Industrial Water Treatment
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Transcript of Industrial Water Treatment
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1
Retrofits & Accessories for
Textile Process Houses from
A.T.E. Enterprises Private Limited
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2
Retrofits &
Accessories
Save Cost
Improve Productivity
Improve Quality
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3
Critical challenges of Indian processing units
Productivity
Quality
High cost of capital
Rising energy costs
Water scarcity
Critical
challenges
faced by Indian
processing
units
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4
Retrofits and utilities from A.T.E.
A range of retrofits
and utilities that will
result in :
Enormous saving in energy
Improved productivity
Improved quality
with a substantially low investment
and fastest ROI!
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5
Retrofits &
Accessories
Save Cost
Improve Productivity
Improve Quality
Improve Quality
Improve Productivity
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6
Mahlo Atmoset SMT-12 is an online
moisture control and monitoring
system, that controls the steam input
in drying cylinders by optimising the
drying process, thus saving heat
energy (30%-50% saving in steam
can be achieved) and results with
consistent quality output.
Payback in just 8 months!!!
Reference: Alok (Vapi), Auro (Baddi), Welspun (Anjar), GHCL (Bhilad)
Sa
ve
en
erg
y
Sa
ve
co
st
Steam consumed per kg. of fabric
processed on drying range (without
Atmoset SMT-12)
1.2 kg
Steam saved per kg. of fabric
processed (considering just 25%
steam saving with Atmoset SMT-12)
0.25 kg
So, steam saved after processing 21
MT (or 80,000 meters) of fabric per
day
0.25 21000
= 5250 kg
Considering 25 days working per
month, steam saved per month
1,31,250
kg/month
Cost of steam saved per year* Rs.
25,20,000
Cost of Mahlo Atmoset SMT-12: Rs.16,25,000**
So, ROI = 7.74 months ~ 8 months (*Cost of steam considered @ Rs.1.6/kg)
Mahlo - Atmoset SMT 12
**Prices of equipment are indicative and are subject to change
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Payback in just 2 months!!!
Reference:
The shell and tube system
recovers heat energy from waste
water and uses it to heat fresh
water, while maintaining
constant process water
temperature by means of a PLC
attached to the system.
Input parameters Output parameters
Waste water 20 m3/hr Fresh water inflow: 20 m3/hr
Wastewater @ 80C
cooled to 41.15C
Fresh water @ 25C; heated up
to 63.57C
Thermal efficiency: 886.1kW
Fuel used: Firewood (calorific value of 3000 kcal/kg)
Cost of fuel: Rs. 3/kg
Total working hours per year: 6000
Fuel saving per year: 2177 MT
Cost of fuel saved: Rs. 65,31,900
Cost of Luwa water to water heat recovery system =
Rs. 8,50,000**
So, ROI = 1.56 months ~ 2 months*
Sa
ve
en
erg
y
Sa
ve
co
st
Luwa - water to water heat recovery system
**Prices of equipment are indicative and are subject to change
N.B: Performance depends on constancy of input parameters and maintenance
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Payback in just 15 months!!!
Reference: Ruby (Khopoli), Oswal F.M. Hammerle (Kolhapur), GHCL (Bhilad)
A retrofit for the Osthoff singeing
machine for objective measurement of
the hairiness of the fabric for proper
control of the singeing process by
regulating gas intensity as per the
fabric hairiness, resulting in uniform
hairiness across the batch. Regulation
of gas intensity also results in saving of
gas.
Without
online
hairiness
tester
With online
hairiness
tester
Consumption of gas in kg/hour 15 11.5
Cost of gas in Rs./hour 945 724.5
Cost of gas in Rs./day 18,900 14,490
Cost of gas in Rs./month 4,72,500 3,62,250
Cost of gas in Rs./annum 56,70,000 43,47,000
Net savings (Rs./annum) 13,23,000
Cost of online hairiness system: Rs.1,625,000**
Cost of propane considered @ Rs. 63/kg
Working hours considered @ 20/day
Working days considered @ 25 days/month
Imp
rove
d q
ua
lity
& c
os
t s
avin
gs
Osthoff - online hairiness tester
**Prices of equipment are indicative and are subject to change
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A robust, third generation retrofit, made
of metal foam for the pre-dryer installed
on the CDR to reduce the moisture on
the fabric before it enters the hot flue, to
avoid migration of dyestuff. Varying gas
intensity with actual temperature
requirements (in the range of 600 to
800 C) results in saving in gas to the
extent of 25-30% as compared to
ceramic pre-dryers.
