Report Ea For Badsha - Updated - 05 Dec 2023 Susnex

SECTION-1
General information
1.1: BADSHA TEXTILES LTD. - A CONCISE OVERVIEW
Introduction:
Badsha Textiles Ltd. is widely recognized for its excellence in yarn manufacturing and its steadfast
commitment to philanthropy and socio-economic development. Since its establishment in 2000,
remarkable success has been consistently achieved by the company, under the visionary
leadership of Managing Director Mr. Md. Badsha Mia.
Mission:
A core mission of being a leader in the textile industry, both in Bangladesh and beyond, is pursued
by the company. With an impressive annual turnover of $258 million, significant contributions to
philanthropic causes and the fostering of sustainable socio-economic development are dedicated
to. Over the past decade, industry benchmarks have been set, and a legacy for future generations
has been established.
Infrastructure and Cutting-Edge Technology:
State-of-the-art production facilities are operated by Badsha Textiles Ltd., equipped with cutting-
edge machinery and technology sourced from renowned global brands in Switzerland, Germany,
Italy, and Japan. Brands like Seema-saki, Rieter, Savio Polar, Texparts, and Uster constitute the
backbone of our production, enabling the consistent production of premium textiles
Sustainability Focus:
As staunch advocates of sustainability, BCI (Better Cotton Initiative) and Organic certified cotton
yarn are offered to meet the growing demand for eco-friendly and socially responsible textiles. Our
commitment to sustainable practices underscores our dedication to a greener future.
1.2: A SUMMARIZED PORTRAIT OF PROCESS
Badsha Textiles Ltd. follows a meticulously designed yarn manufacturing process, ensuring the
production of high-quality yarn that aligns with customer expectations and industry standards. The
process flows systematically from raw cotton procurement to the delivery of the finished product:
1. Raw Cotton Procurement: The journey commences with the careful selection and procurement
of high-quality raw cotton from diverse sources.
2. Storage: Upon arrival, the raw cotton is stored in dedicated areas within the facility, facilitating
efficient inventory management and accessibility.
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3. Blowroom: In the blowroom, the raw cotton bales undergo opening and cleansing processes.
This eliminates foreign particles, dust, and impurities through mechanical means, rendering the
material more manageable.
4. Carding: The cleaned cotton fibers are fed into carding machines. These machines align the
fibers, remove residual impurities, and generate a delicate web of fibers known as a "carded sliver."
5. Breaker Draw Frame: The carded sliver advances to a breaker draw frame for further
processing. This stage involves doubling and drafting the sliver to enhance its quality and
consistency.
6. Simplex: The processed sliver proceeds to a simplex machine, further refining its thickness and
drafting it to the desired level of fineness. This prepares the material for spinning.
7. Ring Spinning: The processed sliver is then transformed into yarn via ring spinning machines.
These machines twist the sliver into single yarn strands, which are wound onto bobbins. This phase
yields the fundamental single yarn.
8. Finishing: To enhance its characteristics, the single yarn undergoes finishing procedures. This
may encompass twisting, plying (if required), and the application of specific treatments or finishes to
achieve the desired yarn properties.
9. Storage: The finished yarn is meticulously stored in a controlled environment to preserve its
quality and prevent any potential damage.
10. Delivery: Upon receiving customer orders, the requisite quantity and type of yarn are retrieved
from storage. The yarn is then meticulously packaged in accordance with customer specifications
and prepared for timely delivery.
11. Documentation and Records: Comprehensive documentation is maintained throughout the

entire process. This documentation encompasses details regarding raw materials, processing
steps, quality assessments, and more. This meticulous record-keeping ensures stringent quality
control and traceability throughout the manufacturing journey.
1.3: THE PRESENT POWER LANDSCAPE OF BADSHA TEXTILES LTD.:
Badsha Textiles Ltd. has established a comprehensive energy management system that optimizes
resource utilization and sustainability:
• Power Generation: The company relies on a Combined Heat and Power (CHP) unit
featuring 8 natural gas generators (10.935 MW) for a steady supply of electrical energy.
• Waste Heat Recovery: To reduce waste and enhance efficiency, exhaust waste heat is
reclaimed via 4 Exhaust Gas Boilers, while engine jacket water waste heat is harnessed by
2 Vapor Absorption chillers.
• Steam Distribution: Steam generated from the Exhaust Gas Boilers not only drives 6
Vapor Absorption chillers but also supports critical processes.
• Backup System: A natural gas boiler (5 tons/hr) stands ready for operation during peak
demand periods, ensuring energy resilience.
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• Operational Consistency: The CHP unit operates around the clock, maintaining a historical
load factor of 75-90% and demonstrating a commitment to reliable power.
• Energy Utilization: By efficiently converting natural gas into electricity and thermal energy,
Badsha Textiles Ltd. powers production, utilities, HVAC systems, and auxiliary equipment.
1.4: ENERGY USE ANALYSIS AND BENCHMARKING
1.4.1: Establishment of base year consumption

In its production processes, Badsha Textiles Ltd. effectively harnesses both Electrical and Thermal
energy. The operational energy spectrum encompasses only Natural Gas as the primary energy
sources. Meanwhile, electricity, steam, and compressed air function as secondary "carrier" energies,
facilitating the transport of energy within the system. Specifically, in the year of 2021~2022
(spanning January to December), the following energy utilization figures were recorded:
Table-1 : Energy Consumption status
ENERGY ALL GHGs

TOTAL ENERGY CONSUMPTION 2021
SOURCE OF ENERGY CONSUMPTION (Tonnes
kWh Ton m³ GJ % BDT USD CO2e)
Natural Gas
65,665,207 -- 17,199,536 670437.91 99.98% 207,082,413 2,443,572 32451.93
(Captive Power Generation)
Natural Gas
-- -- 3,594 140.09 0.02% 43,272 511 6.78
(Boiler-Steam Generation)
Total 65,665,207 -- 17203130 670578.01 100% 207,125,685 2,444,083 32458.71
ENERGY
TOTAL ENERGY CONSUMPTION 2022 ALL GHGs
SOURCE OF ENERGY CONSUMPTION COST
kWh Ton m³ GJ % BDT USD (Tonnes CO2e)
Natural Gas
65,493,258 -- 16,983,995 662036.13 99.93% 1,937,364,310 20,923,535 123572.10
(Captive Power Generation)
Natural Gas
-- -- 11,295 440.28 0.07% 1,288,421 13,915 21.31
(Boiler-Steam Generation)
Total 65,493,258 16995290 662476.40 100% 1,938,652,730 20,937,449 123593.41
Figure-1: Energy consumption share breakdown
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The data tells us that energy consumption decreased slightly from 2021 to 2022, which suggests
some potential improvements in efficiency. However, there was a significant increase in the cost of
energy consumption, primarily due to heavy reliance on natural gas. The most concerning trend is
the sharp rise in greenhouse gas emissions, emphasizing the urgency of addressing emissions to
mitigate environmental impacts and combat climate change.
In summary, it's crucial to focus on optimizing energy use, diversifying energy sources, and
implementing strategies to reduce emissions. These actions are necessary not only to control costs
but also to enhance sustainability and reduce environmental harm.
1.4.2 Energy consumption and production pattern
At Badsha Textiles Ltd., the production processes rely on the consumption of both Electrical and
Thermal energy, with these two forms of energy working together to produce the final product. The
following data showcases the energy consumption and production trends for the baseline year of
2021 and the subsequent year, 2022:
A salient observation is that natural gas consumption and production fluctuated throughout the year.
May 2022 had the highest consumption at 1,550,421 m3, while July 2022 had the lowest at
1,372,754 m3. Notably, there was a decrease in consumption from 2021 to 2022, especially in
September and October. Similarly, production levels were highest in January 2021 at 2,288,770 m3
and lowest in July 2022 at 1,761,210 m3. Production also decreased from 2021 to 2022. Seasonal
trends were observed, with higher levels during winter and lower levels during summer. December
2022 showed a significant decrease in consumption and higher production compared to December
2021, indicating a potential shift in supply and demand dynamics at year-end.
1.4.3 Specific energy consumption (SEC)
Energy's role in production is pivotal, and understanding energy consumption per unit of production
is essential. Specific Energy Consumption (SEC) serves as a critical metric for quantifying this
relationship and facilitating industry-wide comparisons. SusNex conducted a thorough assessment
of SEC data for 2021 and 2022, despite challenges in benchmarking due to varying factors.
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The analysis resulted in the establishment of approximate benchmarks, shedding light on energy
efficiency within the facility. These benchmarks offer invaluable insights for strategic decision-
making, empowering the facility to adopt measures that enhance energy efficiency, reduce costs,
and contribute to a sustainable future. In a business context, where efficiency and sustainability are
paramount, these findings play a crucial role in guiding energy management strategies.
Figure-2: Specific Energy Consumption status
In the baseline year of 2021, we observed that the maximum SEC peaked in July at 28.17 MJ/KG,
while the minimum SEC hit its low point in February at 23.49 MJ/KG, with an average SEC settling
at 25.16 MJ/KG.
Moving to the subsequent year, 2022, SEC values exhibited more significant fluctuations. The
maximum SEC surged in November to 31.47 MJ/KG, while the minimum SEC dipped to 23.49
MJ/KG in February, and the average SEC for the year increased to 27.27 MJ/KG.
Overall observations reveal a noticeable increase in SEC values from 2021 to 2022, as indicated by
the higher average SEC in 2022. The maximum SEC also saw an uptick from 2021 to 2022,
suggesting increased energy consumption during peak months, while the minimum SEC remained
relatively stable between the two years, with minimal variation.
To address these observations, we recommend crucially focusing on energy efficiency measures to

