solution, mercerizing machine intelligent digital information integration solutions.

Third realizing digital control and digitalized management of production process: continuous detection and control of various processes and digitalized management of the process in printing and dyeing production, effective management of water, electricity, gas energy consumption, output and finished product rate in the production process, so as to achieve the purpose of printing and dyeing numerical control.

The company's printing and dyeing intelligent information control system has been successfully applied in printing and dyeing enterprises in Zhejiang, Shandong, Fujian, Guangdong, Jiangsu and other provinces, such as Zhejiang Huili, Zhejiang Qingfeng, Zhejiang, Xinyue dyeing and finishing, Hangzhou Tiancheng dyeing and printing, Yida printing and dyeing, Jiangsu USSR shares, Ru Ruyi group, happy home textiles, Phoenix Phoenix Dongxiang printing and dyeing, Lun Lu Tai Textile Co., Ltd., Hua Hua Lun, Xin Feng Feng (Hsin) printing and dyeing, Qianjin denim, South China printing and dyeing stock, Nan Haiyong Xiang Xiang dyeing, and LeLe Qi and so on, and has been well received by users.

After the introduction of a series of online inspection products for dyeing and printing enterprises to realize energy saving and emission reduction, the company has successfully developed a series of automation products, such as digital inspection cloth system, textile air conditioning intelligent control system and ring spinning intelligent online monitoring system, which provide support for textile enterprises to achieve energy saving and emission reduction.

Digital inspection cloth system uses machine vision technology instead of human eye to detect defects in movement. At present, there are no precedents in China. The repeatability, objectivity and long-term stability of machine vision applications are better than those of human eyes. Applying machine vision to fabric defect detection can not only reduce the loss caused by the quality problems of factory products, but also greatly reduce the number of testing workers, so that the annual net profit of enterprises can be greatly improved.

The intelligent control system of textile air conditioning and energy saving automatically controls the air conditioning in the workshop through the control, regulation and monitoring of all air treatment processes. It uses the expert module of D-Ctrl 6000 System to calculate the optimal operation data with the on-site sensor, transmitter and optimization control algorithm. Through on-site execution system, timely adjust the fan motor, pump motor, valve opening, and the ratio of new return air, and make full use of suitable outdoor air to get free air conditioning. The system can control independently according to weather conditions and production process changes, meet the requirements of high precision temperature and humidity in production workshop, improve fabric quality, enhance enterprise management level, reduce refrigerating machine running time and energy consumption, fan energy consumption, reduce equipment maintenance cost, prolong equipment life and reduce production cost. Based on the existing textile air-conditioners equipped with frequency converters, energy saving and consumption reduction can reach about 30%.

" Ring spinning intelligence The online monitoring system is composed of single point monitoring indicator, ingot group indication, machine terminal display and central database terminal comprehensive analysis. It realizes on-line monitoring and indication of the yarn breakage and slipping of the spindle in the production process of the ring spinning machine, directs the terminal of the machine to transmit the yarn broken ends and spindle slips data to the central database terminal in real time through the field bus, and carries out a unified analysis of the data. Through some rule bases, the yarn spindles can be judged and predicted by some rule bases, so as to provide basis for user maintenance.

Changzhou Hong Da will further increase its R & D investment in the automatic weighing and distribution system of dyestuff powder, production process logistics management system, improve the product system, gradually form the industry standard of products, set up the protection system of intellectual property rights, and lead the Chinese printing and dyeing industry into a new era of digitalization.

　　 Bu Gong tea saponin Minor additives Great uses

Shanghai Jintang light textile new Mstar Technology Ltd Zhang Zhijun

The core point of view is that the application of the tea saponin can not only produce good economic benefits, but also bring good social and environmental benefits. Because of the decrease of energy consumption and water consumption, the contradiction between energy shortage can be alleviated. Due to the decrease of emission and pollution index and the improvement of sewage biodegradability, sewage is easier to handle. Compared with the conventional process, it is conducive to environmental protection.

