Improving energy efficiency using the most appropriate techniques in an integrated woolen textile facility

Abstract The textile industry has a high share in the total energy consumption of the manufacturing industry, especially in global textile supplier countries. Energy consumption and air emissions can be reduced at the source with detailed cleaner production and energy efficiency applications in textile production processes. In this study, energy efficiency studies were carried out in an integrated woolen textile facility. In this context, energy consumptions were analyzed based on the main production and other preparatory processes by detailed onsite investigations. Specific electricity, thermal energy, and air emissions were calculated based on the production processes of the facility. In addition, specific energy consumption values were compared with similar textile facilities to evaluate energy saving potentials and opportunities. A list consisting of 85 energy efficiency techniques was prepared to reduce energy consumption and air emissions in the facility. These techniques were evaluated and prioritized in terms of techno-economic feasibility, potential savings, and environmental benefits using a systematic decision-making model. Ultimately, it was decided to apply the following priority energy efficiency techniques (a total of 13): process optimization, the establishment of a process-based energy monitoring and control system, the recovery of waste heat, the optimization of steam boilers, the modification of radio frequency (RF) dryers, the modification of fan motors in the ventilation-humidification system, the proper positioning of compressors, the installation of a compressor monitoring system, and an air emission treatment system. It was found that with the application of such techniques, electricity, thermal energy, and air emissions could be reduced by 8–27%, 12–28%, and 23–45%, respectively. Based on the financial analysis, the payback periods of the priority energy efficiency techniques were found to be generally less than 36 months.