reduce consumption during peak months in response to the increased SEC values from 2021 to
2022. Implement robust monitoring and energy-saving practices, especially during high-
consumption months like November and August in 2022, to effectively control energy costs.
Maintain or reduce SEC during low-consumption months, such as February, by ensuring efficient
energy management practices are consistently in place. These recommendations aim to tackle the
observed increase in SEC and promote sustainable energy consumption practices in the
subsequent year.This goal not only aligns with international energy efficiency standards but also
contributes to a more sustainable future. The proactive efforts required to maintain this SEC will
result in substantial energy conservation, cost savings, and a reduced carbon footprint. By
embracing this practice, the factory can set itself on a path of sustained energy efficiency and
environmental responsibility, fostering a greener and more prosperous tomorrow.
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SECTION-2
Energy Performance Evaluation
Of
Captive Power Plant (CPP)
2.1 ENERGY UTILIZATION FRAMEWORK
Badsha Textiles Ltd. efficiently satisfies its diverse energy requirements (electrical, steam,
compressed air, cooling) through a robust energy infrastructure. The centerpiece of this system is
the Combined Heat and Power Unit, guaranteeing a dependable energy supply for all production
processes. Below is an overview of Badsha Textiles Ltd.'s energy infrastructure.
Badsha Textiles Ltd.: A Model of Sustainable Energy Integration
In its pursuit of environmentally conscious and energy-efficient practices, Badsha Textiles Ltd. has
established an innovative cogeneration platform that adeptly fulfills its dual energy needs: electrical
and thermal. This cutting-edge system underscores our unwavering commitment to sustainability
while seamlessly integrating various components for optimal energy generation and waste heat
recovery.
Electrical Energy Generation: Powering Progress
The electrical energy demand is met through the utilization of a Combined Heat and Power Unit,
equipped with 8 Natural Gas Generators. Among these, 7 are of the renowned Jenbacher/Austria
JMS420GSNL models, each boasting a capacity of 1415KW, and 1 is a Caterpillar generator with a
capacity of 1030 KW. This collective installation provides an impressive installed capacity of 10.935
MW, ensuring a reliable source of electrical energy.
Waste Heat Recovery: Maximizing Efficiency
A commitment to sustainability is demonstrated through the waste heat recovery system. It

comprises 4 Exhaust Gas Boilers (EGB), with 2 units rated at 2 tons/hr. and 2 units at 3 tons/hr.
These boilers capture the thermal potential of exhaust gases. Additionally, the engine jacket water
waste heat recovery unit includes 2 hot water Vapor Absorption chillers, one with a capacity of 500
TR and the other with 650 TR. Six more vapor absorption chillers, each with a capacity of 496 RT,
are steam-powered by the exhaust gases through a centralized steam distribution system.
Remarkably, an estimated 90% of the generated steam fuels these 6 absorption chillers, with the
remaining 10% dedicated to the YCP process.
Thermal Energy Generation: Ensuring Consistency
The importance of consistent thermal energy supply is recognized, with a Natural Gas-fired
horizontal fire tube packaged boiler with a 5-ton/hr. capacity in place. This boiler primarily operates
during periods of high steam demand, ensuring uninterrupted production processes. Maintenance
records indicate that the boiler operates for a maximum of 2-3 months per year, underscoring its
reliability.
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Operational Excellence: Reliability in Action
The captive generation plant operates 24/7, 26 days per month, maintaining a remarkable load
factor ranging between 75% and 90% based on historical performance data. The Combined Heat
and Power (CHP) unit is consistently well-maintained, ensuring operational excellence and reliability.
Environmental Responsibility: Minimizing Footprint
At Badsha Textiles Ltd., a commitment to environmental responsibility is upheld. Natural Gas is

prioritized as the primary energy source due to its clean-burning nature, resulting in significantly
reduced greenhouse gas emissions. A holistic approach to energy utilization extends to powering
various machinery, utility functions, HVAC systems, and other auxiliaries across the facility.
In summation, a model of sustainable energy integration has been realized by Badsha Textiles Ltd.,
where both operational excellence and a reduced ecological footprint are achieved through
innovative approaches to energy generation and waste heat recovery.
Figure-3: Schematic diagram of existing cogeneration systems.
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Figure-4: Visual representation showcasing the setup of the existing captive power plant infrastructure.
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2.2: OPERATIONAL PROFILE OF CAPTIVE POWER PLANT
The captive plant's natural gas generator operates continuously for 24 hours each day, covering a
span of 26 days per month. The plant's load profile is subject to fluctuations based on the energy
requirements of BTL's process equipment and auxiliaries. The energy audit team has documented
various operational parameters, including gas consumption, average demand and energy
generation daily is presented below.
Figure5-: Generator consumption generation and demand profile
Observations and Analysis:
1. Gas consumption: Shows daily fluctuations, ranging from 52,000 m3 to 55,200 m3. There is
a notable general uptrend from August to September, with most September values
surpassing August. Mid-month peaks occur around the 17th of both months. Although slight
variations exist, a repeating monthly pattern is evident. August witnesses a substantial
increase from around 52,000 m3 to 55,200 m3 by month-end. In contrast, September
maintains steady consumption levels with minor fluctuations around the mid-month peak. In
summary, there is an overall upward trend in gas consumption over the two months.
2. Energy generation: The maximum energy generation observed in any generation of power
plants is 13,941 KWh. This indicates that at the peak performance, one of the power plants
generated a substantial amount of electricity. On average, the power plants generated 2,290
KWh of electricity. This represents a typical level of electricity production across the
generations.
3. Demand: The demand shows daily fluctuations in power demand for all generators. G2, G3,
and G4 consistently have higher power demand, averaging around 1,173 KW to 1,178 KW.
G8 consistently has the lowest power demand, averaging around 1,160 KW. G5, G6, and
G7 exhibit variable power demand with fluctuations, averaging around 1,166 KW. Power
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demand stabilizes in the latter part of August and remains relatively stable into September,
with occasional anomalies.
4. Load factor: In general, most of the days exhibit relatively consistent load factors, which
suggests a stable demand for electrical power during this period. The maximum load factor
observed at 86.87% indicates a peak in electricity demand, which might be due to specific
events or high consumption days. With an average load factor of 82.87%, it's evident that,
on average, the electrical system is operating at a relatively high capacity during this period.
Days with significantly lower load factors, such as the day with 51.83%, may warrant further
investigation to understand the underlying causes, like maintenance or unusual events.
5. Specific fuel consumption (m3/KWh) : A measure of efficiency, fluctuates, with the maximum
being 0.297 m3/KWh, indicating less efficient conversion of gas to electricity, while the
minimum is 0.247 m3/KWh, denoting better efficiency. On average, specific fuel
consumption is around 0.259 m3/KWh.
The overall trend reveals dynamic energy generation and gas consumption patterns across various
generations of power plants, highlighting the plant's adaptability to meet shifting energy demands
within BTL's processes. Fluctuations in total energy output signify the plant's capacity to respond to
increased electricity generation requirements when needed. Daily variations in "Plant Efficiency"
emphasize the importance of monitoring operational efficiency, with lower efficiency values
indicating potential areas for improvement. The variance in energy generation among different
generators underscores the plant's flexibility in adapting to diverse load profiles, a crucial factor in
ensuring the effective and reliable supply of energy for BTL's processes.
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2.3 PERFORMANCE OF CAPTIVE GENERATOR
The performance evaluation of individual Gas Gensets was meticulously conducted using the
indirect method (ASME PTC 22). This method involved systematic analyses performed with the aid
of a Combustion Analyzer, enabling precise measurements of various parameters, including flue
gas characteristics and other essential data. All recorded data was thoughtfully entered into a pre-
programmed Excel spreadsheet for comprehensive analysis.
Within the framework of the indirect method, the resulting thermal efficiency values were calculated
as percentages of the input energy at the generator's front end. This involved the detailed
quantification of different types of measurable losses, each expressed as a percentage of the total
input energy. These losses encompassed combustion losses, radiation losses, convection losses,
unburned fuel losses, excess air losses, and various mechanical losses. The aggregation of these
individual losses yielded the total measurable losses. To ascertain the desired overall thermal
efficiency of the device, these total measurable losses were then subtracted from the initial 100%
input energy.
In summary, this exhaustive evaluation delivers invaluable insights into the gas genset's
performance, affording a lucid understanding of its thermal efficiency. Moreover, it sheds light on
opportunities for optimizing energy utilization through waste heat recovery and other efficiency-
enhancing measures. The key performance parameters of the generator, along with the measured
flue gas data, are presented below for a thorough assessment of the individual genset's actual
performance.
Table-: Measured Generator flue gas data
Figuer-6: Sample operating profile
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The gas engine's operating data indicates that it is operating within anticipated and healthy
parameters. Key observations and findings, such as its ability to handle varying loads, consistent
power factor values, stable frequency at 50 Hz, steady RPM at 1500, and temperatures (including
generator winding, bearing, coolant, and intake air) staying within standard ranges as per engine
manufacturer instruction, ISO 8528, ASME PTC 22 and others guidelines, all conform to industry
best practices, affirming safe and efficient operation. Furthermore, the gas pressure remains
consistently within specified limits.
Table-2 :Measured Flue Gas data
Measured Parameter Symbol Unit Gen # 01 Gen # 02 Gen # 03
Oxygen Content O2 % 9.2 10.1 10.3