Save e
nerg
y
Save c
ost
Payback in 50.4 months
Monforts - infrared pre-dryer for CDR
**Prices of equipment are indicative and are subject to change
Reference: Arvind (Ahmedabad), Auro (Baddi), Alok (Vapi)
Parameter Old New
Consumption of gas in kg/hour 33 kg 20 kg
Cost of gas in Rs./hour Rs. 2,079 Rs. 1,260
Cost of gas in Rs./day Rs. 41,580 Rs. 25,200
Cost of gas in Rs./month 1,039,500 630,000
Cost of gas in Rs./annum 12,474,000 7,560,000
Net savings in Rs. 4,914,000
Cost of infrared pre-dryer for CDR: 295,000 or Rs. 20,650,000**
Cost of propane considered: Rs. 63/kg
Working hours considered: 20/day
Working days considered: 25/month
Return on investment: 50.4 months
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Retrofits &
Accessories
Save Cost
Improve Productivity
Improve Quality Improve Quality
Save Cost
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11
Impro
ve p
rod
ucti
vit
y
Im
pro
ve p
rofit
Description
A residual moisture measurement instrument for drying ranges that controls the degree of dryness of the product by means of dryer speed based on the residual moisture
Benefits
Improved productivity
Energy optimisation
Optimal residual moisture for subsequent processing
References
Alok (Vapi), Oswal Hammerle (Kolhapur), Vardhman (Bhopal), Auro (Baddi), Birla Century (Bharuch)
Mahlo textometer RMS can be used in stenter, pad steam and pad
dry, and CBR.
Mahlo - textometer RMS
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Description
This advanced textile digital metal detector is highly sensitive to all magnetic and non-magnetic metals. The compact and robust construction of this metal detector with plug-and-play settings ensures a high degree of protection (IP 65 RC version)
Benefits
Highly reliable at a
wide range of speeds,
as high as 600
m/minute
Can detect ferrous and
non-ferrous metal as
small as 0.8 mm.
Prevents damage to
rubber rollers and
fabric
Higher machine uptime
Higher productivity
Higher safety
Better quality output
References
Alok (Vapi), Oswal Hammerle (Kolhapur), Vardhman (Bhopal), Auro (Baddi), Birla Century (Bharuch), Jakharia (Boisar), Mandhana (Boisar), etc.
Impro
ve p
rod
ucti
vit
y
Im
pro
ve p
rofit
CEIA metal detectors can be used in shearing, calendar, shrinking
singeing machines, dye padder and CBR
CEIA - bar metal detector
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Description
The THS 21 conveyor satisfies the most stringent requirements for functionality, compact construction, accuracy and reliability of response in dealing with accidental metallic contamination of products
Benefits
Very high sensitivity to
ferrous and all
magnetic metals
Detection sensitivity
compliant with the
textile industry
Standards
Digitally-adjustable belt
speed
Structure and metal
detector in AISI 316L
stainless steel
High flexibility: all parts
completely reversible
and modular
References
Welspun (Anjar), SEL (Punjab), Trident (Budhni)
Impro
ve p
rod
ucti
vit
y
Im
pro
ve p
rofit
CEIA metal detectors can be used in a multitude of textile related
applications
CEIA - conveyor metal detector
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Description
Comprising of Ecomat AML, textometer RMS and Permaset VMT, The ecopac EMC-12 monitors and controls exhaust air moisture, residual moisture, and fabric heat setting temperature respectively, resulting in improved productivity and energy optimisation
Benefits
Improved productivity
Energy optimisation up
to 16%
Consistent quality
References
Alok (Vapi), Oswal Hammerle (Kolhapur), Vardhman (Bhopal), Auro (Baddi), Birla Century (Bharuch)
Impro
ve p
rod
ucti
vit
y
Im
pro
ve p
rofit
Mahlo ecopac EMC-12 can be used in stenters
Mahlo - ecopac EMC-12
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Description
An innovative technology which is CE certified and available in different capacities, to provide moisture-free compressed air to pneumatic systems on various machines.
