Energy and water savings Debriefing Slide (1).pptx

energy savings related report for textile industries

1. FWD>>ENV PROGRAMME ASSESSMENT DE-BRIEFING SESSION 9 May, 2024 Suad Garments Industries Ltd. Plot# 137-146, Adamjee EPZ, Siddhirganj , Narayanganj. P.O Box-1431

2. Baseline Assessment on Water & Energy: December 27, 2023

3. ENERGY BALANCE DIAGRAM

4. WATER BALANCE DIAGRAM

5. ENERGY MIX AND RESOURCE COST DISTRIBUTION

6. SECTION-WISE ENERGY CONSUMPTION  (MJ) *During April and October, production levels are low, yet energy consumption was high, since certain processes required more energy than others or needed to run machines with low loads.

7. SECTION-WISE WATER CONSUMPTION  (m 3 ) *During April production levels were low, yet water consumption remained high. This can occur either because the facility needed to run machines despite low production or because certain processes demand more water than others.

8. Electrical and GHG Emissions KPI Thermal Energy KPI KPI COMPARISON

9. KPI COMPARISON Water and Chemical KPI Total Energy KPI (MJ)

10. Source Fuel/Gas Unit Consumption GHG Factor GHG Emission (tCO 2 e) % Emission Type Grid N/A kWh 2,612,340 0.00076 1,990 41.8% Scope 2 Generator Diesel L 2,123 0.00271 6 0.1% Scope 1 Boiler NG m 3 171,802 0.00192 331 7.0% Diesel L 896,630 0.00271 2,434 51.1% TOTAL SCOPE 1 EMISSION 2,771 58%   TOTAL SCOPE 2 EMISSION 1,990 42%   TOTAL GHG EMISSION (SCOPE 1 + 2) 4,761 100%   GHG Emissions Sources (2023) MAJOR SOURCES OF GHG EMISSIONS

11. Total Energy (MJ/year) Electrical Energy (kWh/year) Thermal Energy (MJ/year) Wat er (m 3 /year) Chemical (kg/year) GHG Emissions (tCO 2 e/year) Baseline consumption 50,668,910 2,618,820 41,182,547 104,786 37,491 4,761 Estimated absolute savings 18,041,636 280,042 17,016,573 34,300 9,768 1,353 Potential for improvement 36% 11% 41% 33% 26% 28% Resource Savings Potential

12. Investment (USD) Savings (USD/year) Payback (months) 466,823 260,200 22 Financial Potential

13. Summary of Savings Savings Type No. of Measures Investment (USD) Estimated Savings (USD)/yr Payback Period (month) Immediate 6 10,525 56,457 2 Short-term 5 36,982 85,934 5 Medium-term 7 48,125 34,094 17 Long-term 4 371,191 83,716 53 Total 22 466,823 260,200 22

14. Categories No. of Measures Investment (USD) Estimated Savings (USD/ yr ) Payback Period (month) Water 1 385 2,676 2 Electricity 10 217,225 68,533 38 Thermal 9 62,122 150,590 5 Process 2 187,091 38,401 187,091 Total 22 466,823 260,200 22 Categories of Savings

15. Sl. No. Improvement project identified Savings/yr GHG Reduction (tCO 2 e) Investment (USD) Savings/yr (USD) Payback Period (months) Payback Type Electricity (kWh) Thermal Energy (MJ) Total Energy (MJ) Water (m 3 ) Chemical (kg) Water 1  Replacing normal taps with aerators taps       4,860     385 2,676 2 Immediate Sub-Total (Water)       4,860     385 2,676 2 Immediate Details of Resources Saving Measures (Water)