Carbon Dioxide Content CO2 % 6.7 6.2 6
O
Flue Gas Temperature TS C 515 504.3 500
O
Ambient Temperature TA C 36 36 36
Carbon Monoxide CO ppm 426 501 500
Gen # 04 Gen # 05 Gen # 06

Measured Parameter Symbol Unit
Oxygen Content O2 % 10.3 10.2 10.1
Carbon Dioxide Content CO2 % 6 6.1 6.2
O
Flue Gas Temperature TS C 504.6 503 506.8
O
Ambient Temperature TA C 36 36 36
Carbon Monoxide CO ppm 540 582 520
Gen # 07 Gen # 08
Measured Parameter Symbol Unit
Oxygen Content O2 % 10.2 9.9
Carbon Dioxide Content CO2 % 6.1 6.3
O
Flue Gas Temperature TS C 501 510
O
Ambient Temperature TA C 36 36
Carbon Monoxide CO ppm 510 515
Table-3: Composition of Natural Gas
Composition Unit Value

Carbon % 74.34
Hydrogen % 24.5
Sulphur % 0.0
Nitrogen % 0.254
Carbon Di Oxide % 0.6
Oxygen % 0.0
Gross Calorific value of kCal/kg 12940
fuel (Natural Gas)
Density of Natural Gas kg/m3 0.718
Specific heat of flue gas kCal/kg.K 0.23
Specific heat of vapor kCal/kg.K 0.45
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Table-4 : Generator Efficiency Calculation Based on Indirect Method
Particulars Unit Gen-1 Gen-2 Gen-3 Gen-4 Gen-5 Gen-6

kg/kg of
Theoretical Air Required 17.15 17.15 17.15 17.15 17.15 17.15
fuel
Excess Air Supplied (EA) % 77.97 92.66 96.26 96.26 94.44 92.66
Actual Mass of Dry Air Supplied/kg of Mass of air/
30.52 33.04 33.66 33.66 33.35 33.04
fuel (AAS) kg of fuel
m = Mass of Dry Flue Gas Kg 31.28 33.80 34.41 34.41 34.10 33.80
Flue Gas losses
L1, Heat loss due to dry flue gas
% 26.63 28.13 28.38 28.66 28.31 28.28
(Sensible)
L2, Heat loss due to evaporation of
water formed due to H2 in fuel % 13.62 13.54 13.51 13.54 13.53 13.56
(Latent+Sensible)
L3, Heat Loss due to Moisture in Air
% 0.92 0.97 0.98 0.99 0.97 0.97
(Sensible)
L4, Heat loss due to incomplete
combustion of Carbon (Formation of % 0.21 0.26 0.27 0.29 0.31 0.27
CO)
Total Flue Gas loss % 41.38 42.91 43.14 43.49 43.13 43.09
Heat Rejection Losses (Engine J/W, Lube Oil, After Cooler and surface radiation)
L5, Heat Rejection to HT circuit % 17.56 14.70 14.70 14.70 14.70 14.70
L6, Heat Rejection to LT circuit % 7.45 5.66 5.66 5.66 5.66 5.66
L7, Heat Rejection to Radiation
% 3.84 2.00 2.00 2.00 2.00 2.00
(Engine side + Alternator side)
Total Heat Rejection Loss % 28.85 22.36 22.36 22.36 22.36 22.36
Combustion and Heat to Electric Efficiency based on HHV
Combustion Efficiency (100-L1-L2-L3-
% 58.62 57.09 56.86 56.51 56.87 56.91
L4)
Heat to Electric conversion Efficiency
% 29.77 34.73 34.50 34.15 34.51 34.55
on HHV
Heat to Electric conversion Efficiency
34.47 40.17 39.89 39.50 39.92 39.97
on LHV
Particulars Unit Gen-7 Gen-8

Theoretical Air Required kg/kg of fuel 17.15 17.15
Excess Air Supplied (EA) % 94.44 89.19
Actual Mass of Dry Air Supplied/kg of fuel (AAS) Mass of air/ 33.35 32.44
kg of fuel
m = Mass of Dry Flue Gas Kg 34.10 33.20
Flue Gas losses
L1, Heat loss due to dry flue gas (Sensible) % 28.18 27.97
L2, Heat loss due to evaporation of water % 13.52 13.59
formed due to H2 in fuel (Latent+Sensible)
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L3, Heat Loss due to Moisture in Air (Sensible) % 0.97 0.96
L4, Heat loss due to incomplete combustion of % 0.27 0.27
Carbon (Formation of CO)
Total Flue Gas loss % 42.95 42.79
Heat Rejection Losses
L5, Heat Rejection to HT circuit (JW+LO) % 14.70 14.70
L6, Heat Rejection to LT circuit % 5.66 5.66
L7, Heat Rejection to Radiation (Engine side + % 2.00 2.00
Alternator side)
Total Heat Rejection Loss % 22.36 22.36
Combustion and Heat to Electric Efficiency based on HHV
Combustion Efficiency (100-L1-L2-L3-L4) % 57.05 57.21
Heat to Electric conversion Efficiency on HHV % 34.69 34.85
Heat to Electric conversion Efficiency on LHV 40.12 40.33
Table-5: Generator Plant Output Base Case
Parameters Unit GEN-1 GEN-2 GEN-3 GEN-4 GEN-5 GEN-6

Specific Fuel Consumption on HHV m3/KWh 0.317 0.272 0.274 0.277 0.274 0.273
Specific Fuel Consumption on LHV m3/KWh 0.274 0.235 0.237 0.239 0.237 0.236
Heat rate based on HHV Mj/Kwh 12.091 10.364 10.435 10.541 10.430 10.420
Heat rate based on LHV Mj/Kwh 10.444 8.961 9.025 9.114 9.019 9.007
Electricity generation per SCM of fuel Kwh/m3 3.15 3.68 3.65 3.62 3.65 3.66
Averag demand of each Generator KW 840 1173 1178 1160 1166 1178
Average Natural Gas consumption per
m3/hr 266.51 318.92 322.56 320.76 319.06 322.03
hour
Fuel cost of electricity generation Tk/SCM 30 30 30 30 31 32
Elect. Gen.cost (consider fuel cost
Tk/KWh 9.52 8.16 8.21 8.30 8.48 8.75
only)
Parameters Unit Gen-7 Gen-8

Specific Fuel Consumption on HHV m3/KWh 0.272 0.271
Specific Fuel Consumption on LHV m3/KWh 0.235 0.234
Heat rate based on HHV Mj/Kwh 10.376 10.329
Heat rate based on LHV Mj/Kwh 8.974 8.926
Electricity generation per SCM of fuel Kwh/m3 3.67 3.69
Average demand of each Generator KW 1185 1181
Average Natural Gas consumption per hour m3/hr 323 320
Fuel cost of electricity generation Tk/SCM 30 33
Elect. Gen. cost (consider fuel cost only) Tk/KWh 8.17 8.94
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Figure-7: Generator heat balance Sankey diagram
Note:__________________________________________________________________________________
Losses listed in item L5 to L7 are estimated from the catalogue based on the operating load and measuring temperature.
The catalog value is based on the following condition
(1) Fuel consumption tolerance according to ISO 3046/1
(2) LHV rate tolerance is ± 1.5%.
(3) Heat rejection to jacket water value displayed includes heat to jacket water alone. Value is based on treated
water. Tolerance is ± 10% of full load data.
(4) Heat rejection to atmosphere based on treated water. Tolerance is ± 50% of full load data.
(5) Lube oil heat rate based on treated water. Tolerance is ± 20% of full load data.
(6) Exhaust heat rate based on treated water. Tolerance is ± 10% of full load data.
(7) Heat rejection to exhaust (LHV to 77°F) value shown includes unburned fuel and is not intended to be used for
sizing or recovery calculations.
(8) Heat rejection to A/C - Stage 1 based on treated water. Tolerance is ±5% of full load data.
(9) Heat rejection to A/C - Stage 2 based on treated water. Tolerance is ±5% of full load data.
(10) Total Jacket Water Circuit heat rejection is calculated as: (JW x 1.1) + (OC x 1.2) + (1AC x 1.05) + [0.753 x
(1AC + 2AC) x (ACHRF - 1) x 1.05]. Heat exchanger sizing.
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2.4: OBSERVATIONS
Generator Air-Fuel Ratio:
• The generators currently operate with an air excess ranging from 77% to 96%, which
aligns closely with the manufacturer's recommendations. However, optimizing further
savings through an air-fuel tuneup may prove challenging due to the strong link
between exhaust emissions and the engine's air-fuel ratio.
Heat-to-Electricity Conversion Efficiency:
•Fortunately, under the present operating conditions, the generators achieve an

