ENERGY CONSERVATION IN SPINNING

Energy  cost has come to occupy the dominate cost in the textile industry, in the process  even relegating behind the cost of labour .In fast energy cost comes next only to raw material cost in every mills. In the years to come and with the looming energy crises, the cost of energy would surely spiral up. More than that, the availability of energy itself will be a question mark. Therefore unless effective  measures are taken now itself to consume and utilise optimal energy in the textile mill, it is going to be extremely difficult in the later years and it will be to late than to realise about energy conservation, especially with the energy availability.

It is quite an eye  opener if we calculate the modest 10%saving of energy by a textile spinning mill

in India which would mean one million barrels of oil a year. The accessories that play a significant role in achieving the energy conservati0n are spindles,

tube ,spindle tapes, and main drive system.

Spindles

A spindle is a heart of the ring frame or a twisting machine not only for its productivity but also for

energy conservation. A spindle consumes 40% of the total ring frame energy and the ring frame consist 60% of the requirement of the spinning mill. There fore serious  attempts are to be made to reduce the energy consumption by a spindle which go a long way in reducing the energy consumption by a spindle which go a long  way in reducing the energy consumed by a spinning mill.

This involves the following

1 The spindle has to be designed so consumes minimum energy.

2 Reduction in the wharve dia of the spindle to reduce the energy consumed by the driving element.

Design of the spindle

This broadly consist of

1   Weight of the spindle

2 Aerodynamic of the spindle design.

3 Ability of the spindle to maintain concentricity and      

  verticality to the ring at high speeds.

Damping characteristics vis-a -vis oil content in the

  4 insert.

 

Weight of the spindle

              Spindle has got a inertia and therefore any reduction in inertial force will naturally reflect on the

energy consumption . But the spindle also has got a stiffness factor which if reduced beyond the certain limit would introduce harmonic motions increasing the critical speed of the spindle. This is undesirable and therefore reduction in the weight of the spindle should commensurate with the above requirement. The reduction in weight should be so effected on the spindle design as not

to have a sudden reduction in one spot there by shifting the center of gravity and also disturbing the stability of the spindle.

Aerodynamics of the spindle design.

The aerodynamic characteristics of the spindle can be achieved by a suitable design and also by a specialised  manufacturing process which ensures dynamic balancing of the spindle.

Ability of the spindle to maintain concentricity and vertically of the ring at high speed

These aspects is very important criterion and normally ignored in many of the spindle design. When the spindle is fixed on the machine, it may be occupying that extra center in relation to the ring .But once it is run with the tube and yarn it may deviated from this center because of  various out side forces acting on the spindle. Even though, all spindles design have recentering capability after short disturbances ,the element that are responsible for recentering eventually wear out. Then the spindle becomes not truly vertical to the ring thereby diluting the standard to which the spindle was manufactured in the beginning. The spindle design which ensures no wear and tear on such recentering can alone maintain if verticality to the ring throughout its life. This ensures the most energy efficient running.                  

      The insert design which starts off with a low oil content will definitely ensure low energy consumption

Reduction in wharves diameter                                         

The spindle is a driven element and therefore the pulley of the driving element when reduce will also make the other power transmitting element tom reduce the speed viz. The tape as well the driver, in this case tin roller

roller pulley. By reducing the speeds of these elements the energy consumed by these elements is brought down significantly.

Spindle tape

            It  is now very well established that very low flex resistance and less weight as well as optimum

weight tape consumed less energy .When the spindle tape is manufactured with lesser flux resistance and lower weight, it should also be ensured that they last longer on one hand and retained their characteristics throughout its life on the other.

Main drive system    

Higher too main drive system has been predominantly occupied by the v belt drive. In fact improvement

in this has come about by suitable modifying the arrangements such that we can have variation in

spindle speed with out changing the pulley . The fact till remains is that v belt system consumes more energy transmission of power is not commensurate with the energy consumed. The v belt by its design is wedged between grooves and therefore the inertia is spent on wasteful energy by wedged anti wedged. In addition, these belts are highly flex resistant. Therefore the flexing  force

consumes more energy. There are many clear options available in textile industry to try and evaluate each and every accessory not only for its quality but also for its in bulk energy efficient performance. It is high time that the textile industry should have a rethinking not only for replacement but also as a mean of energy

conservation technology. The cost of the product should be calculated with the due weightage given to the advantage so as to be more pragmatic. After all energy cost come to equal the wage cost and surely outstrip all other costs in future.

Tube

       Tube is required to wind the yarn being spun. In the other words the tube should be perfect in all respects and should not have its influence on the spindle to any great extent. Therefore when the tube is made

the tube should be light weighted, should have homogenous build of material and truly concentric. This will greatly reduce the strain on the spindle

Drum

       By reducing the drum dia we can reduce the power consumption

       

         CALCULATION OF UKG FOR 40s COUNT

DEPARTMENT        Units(KWh)cosumed in different   

                       departments

   BLOW ROOM   ---    15.5

   CARDING     ---    22.0

   DRAWING     ---    10.4

   SIMPLEX     ---    11.9

   RING FRAMES ---    231.5

   REELING     ---    3.2

   BUNDLING    ---    0.4

   BALING      ---    1.2

   CONE WINDING---    5.3

   HUMIDIFICATION-    40.0

   LIGHTING &OTHERS-  15.0

total units for

 1ookgs yarn    ---   356.4

          UKG   ---   3.564