16. Sl. No. Improvement project identified Savings/yr GHG Reduction (tCO 2 e) Investment (USD) Savings/ yr (USD) Payback Period (months) Payback Type Electricity (kWh) Thermal Energy (MJ) Total Energy (MJ) Water ( m 3 ) Chemical (kg) Electricity 1 Compressor pressure reduction 8,019   29,627     26 - 879 - Immediate 2 Air leak monitoring and repair 45,446   165,097     51 4,545 4,982 11 Short-term 3 Compressor automated line filter using solenoid valve 2,310   8,410     3 91 253 4 Short-term 4 VFD for ETP blowers & boiler ID fan 9,534   34,711     13 1,702 1,045 20 Medium-term 5 Installation of air trigger nozzle 1,203   5,037     24 205 139 18 Medium-term 6 Tube light height reduction 26,634   96,968     37 4,545 2,920 19 Medium-term 7 Use of direct-drive exhaust fan instead of belt-driven exhaust fan 48,000   174,261     50 10,618 5,262 24 Medium-term 8 Power Saving of AC through Programable AC Saver 70,587   256,452     80 11,418 7,738 18 Medium-term 9 Installation of rooftop solar PV* -   6,321     215 171,101 41,082 50 Long-term  10 Replacement of fluorescent light with LED light 38,610   140,513     52 13,000 4,233 37 Long-term Sub-Total (Electricity) 250,342   917,532     551 217,225 68,533 38 Long-term Details of Resources Saving Measures (Electricity)

17. Sl. No. Improvement project identified Savings/yr GHG Reduction (tCO 2 e) Investment (USD) Savings/ yr (USD) Payback Period (months) Payback Type Electricity (kWh) Thermal Energy (MJ) Total Energy (MJ) Water ( m 3 ) Chemical (kg) Thermal 1 Insulation of valves (header)   76,523 76,523 -   5 117 718 2 Immediate 2 Burner tuning and excess air control for boilers   826,217 826,217 -   51 1,091 7,747 2 Immediate 3 Condensate recovery from washing units and garment irons   2,954,214 2,954,214 7,051   162 5,455 26,799 2 Immediate 4 Repair or replacement of steam trap   2,322,978 2,322,978 -   117 3,478 17,638 2 Immediate 5 Flash steam recovery   1,463,359 1,463,359 528   87 6,000 12,644 6 Short-term 6 Installation of G-traps for garment irons   6,696,774 6,696,774 2,520   416 21,800 62,792 4 Short-term 7 Compressor heat recovery   561,330 561,330 -   35 4,545 5,263 10 Short-term 8 Installation of economizer   1,755,917 1,755,917 -   96 14,182 13,621 12 Medium-term 9 Dryer machine heat recovery   359,259 359,259 -   22 5,455 3,369 19 Medium-term Sub-Total (Thermal)   17,016,573 17,016,573 10,099   992 62,122 150,590 5 Short-term Details of Resources Saving Measures (Thermal)

18. Sl. No. Improvement project identified Savings/yr GHG Reduction (tCO 2 e) Investment (USD) Savings/ yr (USD) Payback Period (months) Payback Type Electricity (kWh) Thermal Energy (MJ) Total Energy (MJ) Water ( m 3 ) Chemical (kg) Process & Water 1 Use of Ozone wash 29,700   107,720 9,378 7,326 27 96,182 29,593 39 Long-term 2  Installation of low liquor ratio machine -   - 9,964 2,442 90,909 8,808 60+ Long-term Sub-Total (Process) 29,700   107,720 19,341 9,768 27 187,091 38,401 58 Long-term TOTAL 280,042 17,016,573 18,041,636 34,300 9,768 1,568 466,823 260,200 22 Medium-term Details of Resources Saving Measures (Process)

19. ASSESSMENT RECOMMENDATIONS

20. Quantifiable Recommendation

21. Description: Replace 90 regular water taps with aerator taps to reduce water consumption . Intervention: Install aerator taps blending air with water, maintaining pressure . Savings per Year: Water Savings: 4,860 liters Financials: Investment: USD 385 Annual savings: USD 2,676 Payback Period: 2 months. REPLACING NORMAL TAPS WITH AERATOR TAPS