impressive heat-to-electricity conversion efficiency of approximately 30% to 35% on
the Higher Heating Value (HHV) basis. This indicates that the generators efficiently
convert heat into electrical energy, reflecting a positive aspect of their performance.
Heat Loss Concerns:
•Notably, a significant amount of heat escapes through the engine's jacket water,
intercooler, and exhaust gas. This heat loss represents an area where improvements
can be made to enhance overall energy efficiency and minimize waste.
Addressing Heat Losses:
•To optimize the system and improve energy utilization, addressing these heat losses
from the engine's jacket water, intercooler, and exhaust gas is crucial. Implementing
effective waste heat recovery methods in these areas has the potential to yield
substantial cost savings and further enhance the overall performance of the
generators.
Maximizing Energy Efficiency:
• By carefully managing excess heat and implementing appropriate heat recovery

techniques, the facility can maximize energy efficiency, reduce operating costs, and
foster a more sustainable and environmentally responsible operation.
2.5: WASTE HEAT RECOVERY AND UTILIZATION
Energy Conversion and Heat Recovery: The analysis of gas generator performance indicates
that approximately 30% to 35% of the input energy is efficiently converted into electrical energy,
while the rest is lost through exhaust and cooling systems. To address this energy wastage and
maximize efficiency, two viable methods of recovering and reutilizing waste heat from the engine
generators can be considered:
i) Recovery of High-Temperature Waste Heat from Exhaust:

• One approach involves capturing the high-temperature waste heat emitted by the hot
exhaust gases. This recovered heat can then be converted into usable energy.
ii) Recovery of Waste Heat from Cooling Circuits:

• Another effective approach is the recovery and reutilization of waste heat from various
cooling circuits, including jacket water, lube oil, and intercooler coolers. These cooling
circuits are designed to dissipate excess heat from different engine components. By
recovering and converting this heat, it can be effectively utilized as a source of useful
energy.
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2.5.1: UNLOCKING ENERGY POTENTIAL: BTL'S INNOVATIVE INITIATIVES
Harnessing Exhaust Waste Energy: BTL has embarked on an innovative path to harness wasted
energy effectively. The company has strategically installed four Exhaust Gas Boilers (EGB) with
varying capacities, including 2x3 ton/hour and 2x4 ton/hour models. These EGBs play a pivotal role
in capturing high-temperature waste heat emanating from exhaust gases. This captured heat is
then efficiently converted into valuable steam.
Steam-Powered Absorption Chillers: The steam generated from the EGBs is not wasted;
instead, it powers six absorption chillers, each boasting a substantial capacity of 496 Refrigeration
Tons (RT). This strategic utilization of steam significantly reduces overall energy wastage.
Moreover, it provides valuable support for various operational needs within the company.
Efficiently Utilizing Engine Jacket Water: In addition to exhaust heat recovery, BTL has
embraced another sustainable approach by incorporating two hot water absorption chillers. These
chillers are equipped with substantial capacities of 500 RT and 650 RT, respectively. They
efficiently harness waste heat from the engine's jacket water, a previously untapped energy source.
This recovered heat drives the absorption chilling process efficiently.
A Comprehensive Sustainability Approach: BTL's waste-to-energy concept represents a
forward-thinking commitment to environmental responsibility and economic resilience. It transforms
previously wasted energy into a valuable resource. This transformative approach not only reduces
the company's carbon footprint but also contributes to significant operational cost savings.
Figure: Diagrammatic View of the Transition from Waste to Energy
Page | 17
Optimizing Energy Lifecycle: This innovative technique optimizes the entire energy lifecycle,
showcasing BTL's proactive adoption of cutting-edge technologies for sustainable energy utilization.
Reaping Environmental and Economic Benefits: By harnessing the potential of exhaust gases
and engine jacket water, BTL achieves a dual-purpose impact. It simultaneously reduces its
environmental impact and strengthens its competitive edge through improved energy efficiency,
leading to substantial cost savings.
Visualizing Waste-to-Energy Transformation: Include a visual representation of the reclaimed
waste-to-energy transformation and the corresponding cost savings.
This rearrangement follows international guidelines for clear and structured communication while
highlighting the key elements of BTL's innovative energy recovery initiatives.
Table-6:Status Overview of Harnessing Exhaust Waste Heat
Genset-1 Genset-2 Genset-3 Genset-4

Particulars Unit
EGB-1 EGB-2
Gen Set Overall Conversion Efficiency % 29.77 34.73 34.50 34.15
Genset exhaust Heat Loss % 41.38 42.91 43.14 43.49
o
Ambient Temp, Ta C 36 36 36 36
o
Gen Set Exhaust Gas Temp Te C 515 504.3 500 504.6
Chiller Inlet Temp, T1 = (Te-Tr) as per o
C 500 470 485 480
nameplate
kJ/kg-
Chiller Inlet Gas Cp1 Value o 1.099 1.099 1.099 1.099
C
Chiller Outlet Gas Temp, T2 as per chiller o
C 170 175 170 175
nameplate
kJ/kg-
Chiller Outlet Gas Cp2 Value o 1.013 1.013 1.013 1.013
C
GenSet Exaust Sensible Heat Recovery By
EGB
m x( Cp1 (T1 - Ta)-Cp2(T2-Ta)) % 73.38 70.48 72.49 71.14
Qr = ---------------------------------------
m x Cp1 (T1 - Ta)
Potential heat recovery by using exhaust
% 30.36 30.24 31.27 30.94
and hot water absorption chiller
Estimated Natural Gas input at operational
m3/Hr 267 319 323 321
condition
Natural Gas saving per hour due to EGB m3/Hr 81 96 101 99
Estimated Natural Gas saving per year due
m3/Yr 605899 722139 755348 743114
to EGB
Equivalent cost saving per hour due to EGB BDT/Yr 18176957 21664181 22660425 22293417
Page | 18
Genset- Genset- Genset-
Genset-7
Particulars Unit 5 6 8
EGB-3 EGB-4
Gen Set Overall Conversion Efficiency % 34.51 34.55 34.69 34.85
Genset exhaust Heat Loss % 43.13 43.09 42.95 42.79

o
Ambient Temp, Ta C 36 36 36 36
o
Gen Set Exhaust Gas Temp Te C 503 506.8 501 510
o
Chiller Inlet Temp, T1 = (Te-Tr) as per C 490 485 485 490
nameplate
Chiller Inlet Gas Cp1 Value kJ/kg- 1.099 1.099 1.099 1.099
o
C
Chiller Outlet Gas Temp, T2 as per chiller oC 180 175 180 175
nameplate
Chiller Outlet Gas Cp2 Value kJ/kg- 1.013 1.013 1.013 1.013
o
C
GenSet Exaust Sensible Heat Recovery By % 70.76 71.46 70.44 71.78
EGB
m x( Cp1 (T1 - Ta)-Cp2(T2-Ta))
Qr = ---------------------------------------
m x Cp1 (T1 - Ta)
Potential heat recovery by using exhaust % 30.52 30.79 30.25 30.71
and hot water absorption chiller
Estimated Natural Gas input at operational m3/Hr 319 322 323 320
condition
Natural Gas saving per hour due to EGB m3/Hr 97 99 98 98
Estimated NG saving per year due to EGB m3/Yr 729088 742555 731108 736126
Equivalent cost saving per hour due to BDT/Y 21872650 22276639 21933241 22083776
EGB r
Page | 19
Table-7: Generator jacket water cooling recovery status
Parameters Unit Gen-1 Gen-2 Gen-3 Gen-4

Heat to Electric conversion % 29.77 34.73 34.50 34.15
Generator input Energy at present
m3/hr 267 319
operation condition 323 321
KW/Hr. 2886 3453 3493 3473
operation condition
Available heat energy in input Kj/hr. 10388469 12431537 12573227 12503085
Available heat energy in Engine JW (About
KW/Hr. 507 508 513 511
17.56% and 14.7 % of input as per model)
Total energy available in JW circuit KW/Hr. 2038
a) Total energy available in Hot water
Absorption Chiller-3
(Hot water in/out-= (79/74.8), flow= 320 KW/Hr. 1567
m3/hr.) Water Cp@ 80 deg C=4.1969
Kj/Kg-k
Available energy at Chilled water circuit at
chiller commencement position.
a) HWC -3: Chilled water KW/Hr. 809
in/out=14.7/11,Flow=188 m3/hr
Water Cp@ 20 deg C=4.1844 Kj/Kg-k
combined Energy recovery compared to
input supply energy (already achieving) % 11.78%
Estimated natural gas saving per hour m3/hr 145
Estimated NG saving per year m3/yr 1083557
Estimated Cost saving per year m3/yr 32506720
Parameters Unit Gen-5 Gen-6 Gen-7 Gen-8

