Calculate your Savings

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How to use the calculator

  • Please enter name (optional) and type of factory
  • Select factory type from the drop down menu; if your specific factory type is not listed, you may select the “Gross Average” option
  • Enter annual production (in tonnes), and net margin
  • Next, from the list of recommended measures, select measures that are best suited for implementation in your factory. Check the box next to each recommendation to select
  • When you have selected the measures, click on the “Calculate” button to see potential factory savings

Disclaimer :Please note that the calculator was created using actual resource consumption data from factories participating in the PaCT program. The recommendations were selected from a pool of actual Cleaner Production measures that were recommended to the participating factories. The resulting resource and monetary savings generated by the calculator are projections of what can be achieved by implementing the recommended measures. Real life savings from implementing these measures may vary.

Gross Average: Annual Resource Savings

Utility Recommendations

Fine tuning the pressure setting on compressors to the lowest optimum value will reduce fuel consumption by the compressors, even a pressure drop of 0.5 bar (g) can result in significant fuel savings.

Installing demand side controller for compressed air can optimize its flow by maintaining constant air pressure throughout the system, artificially reducing the demand, satisfy peak demand with useful storage, increase productivity, and reductions in operating and maintenance costs for the compressors.

Proper insulation of all un-insulated steam lines and valves, and correction of steam leakages will ensure natural gas and steam savings.

If a factory is using a cooling tower, consisting of a fan and circulating water to achieve the cooling effect, the cooling tower can be eliminated and fresh water can be circulated and collected in the main water reservoir. Elimination of the cooling tower brings about savings in electrical energy.

Installation of pressure powered pump packaged unit system to recover condensates from dyeing and finishing sections, and deliver that condensate to the feed tank of boilers, reuses heat and water.

If main there are motors running at lower loads, variable frequency drives (VFDs) can be installed to lower the rotations per minute (rpm) of the motors as required. This will help in reducing power consumption.

Replacing fluorescent lights with LEDs can result in significant energy savings

Replacing fluorescent lights with LEDs can result in significant energy savings

Skylights make use of daylight and eliminate the need for electricity for lighting purposes. Areas in the factory where variances in light levels are acceptable, such as storage areas and warehouses, skylights can be a good solution.

An online oxygen tuning system for boilers help maintain the optimum oxygen level in the boilers (2 -3 %), and improve boiler performance, as well as lower emissions of sulfur trioxide, nitrogen oxides, and particulates. Oxygen tuning of boilers results in fuel savings.

Installation of an auto blow-down control system, that senses TDS levels in boilers and operates the blow-down valve automatically, improves boiler performance and results in natural gas savings, and also saves man hours which would have been spent in manual blow-down of the boiler.

The heat from the generator engine jacket is usually released into the cooling tower. A heat exchanger can be installed to recover the heat from the engine jacket to generate hot water that can be used for processes. Hot water generated by recovering engine jacket heat will reduce steam consumption and hence result in natural gas savings.

Installation of waste heat recovery boiler can be a good option to utilize the exhaust heat from the generator which would otherwise be released to the environment.

Process Area Recommendations:

If air nozzles are used instead of open pipes, significant amounts of compressed air can be saved, thus reducing the amount of energy required for compressed air. Using the suitable type of air nozzle is subject to the type of application.

By installing water trigger nozzles on open hose pipes, unnecessary water wastage can be avoided

Installing appropriate steam traps in dyeing machines ensures steam and fuel savings.

Improving lab to bulk Right-First-Time (RFT) involves monitoring of processes and materials for consistency between lab and bulk production, identifying reasons for variance between lab and bulk processes, using properly calibrated instruments for measuring all parameters, intermittent checks on liquor quality for desired parameters, and installing programmable logic controllers for automatic control of parameters such as water level, pH, temperature, etc. Improving lab to bulk RFT results in significant savings of water, chemicals, and energy.

Using waterless direct softener injection spray eliminates the use of water for the softener washing process.

Large amounts of salts (such as sodium sulfate, sodium chloride and sodium carbonate) are used for washing/bleaching and dyeing processes. If these salts are not recovered, they end up in the ETP increasing treatment costs and the use of acid to neutralize the high amount of alkaline effluent. Recovering these salts from drained liquor can lower ETP operating costs, and the salts can also be reused.

After the dyeing process, hot liquor is usually drained into the ETP which results in lost energy and added load for the ETP. It is possible to use the heat from the dyeing liquor to heat up the water entering the dyeing machine for the next batch.

Worn out mangles in stenter machines do not efficiently reduce the moisture content of wet fabric before it enters the machine, and this results in higher thermal energy consumption to dry the fabric. Replacing the rubber padding mangles can easily solve this problem, and prevent unnecessary energy consumption.

Retrofitting dyeing and washing machines with programmable logic control (PLC) systems for parameters such as water level, auto fill and drain, monitoring temperature and pH will save water in every batch of dyeing and washing. These water savings can add up to a significant amount annually.

Annual Resource Savings

Chemicals(tonne) GHG(tonne) E.Energy(MWh) Gas(1000m3) Water(m3)
Baseline
After Implementation
Savings
           
Total Investment Required USD
Annual Economic Benefit USD
Payback Period Year
Additional sales required to make similar savings without any improvement in resource efficiency USD