22. COMPRESSOR PRESSURE REDUCTION Description Reduce energy consumption of compressors by optimizing air pressure without affecting process operations. Intervention : Reduce compressor pressure: 6.5 bars to 6 bars. Monitor closely, and reduce if possible. Install separate compressors for high-pressure machines Savings per Year: Electricity: 8,019 kWh GHG Emission Reduction: 26 tCO2e Financials : Investment: No Investment Savings per Year: USD 879 Payback Period: No Investment

23. AIR LEAK MONITORING AND REPAIR Project Description : Air leakage measured before baseline visit: 39 %, exceeding allowable rate of 10-15%. Recommended Intervention: Regular air leakage monitoring is advised. Immediate repair post-identification of leaks. Savings per Year : Electricity: 45,446 kWh. GHG Emission Reduction: 51 tCO2e. Financials: Investment: USD 4,545. Yearly Savings: USD 4,982 Payback Period: 11 months.

24. COMPRESSOR AUTOMATED LINE FILTER USING SOLENOID VALVE Project Description: Install auto drainer with solenoid valve in the 1-line filter., it is estimated that 20% of energy can be saved. Recommended Intervention: Efficient Moisture Control Energy Savings Improved Performance Savings per Year: Electricity: 2,310 kWh. GHG Emission Reduction: 3 tCO2e. Financials: Investment: USD 91 Yearly Savings: USD 253 Payback Period: 4 months.

25. VFD FOR ETP BLOWERS & BOILER ID FAN Project Description: Install VFD in 2 ETP blowers & 1 boiler ID fan Recommended Intervention: VFD regulates motor speed, reducing energy consumption. VFD: Optimize energy use for high-capacity motors. Savings per Year: Electricity: 9,534 kWh. GHG Emission Reduction: 13 tCO2e. Financials: Investment: USD 1,702 Yearly Savings: USD 1,045 Payback Period: 20 months.

26. INSTALLATION OF AIR TRIGGER NOZZLE Project Description: 50 open air hose points without nozzles leading to compressed air misuse. Recommended Intervention: Install air trigger nozzles to reduce airflow and prevent continuous waste. Savings per Year: Electricity: 1,203 kWh GHG Emission Reduction: 24 tCO2e Financials: Investment: USD 205 Savings per Year: USD 139 Payback Period: 18 months

27. TUBE LIGHT HEIGHT REDUCTION Project Description : Reduce to 6.8 ft in finishing & inspection. Recommended Intervention : Reduce from 7.5 ft to 6.8 ft. Conduct LUX study: Determine required light quantity. Reduce overhead lights: Up to 20% reduction achievable. Savings per Year: Electricity: 26,634 kWh GHG Emission Reduction: 37 tCO2e Financials : Investment: USD 4,545 Savings per Year: USD 2,920 Payback Period : 19 months

28. USE OF DIRECT-DRIVE EXHAUST FAN INSTEAD OF BELT-DRIVEN EXHAUST FAN Project Description : 40 3-phase 1.1 kW belt-driven exhaust fans. Recommended Intervention : Transition to direct-drive fans for improved reliability and reduced maintenance complexity. Enhanced efficiency, and minimized downtime from belt-related issues. Savings per Year: Electricity: 48,000 kWh. GHG Emission Reduction: 50 tCO2e . Financials: Investment: USD 10,618 Yearly Savings: USD 5,262 Payback Period: 24 months.

29. POWER SAVING OF AC THROUGH PROGRAMMABLE AC SAVER Project Description: The facility has 48 non-inverter and inverter air conditioning units Recommended Intervention: O ptimize compressor runtime Micro-controller-based AC control saves 20-25% electricity, and maintains accurate temperatures. Savings per Year: Electricity: 70,587 kWh. GHG Emission Reduction: 80 tCO2e. Financials: Investment: USD 11,418 Yearly Savings: USD 7,738. Payback Period: 18 months.

30. INSTALLATION OF ROOFTOP SOLAR Project Description: Available rooftop area: 2,027 m 2 for 290 kWp solar plant. Recommended Intervention: Install solar plant with net energy metering (NEM) system. Utilize solar energy to achieve long-term savings. Maximize ROI through NEM policy mechanism. Offset electricity bills with solar-generated credits Savings per Year: Electricity: - kWh. GHG Emission Reduction: 363 tCO2e. Financials: Investment: USD 171,101 Yearly Savings: USD 41,082. Payback Period: 50 months.