Heat to Electric conversion % 34.51 34.55 34.69 34.85
m3/hr
operation condition 319 322 323 320
KW/Hr. 3455 3487 3495 3466
operation condition
Available heat energy in input Kj/hr. 12436927 12552608 12581243 12477111
Available heat energy in Engine JW circuit
KW/Hr. 508 513 514 509
(About 14.7 % of input as per model)
Total energy available in JW circuit KW/Hr. 2044
a) Total energy available in Hot water
Absorption Chiller-4
(Hot water in/out-= (80/75.8), flow= 370 KW/Hr. 1812
m3/hr.)at chiller operation condition.
Available energy at Chilled water circuit at
chiller commencement position.
a) HWC -4 : Chilled water KW/Hr. 1237
in/out=15.9/9.4,Flow=163.7 m3/hr
combined Energy recovery compared to
input supply energy (already achieving) % 13.03%
Estimated natural gas saving per hour m3/hr 167
Estimated NG saving per year m3/yr 1252863
Estimated Cost saving per year m3/yr 37585895
Page | 20
2.6: ERFORMANCE OF ENERGY DISTRIBUTION SYSTEM
The primary objective of this comprehensive power quality assessment was to evaluate the power
quality of a natural gas-fired generator within a synchronous bus system consisting of seven similar
generators in the electrical system. The assessment encompassed various aspects of power
quality, including Total Harmonic Distortion (THD), system frequency variation, power factor, voltage
deviation, imbalance, and other critical parameters. The aim was to identify any deviations from
established international standards and benchmarks, as well as to assess potential indirect losses.
Figure-9: Electrical system parameter
These issues collectively lead to energy losses, both directly and indirectly, while also reducing the
safety margin for the electrical system and its equipment. This can result in higher maintenance
costs, increased equipment failure risks, and premature aging of equipment. The assessed power
quality profile, which encompasses these aspects, is presented below. It underscores the
importance of addressing power quality concerns to prevent energy wastage and protect the
integrity of the electrical system and associated equipment.
Page | 21
Figure-10:Sample Power profile
Table-8: System operating parameters status
Voltage Profile (V) Current Profile (A) Frequency

Particulars 229.51 234.90 233.87 Particulars R Y B
Vmax 228.33 233.87 232.70 Imax 1789.00 1864.10 1814.50 50.03
Vmin 229.03 234.53 233.43 Imin 1698.70 1764.10 1715.70 49.92
Vavg 229.51 234.90 233.87 Iavg 1748.08 1819.49 1771.04 49.98
Active Power Profile (kW) Apparent Power Profile (kVA)

Particulars RN YN BN Total RN YN BN Total
Max 391.00 414.10 394.60 1199.70 408.90 436.70 422.70 1268.40
Min 370.10 390.30 371.30 1131.70 389.10 413.70 400.60 1203.30
Avg 381.47 403.32 384.16 1168.95 400.36 426.72 413.41 1240.49
Reactive Power Profile (kVAR) Power Factor Profile

Particulars RN YN BN Total Particulars RN YN BN
Max 126.50 144.80 158.70 431.40 Max 0.96 0.95 0.94
Min 115.10 132.00 145.00 393.70 Min 0.95 0.94 0.92
Avg 121.52 139.33 152.73 415.13 Avg 0.95 0.95 0.93
Page | 22
Particulars Red Yellow Blue
PST (Flicker) 0.09 0.12 0.12
tanꝊ 0.335 0.314 0.398
cosꝊ 0.967 0.974 0.947
PF 0.947 0.953 0.928
KF 1.67 1.7 1.71
UVoltage-balance, 0.2%
I Currenr-nbalance 11.10%
Observation:
Upon conducting an exhaustive power quality assessment of the electrical system, which
encompasses voltage deviation, voltage and current imbalance, frequency variation, power factor,
voltage flicker, Total Harmonic Distortion (THD), transients, and inrush current, the following key
observations have emerged:
1. Harmonic status: The Total Harmonic Distortion (THD) assessment reveals that both
voltage and current levels fall within an unacceptable range. For voltage, THD levels follow
a classification system: THD up to 5% is considered normal, 5% to 8% signifies significant
pollution, and above 8% indicates major pollution. In the case of current, THD levels
similarly have categories: THD up to 10% is considered normal, 10% to 50% signifies
significant pollution, and above 50% indicates major pollution. This evaluation is in line with
internationally recognized standards, including IEC 1000-3-2, IEEE 519-2014, and BS-EN
6100-3-4.
2. Voltage Deviation: The voltage levels consistently remain within an acceptable range, both
over and under the nominal voltage. These deviations align with the ±10% tolerance
stipulated by the National Electrical Manufacturers Association (NEMA MG1), affirming the
system's stability and reliability.
3. Voltage and Current Imbalance: The electrical system demonstrates minimal voltage and
current imbalances, with the voltage imbalance well below the 1% maximum limit and the
current imbalance comfortably within the specified threshold of 10%, as per NEMA MG1.
These negligible imbalances foster uniform distribution and alleviate equipment stress,
culminating in efficient operation.
4. Frequency Variation and Power Factor: The system exhibits satisfactory performance
concerning frequency variation and power factor. Although the power factor is slightly lower,
likely due to a low load factor, it remains within acceptable limits. Frequency variations fall
well within defined tolerances, ensuring a stable electrical supply. While enhancements in
power factor could yield improved efficiency, the current values do not denote a critical
concern.
5. Voltage Flicker: The voltage flicker, as assessed by Pst and Plt values, comfortably falls
within acceptable limits, complying with the specifications outlined in the IEC 61000-2-2*2
standard. This underpins a consistent electrical supply, especially for sensitive equipment
susceptible to voltage fluctuations.
6. Transients and Inrush Current: It is noteworthy that no transient voltage fluctuations or
inrush currents were detected during the measurement period, underscoring the electrical
system's stable and consistent behavior.
Page | 23
Recommendations:
To rectify the identified power quality deficiencies and ensure optimal system performance, the
following recommendations are proposed:
1. Active Harmonic Filter: It is imperative to promptly install active harmonic filters. These
indispensable devices serve as adept conductors of harmony within the electrical system,
efficaciously suppressing harmonics across various orders. This intervention will not only
reinstate compliance with international standards but also impart a substantial boost to
power quality.
2. Detuned Capacitor Bank: In order to mitigate the risk of resonance and uphold system
stability, the installation of a detuned capacitor bank is strongly endorsed. These capacitors
are equipped with harmonic "restrainers" designed to avert resonance while concurrently
enhancing power factor.
Addressing these recommendations will usher in a discernible improvement in power quality,

circumvent equipment overheating, forestall damage resulting from short circuits and resonance,
and engender stability in the power factor. Ultimately, these measures will lead to heightened power
utilization efficiency and the potential for cost savings.
2.7: ENERGY PERFORMANCE AT DEMAND SIDE
Badsha Textiles Ltd. focuses on electricity consumption, energy efficiency, and conservation
opportunities in its operations. The company uses advanced and energy-efficient machinery like
Ring machines, simplex machines, Carding machines, drawing machines, compressors, HVAC, and
lighting. Susnex audit team conducted a random energy audit, identifying these as significant
energy consumers. To improve energy efficiency and conservation, the following opportunities have
been identified:
Optimizing Control Systems: Fine-tuning control systems for machinery to reduce energy
waste.
Intelligent Temperature Management: Implementing smart temperature control for heating

and cooling to reduce energy usage.
Process Enhancements: Improving production processes to reduce energy consumption

while maintaining quality.
Efficient Stitching Methods: Adopting more efficient stitching techniques for textiles.
Modern Techniques: Incorporating modern manufacturing methods and technologies for

energy-efficient production.
Better Maintenance: Regular and proactive equipment maintenance to prevent energy

losses.
Energy-Efficient Technologies: Using energy-efficient technologies like high-efficiency

