Introduction
A leading textile company planned to expand its existing plant, which already had two heaters. Although the heater efficiency was measured by the manufacturer, there was a noticeable gap between heat generation and utilization. Given the current load and generation capacity, a new heater was not theoretically necessary. However, the existing machines were experiencing temperature issues, with heat generation located about 1.5 kilometer away from the utilization point.
Background
Ensuring efficient heat transfer and utilization is critical in textile production. Addressing the temperature issues without adding new equipment was essential for maximizing operational efficiency.
Challenges
- Insufficient heat flow leading to temperature issues in existing machines.
- High heat losses in the system despite satisfactory heat generation.
- The need to analyse and optimize the existing setup rather than invest in new machinery.
Solution
The company entrusted Dr Thermic fluid – Eximious, specialists in thermic fluid systems, to tackle this challenge. Eximious undertook the following steps:
- Data Verification: Eximious began by verifying the collected data and the methodologies used in the initial assessments.
- Heat Generation Confirmation: The heat generation was confirmed using two independent methods, and pump flow rates were calculated to understand the system better. Machine requirements were also validated with the manufacturers.
- Loss Analysis: After a thorough analysis, it was determined that while heat generation was adequate, the flow was insufficient, insulation losses were high.
- Booster Circuit Design: Eximious designed a complete booster circuit to improve flow and insulation method to reduce losses in the system.
Results
- Enhanced Temperature Profiles: With the implementation of the booster circuit, the temperature profiles of the existing machines improved significantly.
- Increased Production: The optimized heat utilization led to increased production efficiency without the need for a new heater installation.
Conclusion
Eximious successfully optimized the heat utilization in the textile plant, addressing temperature issues and enhancing production capabilities. For thorough analysis and innovative solutions in thermic fluid management, call Eximious.