31. Project Description: 2,600 pcs of 28W T5 fluorescent tube lights being used in 3 rd - 5 th floors. Recommended Intervention: Replace 28W T5 with 22 W LED lights. Better efficiency and longer lifespan. Savings per Year: Electricity: 38,610 kWh. GHG Emission Reduction: 52 tCO2e. Financials: Investment: USD 13,000 Yearly Savings: USD 4,233 Payback Period: 37 months. REPLACEMENT OF FLUORESCENT LIGHT WITH LED LIGHT

32. INSULATION OF VALVES (HEADER) Project Description: Uninsulated steam valves: 7 valves with temperatures of 130 – 165 °C. Recommended Intervention: Apply insulation to all uninsulated portions. Insulation prevents condensate formation, improves steam dryness and heat transfer. Savings per Year: Natural Gas: 2,470 m 3 . GHG Emission Reduction: 5 tCO2e. Financials: Investment: USD 117 Yearly Savings: USD 718. Payback Period: 2 months.

33. BURNER TUNING AND EXCESS AIR CONTROL FOR BOILERS Project Description: Perform tuning on two boilers in SGIL Recommended Intervention: Perform professional boiler tuning. Enhance efficiency Savings per Year: Natural Gas: 26,670 m3 . GHG Emission Reduction: 51 tCO2e. Financials: Investment: USD 1,091 . Yearly Savings: USD 7,747. Payback Period: 2 months.

34. CONDENSATE RECOVERY FROM WASHING UNITS AND GARMENT IRONS Project Description: Condensate from washing unit and ironing section not being recovered.. Recommended Intervention: Recover condensate from dyeing unit and ironing section. Savings per Year: Water: 7,051 m3 . Natural Gas: 84,026 m3 . GHG Emission Reduction: 162 tCO2e. Financials: Investment: USD 5,455. Yearly Savings: USD 26,799 Payback Period: 2 months.

35. REPAIR OR REPLACEMENT OF STEAM TRAPS  Project Description: During the baseline visit, sixteen 1 inch steam traps were found to have leaks or malfunctions, resulting in steam loss. Recommended Intervention: Repair or replace faulty steam traps and implement a regular monitoring system. Savings per Year: Natural Gas: 60,720 m3 . GHG Emission Reduction: 117 tCO2e. Financials: Investment: USD 3,478 Yearly Savings: USD 17,638. Payback Period: 2 months.

36. FLASH STEAM RECOVERY  Project Description: Loss of water and heat energy due to uncollected flash steam. Recommended Intervention: Install a heat exchanger to capture energy from the flashing steam. Redirect the recovered flash steam to the boiler feedwater tank for direct injection. Savings per Year: Water: 528 m3 . Natural Gas: 45,294 m3 . GHG Emission Reduction: 87 tCO2e. Financials: Investment: USD 6,000. Yearly Savings: USD 12,644. Payback Period: 6 months.

37. INSTALLATION of G-TRAPS FOR GARMENT IRONS Project Description: Install G-traps in the condensate return lines of 400 steam irons in the garment section. Recommended Intervention: Efficient condensate removal Prevention of live steam loss improved steam heat utilization and energy efficiency. Savings per Year: Water: 2,520 m3 . Natural Gas : 216,169 m3 . GHG Emission Reduction: 416 tCO2e. Financials: Investment: USD 21,800 . Yearly Savings: USD 62,792. Payback Period: 4 months.