motors and lighting.
These initiatives align with sustainability goals, showcasing Badsha Textiles Ltd.'s commitment to
responsible and efficient energy usage. Sampled machine power consumption data is provided
below for reference.
Page | 24
Figure-11: Ring machine power consumption profile
Page | 25
Figure-12: Simplex machine power consumption profile
Page | 26
Figure -13: Carding machine power consumption profile
Figure-14: Drawing Breaker machine power consumption profile
Page | 27
Figure -15: Process coner-2 machine power consumption profile.
Figure-16: Cooling waterPump-8 power consumption profile.
Page | 28
Figure-17: Cooling waterPump-1&2 power consumption profile.
Figure-18: Compressor (BOGE) power consumption profile.
Page | 29
Figure-19: Compressor (KAESER) power consumption profile.
Figure-20: Air supply fan power consumption profile.
Page | 30
Observation:
Based on a comprehensive analysis of the sampled power profile and the existing operational
conditions, it is evident that Badsha Textiles Ltd. has already reached an exceptional level of energy
efficiency. The company has successfully harnessed the full potential of available technologies,
showcasing their commitment to sustainability and responsible energy management.
At this juncture, further improvements in energy efficiency may not yield substantial financial
benefits. However, this is a testament to Badsha Textiles Ltd.'s proactive approach in adopting
cutting-edge technologies and optimizing their processes. It underscores their dedication to
environmental responsibility and operational excellence.
While the immediate financial gains from energy conservation measures might be limited, the long-
term benefits of maintaining their energy-efficient practices, reducing environmental impact, and
upholding sustainability goals remain invaluable. Badsha Textiles Ltd.'s forward-thinking approach
continues to set a positive example in the industry, emphasizing the importance of balancing
economic considerations with environmental stewardship.
2.8.1 : ECM-1: Transitioning from 36W FTL Lamps to 18W LED Lamps
Existing Condition:
Badsha Textiles Ltd.'s comprehensive lighting system stands out for its energy-saving attributes.
The integration of various lighting technologies, including 4-foot T8 Fluorescent Tube Lamps,
Compressed Fluorescent Lamps, and a substantial incorporation of LED Lamps, deserves
commendation.
At present, indoor lighting relies on 36W illumination. An opportunity for enhanced energy efficiency
presents itself through the adoption of 18W LED Lamps, a considerable reduction in power
consumption. This transition not only aligns with the company's commitment to energy conservation
but also holds potential for cost savings and a more sustainable operational approach.
Features:
Energy Efficiency: LED lamps have an impressive efficacy range of 130-145 lumens/watt, which is
a significant improvement over the 46-60 lumens/watt efficacy of FTL lamps.
Extended Lifespan: LED lamps offer an extended lifetime of over 60,000 hours, which is a
substantial enhancement compared to the 5,000-hour lifespan of FTL lamps.
Recommendations:
In pursuit of heightened energy efficiency, a prudent step for consideration is the replacement of
current 36W Fluorescent Tube Lamps (FTL) with 18W LED lamps. This transition not only aligns
with sustainability objectives but also offers substantial benefits.
The projected benefits of this replacement are substantial and impactful. The potential for energy
savings is poised to be a key highlight. By harnessing the energy efficiency of LED technology,
Badsha Textiles Ltd. can significantly reduce energy consumption, translating into cost savings and
a lowered environmental footprint.
Page | 31
Table-10: Energy efficiency status of Transitioning LED lamp
Particulars Units Values

Total connected Load of 4" FTL (5500X36 W/TFL) KW 198
Equivalent operational Wattage of LED Lamps KW 99.00
Connected Load Saving (18W LED) KW 99.00
Diversity factor of lighting system Ks 0.9
Energy Saving per Hour KWh 89
Annual Energy savings (Consider 24x26X12 Hour) kWh/Annum 667180.80
Annual Cost Savings (9 TK/KWh) BDT 6004627.2
Estimated Investment BDT 800000.00
Anticipated Payback Period Year 0.13
2. 9: STEAM GENERATION AND DISTRIBUTION SYSTEM PERFORMANCE
2.9.1: Steam system at a glance.
Badsha Textiles Ltd. heavily relies on steam as a primary resource for its production processes,
accompanied by the operation of a steam-driven absorption chiller. The steam allocation can be
delineated into approximately 10% dedicated to powering the YCP (Your Chemical Plant) process,
while the majority, amounting to 90%, is directed towards fueling the absorption chiller. This cooling
system efficiently harnesses the energy embedded in steam.The steam generation system at
Badsha Textiles is meticulously structured, featuring various integral components:
EGB: Four Exhaust Gas Boilers are strategically incorporated into the system. Two of these
possess capacities of 2X3 tons/hr each, while the other pair boasts capacities of 2X4 tons/hr each.
These boilers are instrumental in capturing waste heat from exhaust gases to generate steam,
playing a pivotal role in the facility's energy matrix.
NGB: In addition to the Exhaust Gas Boilers, a natural gas-fired horizontal package boiler is a
significant contributor to the system. With a capacity of 5 tons/hr, this boiler operates primarily as a
standby unit, coming into play exclusively during periods of peak load. These peak load
occurrences are infrequent, happening at most once or twice daily and lasting no more than an hour.
This standby approach ensures the efficient utilization of resources while maintaining reliability. The
status of the boiler plant is outlined further down.
Table-11: Boiler plant status
EGB (1-4) NGB

PARTICULARS
YES NO YES NO
Feed Water Flow Meter √ √
Softener plant √ √
Softener Water Test Report √ √
Feed Tank √ √
Feed Tank Insulation √ √
Temperature Gauge In Feed Tank √ √
Condensate Return Line to Feed Tank √ √
Boiler Insulation √ √
Steam Pressure Gauge √ √
Steam Temperature Gauge √ √
Page | 32
Steam Flow Meter √ √
Blow Down Water Test Report √ √
Economizer Status √ √
Economizer Input Pressure Gauge √ √
Economizer Input Temperature Gauge √ √
Economizer Output Pressure Gauge √ √
Economizer Output Temperature Gauge √ √
Temperature Gauge In Exhaust Line √ √
Header Insulation √ √
Pressure Gauge In Header √ √
Steam Line Insulation √ √
Condensate Return Line √ √
Condensate Return Line Insulation √ √
Steam Trap, Flange, Strainer & Valve
√ √
Insulation
2.9.2: Already practiced Energy Efficiency Measures in Steam Generation System
Badsha Textiles Ltd. takes a proactive approach to energy conservation within its steam generation
system, implementing several key measures to enhance efficiency and sustainability. These
measures not only optimize the utilization of resources but also contribute to reducing
environmental impact.
Boiler Air-Fuel Ratio Adjustment: The company operates boilers using exhaust gases
from generators. As a result, the air-fuel ratio is inherently balanced, eliminating the need for
continuous adjustments. This approach ensures that fuel is utilized efficiently, minimizing
waste and associated costs.
Condensate Recovery: Badsha Textiles Ltd. places a strong emphasis on condensate