Compressed air cools the incoming air and separates the moisture via a timer-controlled electronic drainage wall
Benefits
Higher machine uptime
Higher productivity
Long life of pneumatic
systems
Less maintenance
References
Manan Cotsyn (Boisar), Valiant (Boisar), Sutlej (Bhilad)
Impro
ve p
rod
ucti
vit
y
Im
pro
ve p
rofit
Advance Cooling - compressed air dryer
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Description
CE-certified and available in different capacities, panel ACs help protect costly electronic equipment from the heat generated by drives in the electrical panel as well as dust and humidity
Benefits
Higher machine uptime
Higher productivity
Long life of electronics
Less maintenance
References
Alok (Vapi), Ruby (Khopoli), BRFL (Boisar), Kothari Exports (Kolkata), Khosla (Mumbai), etc.
Impro
ve p
rod
ucti
vit
y
Im
pro
ve p
rofit
Advance Cooling - panel air conditioner
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Description
A unique system that is CE-certified and available in different capacities to maintain constant temperature of the dye liquor and chemicals in the trough. This water chiller circulates chilled water around the walls of the trough to maintain its temperature at a desired level
Benefits
Improved productivity
Evenly dyed fabric
Reduced re-dyeing
Minimum tonal and
shade variations in the
dyed fabric
References
Ruby (Khopoli), Auro (Baddi), Raymond UCO (Yavatmal)
Impro
ve p
rod
ucti
vit
y
Im
pro
ve p
rofit
Advance Cooling - water & oil chiller
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Retrofits &
Accessories
Save Cost
Improve Productivity
Improve Quality
Save Cost
Improve Productivity
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Impro
ved q
uality
Im
pro
ve p
rofit
Corino - beating & brushing systems
Benefits
Improves productivity
Improves quality
Energy optimisation
References
Alok (Vapi), Oswal Hammerle (Kolhapur), Vardhman (Bhopal), Auro (Baddi), Birla Century (Bharuch)
Description
A compact unit with the provision to
attach different brushing or beating
systems.
Used in singeing machines,
CBRs, and printing machines
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Impro
ved q
uality
Im
pro
ve p
rofit
A.T.E. - rotary drum filter
Benefits
Improves productivity
Improves quality
Reduces maintenance
References
Alok (Vapi), Indocount (Kolhapur), Himatsingka (Hasan), Birla Century (Bharuch), GHCL (Bhilad), Aarvee Denim (Ahmedabad), Welspun (Anjar)
Description
A compact unit with a brushing system
for removal of fluff from drums without
using water
Used in singeing / desizing
systems, CBRs, and CRP (Caustic
Recovery Plant)
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Impro
ved q
uality
Im
pro
ve p
rofit
A.T.E. - screen filter
Benefits
Reduces labour cost
Less maintenance
Hassle-free system
References
Chenab Textile (Kathua)
Mandhana (Boisar)
Description
A compact unit with screen type
brushing system for removal and
collection of fluff
Used in ETP inlet at preliminary
treatment stage and various
drainage outlet as well
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Impro
ved q
uality
Im
pro
ve p
rofit
Rotovac - online dust & lint removal system
Benefits
Reduces labour cost
Less maintenance
Hassle-free system
References
Arvind (Ahmedabad), NSL Textiles (Hyderabad), BRFL (Boisar)
Description
A compact unit with a spring-type
brushing system for automatic
removal and collection of fluff
Used in rotary and flat bed
printing machines
PPT/Rotovac.pptx
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Impro
ved q
uality
Im
pro
ve p
rofit
Monforts - chambers for stenter, pad dry
Benefits
Improves productivity at low investment
References
India Dyeing (Erode), Alok (Vapi), BJ
Textiles (Naidupet)
Description
Additional chamber with running
stenters, hot flues
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Impro
ved q
uality
Im
pro
ve p
rofit
Montimac - rail sewing machine
Benefits
Reduces wastage of fabric
Improves fabric & stitch quality
References
BRFL (Boisar), Indocount (Kolhapur),
Shreeji Lifestyle (Dombivali)
Description
Rail sewing machine for head to
head stitching of fabric edges before
batching
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Impro
ved q
uality
Im
pro
ve p
rofit
Corino - guidance system for digital printing
machine
Benefits
Perfect feeding and winding of fabric
with uniform tension
Improves printing quality
References
Shreeji Lifestyle (Dombivali)
Description
Compact unit that ensures uniform &
tensionless feeding of fabric to
printing machine
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Impro
ved q
uality
Im
pro
ve p
rofit
Monforts - eco applicator
Benefits
Improves fabric quality
Reduces energy costs for drying /
increases speed
References
Not yet sold in India; numerous
installations abroad
References available on request
Description
For controlled application of
chemicals (softener, hydrophobic,
hydrophilic, stain repellants, etc)
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Impro
ved q
uality
Im
pro
ve p
rofit
Dunline - endless rubber shrinking belts
Benefits
Uniform performance throughout the
life of the belt
No material defect
Improves fabric quality
References
Alok (Vapi), Raymond (Kolhapur), Arvind
(Ahmedabad), JCT (Pagoda), RMB
Denim (Surat), Century Denim (Indore),
etc.