38. COMPRESSOR HEAT RECOVERY Project Description: Install heat recovery system for a 75 kW compressors to enable utilization of waste heat. Potential integration of chiller or hot water module. Recommended Intervention: Utilize compressors heat recovery system to transfer waste heat via a heat exchanger. Heat transfer fluid absorbs waste heat for various applications. Savings/Year: Natural Gas : 18,119 m3 GHG Emission Reduction: 35 tCO2e Financials: Investment: USD 4,545 Annual Savings: USD 5,263 Payback Period: 10 months

39. INSTALLATION OF ECONOMIZER Project Description: Fixing Economizer in old 4 ton boiler Recommended Intervention: Use exhaust gas heat to elevate boiler feed water temperature. Manufacturers utilize economizers for efficient boiler operation . Savings/Year: Natural Gas : 49,943 m3 GHG Emission Reduction: 96 tCO2e Financials: Investment: USD 14,182 Annual Savings: USD 13,621 Payback Period: 12 months

40. DRYER MACHINE HEAT RECOVERY Project Description: Installing a heat recovery unit in 6 dryer machines. Recommended Intervention: Capture and utilize waste heat from dryer machine. Heat exchanger transfers heat for preheating. Heat recovery unit improves dryer machine efficiency. Reuse waste heat, reduce heating energy.. Savings/Year: Natural Gas : 11,597 m3 GHG Emission Reduction: 22 tCO2e Financials: Investment: USD 5,455 Annual Savings: USD 3,369 Payback Period: 19 months

41. USE OF OZONE WASH Project Description: Install one ozone washing machine Recommended Intervention: Energy and water efficient. Jeanologia G2 : Latest eco-efficient ozone textile technology. Excess dye elimination: Achieve desired outdoor garment look. Zero-discharge process: No water or chemicals involved. Reduced production steps: Efficient denim and knit manufacturing. Savings/Year: Electricity: 29,700 kWh Water : 9,378 m3 GHG Emission Reduction: 27 tCO2e Chemical: 7,326 kg Financials: Investment: USD 96,182 Annual Savings: USD 29,593 Payback Period: 39 months

42. LOW MLR MACHINE Project Description: Replace 5 belly washing machine with low liquor ratio machine Recommended Intervention: Reduced water consumption Cost-effective solution Savings/Year: Water : 9,964 m3 Chemical: 2,442 kg Financials: Investment: USD 90,909 Annual Savings: USD 8,808 Payback Period: 60+ months

43. Non-quantifiable Recommendation

44. Repairing the Variable Frequency Drive (VFD) in a washing machine Diagnose, replace faulty components, reprogram, and configure. Replace faulty parts in the VFD. Reprogram and configure Closed loop compressed air system` Closed loop air system maintains pressure better Loop design maintains the same pressure at distant points Daylight utilization Maximize daylight use to reduce floor lighting. Add transparent sheets in sheds for more daylight. Increase daylight use, cut energy consumption Non-quantifiable Recommendation

45. Switching off lights and fans when not required. Keep off light-fan, when no need to use Installation of automatic emergency light Upgrade to automatic emergency light: Activates during power disruptions. Energy-saving solution: Efficient usage during main power loss. Safety and efficiency enhancement: Replace with automatic emergency light. Power outage activation: Automatic light for improved energy usage. Installation of spot light in sewing machine Provide individual spotlights for each machine. train workers reduce overhead lighting. Non-quantifiable Recommendation

46. Air amplifier Air amplifiers reduce compressor pressure by utilizing surrounding air. High-pressure machines benefit from air amplifiers' efficiency. Air amplifiers pull in large volumes of air for high-velocity flows. Proper steam line designing Install a moisture separator to remove excess steam moisture. Place steam traps every 30 meters for efficient condensate removal. Install g-traps in steam irons for condensate drainage. Ensure optimal steam distribution and iron performance. Design steam line with separator, traps, and g-traps Non-quantifiable Recommendation

47. Energy efficient ceiling fans Reduce electricity consumption by up to 40%. IE4 motor installation Gradually replace old motors with IE4 motors . Section-wise meter installation Meters track resources accurately. Installation leads to noticeable improvements. 10 electricity meters 2 water meters 2 Steam meter Non-quantifiable Recommendation