recovery. This practice involves collecting and returning condensate (the condensed steam)
to the feed pump. By doing so, the facility maximizes the reuse of water and heat energy,
resulting in significant energy savings. It not only conserves water resources but also
reduces the energy required to heat incoming water.
Economizer Installation: The facility has installed economizers in its steam generation
system. Economizers recover heat from the flue gas and transfer it to the feedwater,
preheating it before it enters the boiler. This preheating process significantly improves the
energy efficiency of the system, reducing fuel consumption and operating costs.
Water Treatment and Softener Plant: Badsha Textiles Ltd. has developed a
comprehensive water treatment process, ensuring that raw water sourced from the ground
meets the required quality standards for steam generation. The incorporation of a softener
plant further enhances water quality, preventing scale buildup in the boiler system and
maintaining its efficiency.
Good Insulation Practices: The facility has implemented effective insulation throughout the
steam generation system. This insulation helps retain heat, preventing energy losses and
ensuring that the steam remains at the desired temperature as it travels through the system.
Good insulation practices are vital for maintaining high energy efficiency. Currently, some
small valves and flanges remain uninsulated. To further optimize performance and minimize
Page | 33
heat loss, it is strongly recommended to insulate these exposed components. This additional
step will further optimize system performance and conserve energy. Thermal imaging
surveys have been conducted to assess heat loss across the facility, and the associated
costs in terms of surface area have been detailed in the appendices.
TDS-Based Blowdown System: The facility has developed and implemented a Total
Dissolved Solids (TDS)-based blowdown system. This system helps manage the
concentration of impurities in the boiler water, ensuring that it remains within acceptable
limits. By efficiently controlling blowdown, the facility minimizes water and energy wastage,
contributing to energy conservation.
Overall observation: In the context of the current operating condition at Badsha Textiles Ltd., it
becomes evident that there are limitations to achieving further energy savings through additional
measures. The energy conservation initiatives that have already been implemented, including
condensate recovery, economizer installation, and other practices, have significantly optimized the
efficiency of the steam generation system. These measures have already delivered substantial
benefits in terms of resource utilization, waste reduction, and enhanced overall system performance.
However, it's important to recognize that every system has a point of diminishing returns when it
comes to energy savings. Beyond a certain level of optimization, the cost and effort required to
implement further measures may not be commensurate with the additional savings that can be
achieved. In other words, the return on investment for additional energy conservation measures
may no longer be favorable in the current operational context.
Instead of pursuing further modifications to the system, it may be prudent to focus on standardized
preventive maintenance practices. Regular and systematic maintenance can help ensure that the
existing energy efficiency measures continue to perform at their peak, preventing any degradation
in system efficiency over time.
Furthermore, it's worth noting that seeking additional savings from the condensing economizer,
while technically feasible, may not be financially justified. The cost of implementing such measures,
considering the limited additional savings they would yield, may not align with the organization's
financial objectives.
In conclusion, Badsha Textiles Ltd. has already made commendable strides in energy conservation
and efficiency. The decision to continue pursuing energy savings should be carefully evaluated in
terms of both technical feasibility and financial viability. At this stage, maintaining the current level of
efficiency through preventive maintenance practices may be the most prudent approach to ensure
sustained operational excellence and environmental responsibility.
Page | 34
SECTION-3
Energy Management, Monitoring and Accounting System
In various industrial sectors, there exists a network of systems delivering specific forms of energy
such as gas, diesel, electricity, steam, compressed air, and water circuits. These energy sources
serve diverse purposes, including heating, cooling, and powering operational processes. However,
the production, distribution, and consumption of these energy media come with escalating costs. As
a result, it becomes paramount for all companies to adopt efficient energy utilization and monitoring
practices to mitigate these expenses.
Energy costs are not merely on the rise; they are accelerating at an alarming pace. Energy
expenditure is often the swiftest growing item in an operational budget and often represents the
most significant controllable expense. As companies navigate this landscape, it becomes crucial to
comprehensively manage and evaluate their energy usage to curb these escalating costs.
For instance, factors like heating, cooling, compressed air, natural gas, electricity, and steam all
contribute significantly to the overall energy expenditure. Consequently, adopting strategies to
optimize the production, distribution, and consumption of these energy forms is pivotal. This
proactive approach enables companies to navigate the challenges posed by surging energy costs
and establish a foundation for sustainable operational practices.
As we delve into the specifics, a thorough analysis of the existing energy monitoring and accounting
system is warranted. This examination encompasses aspects such as metering accuracy,
meticulous record-keeping, data logging efficiency, and a systematic approach to periodic
performance analysis.
The following table provides a detailed overview of these critical components, ensuring a holistic
understanding of the energy management framework. By embracing a comprehensive strategy that
addresses all facets of energy utilization, companies can navigate the era of accelerating energy
costs while maintaining operational efficiency and fiscal prudence.
Page | 35
Table: Energy data-monitoring schedule
Frequency Department
Source of Source of Method of
Type of File Type responsible
Energy Data Recording
Recording for file
Primary Grid Power -- -- -- -- --
Energy Utility Gas
Natural Gas Monthly Manual Utility Bill Maintenance
(Generation Meter
Side) Diesel -- -- -- -- --
Energy
Electricity hourly Manual Log Book Maintenance
Carrier meter
Energy Steam Flow meter hourly Manual Log Book Maintenance
(Distribution Compressed
No meter -- -- -- --
Side) Air
Water Flow meter Daily Manual Log book Maintenance
During the course of the energy audit, a noteworthy observation emerged regarding the existing
energy monitoring practices. Presently, only the primary energy sources (Electricity, Natural gas,
Diesel) feeding into the facility's main incomer are being tracked.
However, a significant gap was identified – the absence of sub-meters to monitor