Description
For fabric shrinking on shrinking
ranges
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Impro
ved q
uality
Im
pro
ve p
rofit
Dunline - endless felts
Benefits
Designed to offer uniform performance
throughout the life of the felt; no
material defects
Improves fabric quality
References
Jindal Worldwide (Ahmedabad), Bhaskar
Denim (Bhopal)
Description
For drying & giving feel to fabric
used on palmer drum of sanforizer,
relax dryer, printing dryer
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Impro
ved q
uality
Im
pro
ve p
rofit
Dunline - accessories
Benefits
Maintain and increase longevity of
the belt & felt
References
BRFL (Tarapur), Mandhana (Tarapur), Oswal Denim (Lalru and Bhopal), Nahar (Lalru), Bhaskar Industries (Bhopal), Indocount (Kolhapur)
Description
Topline belt safe compound
Topline safe wash
Topline belt lube
Topline paralel gauge
Topline surface contact thernmom
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Impro
ved q
uality
Im
pro
ve p
rofit
MAG - textile testing instruments
Benefits
Quality assurance
Support customization
Calibration & test certification
Provision of AMC and OMC
References
E I Dupont India (Hyderabad), Alok
(Silvassa), Morajee (Nagpur), Alps
(Ghaziabad), Grasim (Bhiwani), Shree
Sidvinayak Texco (Ludhiana), Shree Balaji
(Ludhiana), Pratap (Ambala), Ahuja Cotspin
(Punjab), Garg Acrylics (Punjab), KPR
(Tamil Nadu), Keshar Multi Yarns (Kolkata),
Vishnu Cotton Mills (Kolkata)
Description
High quality textile testing instruments at
affordable cost
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Impro
ved q
uality
Im
pro
ve p
rofit
Valence - static discharge bars
Benefits
Improves safety
Helps to improve productivity
Helps to improve quality
References
Nahar (Lalru), Tex n Nets (Gurgaon), Jain
Textiles (Gurgaon), Surya Processors
(Ghaziabad), Alps (Ghaziabad), Kudu Knits
(Ludhiana)
Description
Compact, sturdy and reliable static
discharge bars to eliminate electrostatic
charge on moving parts
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Impro
ved q
uality
Im
pro
ve p
rofit
A.T.E. - material handling system
Benefits
Low effort transport system
Suitable for heavy loads
Trouble-free working
References
NSL (Guntur), Birla Century (Bharuch),
K G Denim (Mettupalayam), D Dcor
(Tarapur), Premier Fine Linens
(Perundurai), Trident (Budhni) and
Himatsingka Linens (Hasan), Welspun
(Anjar)
Description
Supply of all types of material handling
equipment to store and move textile
substrates from one machine to another
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Impro
ved q
uality
Im
pro
ve p
rofit
A.T.E. - lubricants and greases
Benefits
Resists hydrocarbon washout/dilution
High load carrying capacity
Reduced sludge and deposit formation
Excellent oxidative and thermal stability
Low friction and less power
consumption
References
Description
High quality speciality lubricants which
can perform under extreme conditions
of speed, temperature & load. Different
purpose grease & oil, aerosol sprays for
wet and dry applications for trouble free
operation of machines for longer
duration
Mandhana (Boisar), Alok (Vapi), BRFL (Boisar), Valiant Glass (Boisar), Mudra Lifestyle (Boisar), Ruby (Khopoli), Arvind (Ahmedabad), Premier (Bengaluru), Himatsingka Linens (Hasan), Vardhman (Budhni), Nahar (Lalru), etc
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34
Impro
ved q
uality
Im
pro
ve p
rofit
A.T.E. - textile automation control systems
Benefits
Improves the performance of old
machines
Hassle free operation
Improves production of machines
Reduces operation time
Reduces operation cost
References
Welspun Syntex (Silvassa), Bhaskar
Denim (Bhopal), Balkrishna Synthetic
(Tarapur), Indorama Synthetic (Nagpur),
Arvind (Ahmedabad), JCT (Phagwara),
Premier (Coimbatore)
Description
Complete, customized retrofit and
automation solutions for the textile
industry
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35
THANK YOU