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Energy optimization in textile finishing: heat recovery from the flue gas of a stenter

Context and objective

In the textile industry, finishing is a crucial step in the production process, in which fabrics are treated to improve their aesthetic and functional characteristics. However, this processing involves high energy consumption, particularly in machinery such as the stenter, a piece of equipment used to heat-treat fabrics using hot air generated by gas burners.

To reduce operating costs and improve energy efficiency, a thermal recovery system from flue gas was implemented. The main objective of the intervention was to harness waste heat from flue gas to optimize the plant’s energy consumption, reducing dependence on natural gas and improving the overall sustainability of the production process.

The intervention

The implementation of the recovery system included the installation of two heat exchangers to reuse the thermal energy contained in the spent flue gas from the stenter, preventing it from being unnecessarily dispersed into the atmosphere

1

First exchanger: process air preheating

Ambient air entering the stenter is preheated by heat recovered from the exhaust fumes.

This process reduces the energy required to bring the air to operating temperature, improving the overall efficiency of the machine.

2

Second exchanger: preheating of boiler feedwater

The flue gases then pass through a second air/water exchanger, transferring some of the waste heat to the feedwater of the thermal oil boilers.

This decreases the consumption of methane needed to heat the boilers, with a double benefit: reduced energy costs and lower environmental impact.

Results and benefits

As a result of this intervention, the company has achieved significant energy savings, estimated at about 67,000 Sm³/year of methane, equivalent to a reduction in energy expenditure of about €21,000 per year.

Main benefits:

Improved energy efficiency

Optimization of natural gas consumption.

Reduction in operating costs

Lower fuel expenses.

Lower environmental impact

Reduction of CO₂ emissions.

Optimization of the production process

Less waste of thermal energy.

The adoption of heat recovery solutions is an effective strategy for reducing energy consumption and improving the competitiveness of manufacturing companies. In this specific case, the integration of heat exchangers made it possible to transform a dissipated energy stream into a useful resource, with immediate economic benefits and a positive impact on corporate sustainability.

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