48. KPI trend analysis and root-cause analysis KPI trend analysis clarifies resource efficiency. Improvements guided by analysis enhance resource utilization. Presenting KPI data raises employee resource awareness. Awareness-raising and training on resource optimization Regular training boosts resource awareness for employees. Training enhances management's resource management knowledge. Non-quantifiable Recommendation

49. CHEMICAL MANAGEMENT (BASELINE ASSESSMENT)

50. Self Assessment Report Varified Report Score Card Varified Report

51. Self Assessment Report Varified Report

52. Chemical Inventory List (CIL) The chemical inventory list was quite informative. Names of all chemicals, names of chemical suppliers, lot number, batch number, CAS number, purchase & expiry date, PPE information, hazard information from Safety Data Sheets (SDS), and chemical stock & balance information were given in the list. Safety Data Sheet (SDS) SDS was found for all chemicals. SDS were available for floors where chemicals were being used. All the SDS was translated into the local languages. Factory Best Practices

53. Employee Training The workers are well-trained. They are aware of the uses of chemicals. They know how to handle chemicals & they know what to do in case of a chemical spill. The facility conducts monthly training for staff and the training modules cover all chemical topics. Personal Protective Equipment (PPE) PPE was used where the chemicals were used. All the workers were wearing the proper PPE while they were handling the chemical. All the workers know about the use of PPE & importance of PPE. Factory Best Practices

54. Chemical Store & Sub-Store The chemical store was well-organized and clean. First Expiry, First Out (FEFO) was properly maintained. All the dyestuff & pigment are opened carefully and closed tightly. Chemical storage area easy entry and exit in case of any emergencies. PPE & spill kit was available & well-maintained. Effluent Treatment Plant (ETP)   A backup Plan is available and meets the requirements.  An In-house ETP lab is available. Inlet and outlet flow meters are available & functional. Factory Best Practices

55. Policy & Procedure All policies and procedures should be made strong & all clear information should be mentioned there. The facility has to make some policies- Chemical traceability policy. Supply chain traceability policy. Chemical use and handling policy & procedure. Health and safety policy & procedure. All policies and procedures must be signed off by top management. All policies must be transparent. Factory Needs to Update

56. Safety Data Sheet (SDS) SDS were available for floors where chemicals were being used, however - All the SDS was translated into the local languages but they were not translated like the original SDS. SDS were not in GHS format. PPE is different for different chemicals. However, the facility wrote the same PPE for all chemicals. Employee Training & Evaluation Process There is no evaluation after training. Evaluation is important, because- Select the method ● Written exam ● MCQ ● Assignment submission. Through evaluation, every worker will know better about chemical uses & handling or any accidental issues that occur through chemicals. If there is any gap in someone's knowledge, it will be cleared through the evaluation process. Factory Needs to Update

57. Emergency Response Plan (ERP) Have to make individual (ERP) for chemical incidents. This plan should include some topics like- Details about Eye Wash and body shower station management . Chemical spill management. Chemical fire safety management for chemical-related fires. First aid management. (SOP) for Transporting Chemicals During the visit, no SOP was found for transporting chemicals. The facility needs to maintain a SOP for transporting chemicals both internally and externally. Factory Needs to Update

58. Chemical Store & Sub-Store A few things need to be updated- In the main store, some chemicals were not labelled. Maybe the label was torn during transport. In such circumstances, additional labels must be kept by the supplier. Storages for dry (solid) and wet (liquid) chemicals need to be segregated. In the sub-store, secondary containment should be available for solid and liquid. Chemical Flow Diagram Have to make a chemical flow diagram. This diagram indicates the flow of chemicals through- Factory Needs to Update Purchasing Handling Delivery Processing Storage Disposal

59. CHALLENGES & OPPORTUNITY One significant hurdle arises from the frequent turnover of factory personnel, which complicates the tracking of crucial documentation and data.  Additionally, the lack of proper metering exacerbates the difficulty in accurately monitoring energy consumption. Inadequate metering infrastructure limits the ability to gather precise data on energy usage across various production processes, hindering the identification of inefficiencies and areas for improvement.