In June 2009, a kind of product named Bu Gong tea saponin, which can replace alkali, auxiliaries and hydrogen peroxide, was developed successfully. This product can be applied to the pretreatment process of pure cotton, chemical fiber, blend, linen, flocking, batik and other fabrics, which can reduce the use of chemicals and ease the problem of heavy pollution and heavy pollution in the pretreatment stage of printing and dyeing factories. In the next 4 months, the product was approved and applied in the Shanghai dyed bridge, Shanghai Jing Sheng, Zhejiang China Textile Group and Yi Bena (Germany) factory. As of October 2013, the sales volume of the tea leaves was 873.86 tons, double the same period in 2012. At present, more than 50 enterprises in the country, Indonesia, India, Singapore, Bangladesh and other countries 5 printing and dyeing factories are using the public tea saponin products. In 2013, there were 25 new customers. The use of Bu Gong tea saponin made the printing and dyeing factories reduce the cost, increase efficiency and save energy and reduce emissions.

After using the information of feedback from saponin products in the dyeing factory, we know that:

The application of Pugong tea saponin to pure cotton woven fabric can reduce the use of 20% steam. The process flow is shortened by 1/3. It can avoid the use of 1 steamboxes and 5 washing tanks. The fabric has little strength damage and no oxidation burrows. Especially those low quality batik fabrics, the use of bugong tea saponin before processing can enhance the fabric's strength and avoid the danger of oxidation hole breaking, and the wool efficiency and whiteness can meet the printing requirements of wax printing cloth. At the same time, a large reduction in the amount of chemicals is beneficial to the treatment of wastewater and the reduction of wastewater discharge, and it is easy to wash, and it can save multiple washing water and do not use deaeration process, which can save water and other energy sources. The bleaching and bleaching of a single type of auxiliaries of Bu Gong tea saponin can effectively ensure that fabrics do not contain other harmful chemical elements such as APEO, which is conducive to the safe export of textiles. The use of Bu Gong tea saponin can also reduce the COD concentration of wastewater by more than 30%, and the environmental protection benefits are very obvious. At present, Fujian Lian Feng Sheng bleaching and dyeing flocking Co., Ltd., Nantong new Jinjiang printing and dyeing Co., Ltd., Zhejiang new Tianlong printing and dyeing Co., Ltd., Nantong Jin Shi Da printing and dyeing Co., Ltd., Zhejiang China Textile Group are all in use.

The main characteristic of Pugong tea saponin used in chemical fiber woven fabric is to replace many auxiliaries used in the traditional process of chemical fiber woven fabric. The first step is to finish the pretreatment of the woven fabric with a dosage form. It not only has high desizing rate, brightens the fabric's background color, and brightens it, but also removes mildew spots on the fabric, especially the polyester fabric's anti staining phenomenon, the dyeing and dyeing rate is high, and the operator is easy to operate and safe. The main application customers are Fujian long Xing long printing and dyeing Co., Ltd., Fujian Wan Xing long printing and dyeing Co., Ltd., Huzhou Chengxin Textile Co., Ltd., Nantong Chang Lin Textile Co., Ltd., Changxin Hongfeng textile printing and dyeing Co., Ltd., and the market feedback is good.

The use of Pugong tea saponin before pretreatment is the biggest highlight of knitted fabric. It can reduce the weightlessness rate of fabric. Not only can the semi product quality index meet the requirements of fabric dyeing before, but also soft and fluffy handle, it can save the use of softener and anti cavity agent. At the same time, as a result of the use of a form of saponin, it is unnecessary to add any chemicals such as caustic soda, soda ash, hydrogen peroxide, osmotic agent and so on. Therefore, there will not be any quality accidents due to omission or forget of additives. It can improve the success rate of color matching and reduce defective products. Bu Gong tea saponin can effectively replace all kinds of auxiliaries used in the traditional refining and bleaching process. It is not necessary to add caustic soda, hydrogen peroxide and other chemical auxiliaries when using ordinary fabrics. Special fabrics can be used with a small amount of hydrogen peroxide to achieve better whiteness and wool effect, and meet the requirements of the fabric. It is suitable for one-time pretreatment of cotton, polyester and blended fabrics for refining, degending, removing impurities and bleaching. The strength damage and weightlessness rate of fabrics are lower than those of traditional traditional technology, and the use is simple and safe. It not only reduces waste water discharge and reduces COD concentration, but also reduces labor intensity and improves product quality while saving water, saving electricity and saving steam. At present, Zhangjiagang Chun Ma Textile Co., Ltd., Fujian Longsheng Knitting Co., Ltd., Zhejiang Shangyu Jinchen printing and dyeing Co., Shanghai Jing Sheng printing and dyeing Co., Ltd., Nantong Sanqi Textile Co., Ltd. are all in use.