consumption at the individual process, system, and equipment levels. This gap calls for an
enhancement in the energy accounting system at the plant, aiming to establish a comprehensive
and focused monitoring of energy consumption in correlation with production levels.
It is imperative to address this gap by implementing subsection or area-specific energy meters that
measure the consumption of various energy sources, such as electricity, steam, and compressed
air. The installation of these meters not only facilitates a granular understanding of energy usage
but also empowers the facility to perform comprehensive analyses. This approach enables the
identification of significant energy consumption contributors, detection of anomalies, setting energy
reduction targets, and evaluating greenhouse gas emissions.
A key aspect of this enhanced monitoring system is the utilization of meaningful Key Performance
Indicators (KPIs). By constantly monitoring the system and evaluating it against these KPIs,
operators, supervisors, and management remain well-informed. This not only enables a proactive
approach to energy management but also fosters an environment of constructive engagement.
The implementation of an Energy Monitoring and Management System holds multiple advantages.
It provides a comprehensive view of the facility's energy consumption landscape, thereby enabling
informed decisions aimed at reducing energy usage. This enhanced understanding can lead to the
optimization of utility contracts, compliance with energy regulations, and improved operation and
maintenance practices.
Ultimately, the integration of such a system facilitates intelligent analysis of energy data, resulting in
minimized utility energy consumption, cost savings, and a reduced carbon footprint. This aligns
seamlessly with the broader goals of sustainability and responsible resource utilization, contributing
to both economic and environmental well-being.
Page | 36
Recommended energy management actions
Badsha Textiles Ltd. energy management improvement steps:
Policy: Create a concise energy policy signed by CEO, displayed prominently in the factory.
Develop an Action Plan with identified improvements and update it every six months.
Organizing: Incorporate energy efficiency in board meetings, with energy team reporting progress
to management. Highlight energy benefits for company profitability.
Motivation: Provide feedback on energy savings to all staff. Promote energy efficiency in meetings
with the workforce. Develop awareness through counseling, training, and encouraging energy-
saving practices.
Information Systems: Produce informational leaflets or a green notice board detailing energy
savings progress. Implement individual metering systems for specific utilities and production
sections.
Marketing: Promote energy efficiency to staff and customers, enhancing the company's green
image. Encourage participation in energy-saving practices and showcase green credentials to
clients.
Investment: Reinvest financial savings into more energy-saving measures. Actively invest in low-
cost opportunities and use resulting profits to fund medium to high-cost energy-saving initiatives.
Page | 37
SECTION-4
Measurement And Verification Method For ENMS
When companies invest in energy efficiency, they seek clear insights into the savings achieved and
their sustainability. This necessitates accurate measurement and a replicable methodology, known
as a measurement and verification (M&V) protocol. Developing an M&V Plan is pivotal for accurate
savings determination and serves as the foundation for verification. Thorough planning guarantees
the availability of data required for accurate savings calculation post-implementation, all within a
feasible budget.
An M&V plan encompasses:
ECM Description: Clearly outlining the Energy Conservation Measure (ECM) and its intended
outcomes.
Boundary Identification: Defining the scope of the savings determination, outlining which
elements are under consideration.
Base Year Context: Documenting the facility's conditions during the base year and the
corresponding energy consumption data.
Base Year Adjustments: Identifying any planned changes to base year conditions, such as
alterations in nighttime temperatures.
Post-Retrofit Period: Specifying the timeframe for the post-retrofit period, which could be as short
as a brief test following the implementation of an ECM.
In essence, a well-crafted M&V plan lays the groundwork for accurate assessment, ensuring that
energy savings are quantified reliably and with confidence.
Page | 38
Types of M & V methods
Four primary types of Measurement and Verification (M&V) methods are utilized: Here's an
overview of the M&V methods, their savings calculation approaches, and typical applications:
Partially Measured Retrofit Isolation:
Savings Calculation Method: Savings are determined by measuring the energy use of the system(s)
where an ECM is applied, separate from the rest of the facility. Some parameters may be stipulated
if the potential error's impact isn't significant. ECM design and installation should ensure stipulated
values fairly represent actual values.
Typical Application: For instance, in a lighting retrofit, power draw is periodically measured.
Operating hours are assumed to be slightly longer than store open hours.
Retrofit Isolation:
Savings Calculation Method: Savings are determined by measuring the energy use of the systems
to which the ECM is applied, separate from the rest of the facility. Short-term or continuous
measurements are taken during the post-retrofit period.
Typical Application: An example is applying controls to regulate load on a constant-speed pump with
a variable speed drive. Electricity use is measured by a kWh meter on the pump motor's supply.
The meter is in place throughout the post-retrofit period.
3. Whole Facility:
Savings Calculation Method: Savings are determined by analyzing utility meter data for the entire
facility or using multifaceted energy management programs. Short-term or continuous
measurements are taken at the whole facility level throughout the post-retrofit period.
Typical Application: This method is suitable for analyzing broad energy-saving initiatives that affect
numerous systems within a building. For instance, measuring energy use through simple regression
analysis and comparison of utility billing data.
Calibrated Simulation:
Savings Calculation Method: Savings are determined using energy simulation, where components
or the entire facility are simulated and calibrated to actual performance measurements. Simulation
routines must effectively model real energy performance within the facility.
Typical Application: Calibrated simulation is ideal when no base year data are available. It involves
creating a model that's calibrated using post-retrofit period utility data, requiring skilled simulation
expertise.
These M&V methods offer diverse approaches for evaluating energy savings in different contexts.
The choice of method depends on the nature of the project, the availability of data, and the desired
level of accuracy.
Page | 39
SECTION-5
Suggested Best Operating Practices (BOPs)
Best Operating Practices (BOPs) refer to a set of guidelines and procedures that are considered the
most effective and efficient way to operate a particular system, process, or piece of equipment. BOPs
are designed to ensure safety, optimize performance, and minimize the risk of errors or accidents.
The specific BOPs you should follow will depend on the context, industry, and equipment or process
in question. However, here are some general principles and suggested BOPs that can be applied
across various domains:
BOP 1: Boiler maintenance
Boiler maintenance is vital for energy efficiency and operational reliability. To minimize energy
consumption and unexpected downtime, a systematic approach is essential. Assign responsibility
for maintaining and documenting daily, weekly, monthly, and annual tasks with checklists. Regular
maintenance includes inspections, cleaning heat transfer surfaces, and maintaining insulation.
Performing a tune-up helps identify off-design equipment performance and site-specific constraints
before optimizing boiler efficiency. For negative-draft boilers, check for air leakage using smoke, a
flame, or ultrasonic equipment. Address high oxygen readings from air leaks that lead to fuel waste.
Use ultrasonic probes to detect steam leaks in water-tube boilers. For boilers with storage tanks,
shut off water supply and observe water levels to identify leaks. Ensure low-water cutoff controls are
functional before testing.
BOP 2: Air-to-Fuel ratio
Efficient operation of any combustion equipment is highly dependent on a proper air-to fuel ratio.
Due to the mechanics of combustion, it is necessary to provide more air than would be required to
provide exactly the right quantity of oxygen (O2) to burn all the fuel without any O2 left over.
Because air is comprised of approximately 21 percent O2 and 79 percent nitrogen (N2), in
delivering the right amount of O2, nearly four times as much N2 is also delivered. Nitrogen absorbs
Page | 40
heat and carries it out the stack, resulting in a loss to the system. Minimizing excess air, consistent
with complete combustion, minimizes this heat loss. Complete carbon combustion forms carbon
dioxide (CO2) as heat is released. Incomplete combustion forms carbon monoxide (CO) and less
than one-third as much heat is released. CO is an un-burned combustible and, in the stack gas, an
efficiency loss to the system. Most systems will also display a calculated combustion efficiency
value. Even with continuous monitoring of the flue gas, non-optimum air-to- fuel ratios may result
due to air leaking in upstream of the analyzer; infrequent or incorrect analyzer calibration;
insufficient combustion air supply at full load; or an analyzer placed at a non- representative
location.
BOP 3: Combustion uniformity
Complete combustion at efficient excess air levels requires the fuel and air to be uniformly mixed
throughout the primary combustion zone. In multi-burner gas boilers, non-uniform combustion can
result if the fuel and air are not evenly distributed due to a malfunctioning burner. The natural
tendency when encountering noticeable CO levels is to raise excess air levels for the whole boiler,
causing the other burners to operate at unnecessarily high O2 levels. Uniform combustion can quite
often be achieved by simple adjustments to the air. Register or damper settings. In other cases,
further diagnostic testing is required. Considerable insight into combustion uniformity can be
obtained by mapping the O2 profile at the economizer exit. Systems exist that will automatically
measure and map O2 concentrations on a continuous basis.
BOP 4: Blowdown management
Blowdown is essential for maintaining low concentrations of dissolved solids in the water (skimming
blowdown) or removing solids that have settled out of the water (bottom blowdown). Both practices
result in unavoidable energy losses as hot water is wasted to the drain, and a balance must be
maintained between acceptable results and energy losses. Skimming blowdown is best used as a
continuous process; bottom blowdown is best done periodically as several short blowdowns.
Continuous blowdown makes the use of heat recovery devices more feasible.
BOP 5: Load management
When multiple boilers serve many loads, it is important to manage them as efficiently as possible.
Individual boilers achieve maximum efficiency over a specific firing range. Units with high excess air
requirements or significant radiation losses at low loads will have peak efficiency at a high load.
Boilers with constant excess air levels and small radiation losses over the load range will exhibit
peak efficiency at a lower load. Efficiencies should be determined over the full range of firing rates.
More efficient boilers should be brought on line first as loads increase, and less efficient units
should be taken off-line first as loads drop. Where possible, scheduling of loads can help achieve
optimum system performance.
Page | 41
BOP 6: Reduce steam pressure
To the extent practical, steam should be generated at the lowest pressure that will meet the highest-
pressure demand. Less fuel is required and lower stack temperatures result, improving efficiency.
Savings may be as much as 1 or 2 percent, but actual savings depend on the starting pressure and
the pressure reduction that is realized.
BOP 7: Maintenance of insulation
The primary mechanism for heat loss through the skin of an uninsulated boiler is radiant heat loss.
The higher the temperature of the boiler skin (insulated or not), the greater the radiant heat loss to
the surroundings. The first inch of insulation reduces heat loss by about 90 percent. Each additional
inch obviously will have much less impact. One rule of thumb is that any surface above 120°F
should be insulated, including boiler surfaces, steam or condensate piping and fittings.
BOP 8: For Compressed Air System
▪ Ensure air intake to compressor is not warm and humid by locating compressors in well
ventilated area or by drawing cold air from outside. Every 4°C rise in air inlet temperature
will increase power consumption by 1 percent
▪ Clean air-inlet filters regularly. Compressor efficiency will be reduced by 2 percent for every
250 mm WC pressure drop across the filter.
▪ Keep compressor valves in good condition by removing and inspecting once every six
months. Worn- out valves can reduce compressor efficiency by as much as 50 percent.
▪ Install manometers across the filter and monitor the pressure drop as a guide to
replacement of element.
▪ Minimize low-load compressor operation; if air demand is less than 50 percent of
compressor capacity, consider change over to a smaller compressor or reduce compressor
speed appropriately (by reducing motor pulley size) in case of belt driven compressors.
▪ Consider the use of regenerative air dryers, which uses the heat of compressed air to
remove moisture.
▪ Fouled inter-coolers reduce compressor efficiency & cause more water condensation in air
receivers & distribution lines resulting in increased corrosion. Periodic cleaning of
intercoolers must be ensured.
▪ Compressor free air delivery test (FAD) must be done periodically to check the present
operating capacity against its design capacity and corrective steps must be taken if required.
▪ If more than one compressor is feeding to a common header, compressors must be
operated in such a way that only one small compressor should handle the load variations
whereas other compressors will operate at full load.
▪ The possibility of heat recovery from hot compressed air to generate hot air or water for
process application must be economically analyzed in case of large compressors.
Page | 42
▪ Consideration should be given to two-stage or multistage compressor as it consumes less
power for the same air output than a single stage compressor.
▪ If pressure requirements for processes are widely different (e.g., 3 bar to 7 bar), it is
advisable to have two separate compressed air systems.
▪ Reduce compressor delivery pressure, wherever possible, to save energy.
▪ Provide extra air receivers at points of high cyclic-air demand which permits operation
without extra compressor capacity.
▪ Retrofit with variable speed drives in big compressors, say over 100 kW, to eliminate the
unloaded' running condition altogether.
▪ Keep the minimum possible range between load and unload pressure settings. • Automatic
timer-controlled drain traps waste compressed air every time the valve opens. So, frequency
of drainage should be optimized.
▪ Check air compressor logs regularly for abnormal readings, especially motor
current cooling water flow and temperature, inter-stage and discharge pressures and
temperatures and compressor load-cycle.
▪ Compressed air leakage of 40 – 50 percent is not uncommon. Carry out periodic
leak tests to estimate the quantity of leakage.
▪ Install equipment interlocked solenoid cut-off valves in the air system so that air
supply to a machine can be switched off when not in use.
▪ Present energy prices justify liberal designs of pipeline sizes to reduce pressure drops.
▪ Compressed air piping layout should be made preferably as a ring main to provide
desired pressures for all users.
▪ A smaller dedicated compressor can be installed at load point, located far off from
the central compressor house, instead of supplying air through lengthy pipelines.
▪ All pneumatic equipment should be properly lubricated, which will reduce friction,
prevent wear of seals and other rubber parts thus preventing energy wastage due to
excessive air consumption or leakage.
▪ Misuse of compressed air such as for body cleaning, agitation, general floor
cleaning, and other similar applications must be discouraged in order to save
compressed air and energy.
▪ Pneumatic equipment should not be operated above the recommended operating
pressure as this not only wastes energy bus can also lead to excessive wear of
equipment's components which leads to further energy wastage.
▪ Pneumatic transport can be replaced by mechanical system as the former
consumed about 8 times more energy. Highest possibility of energy savings is by
reducing compressed air use.
▪ Pneumatic tools such as drill and grinders consume about 20 times more energy
than motor driven tools. Hence, they have to be used efficiently. Wherever possible,
they should be replaced with electrically operated tools.
▪ Where possible welding is a good practice and should be preferred over threaded
connections.
▪ On account of high pressure drop, ball or plug or gate valves are preferable over
globe valves in compressed air lines.
Page | 43
Appendices
Page | 44
Appendix-1: Power quality snapshot
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Appendix-2: Thermographic survey sample
rea
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Appendix-3: Energy Auditing sample photo
Page | 57
Appendix-4 : Generator and Boiler Specifications and sample documentation
Generator # 01 Particulars Info

Manufacturer Caterpiler/USA
Model G3516
Generator S/N 8GW01375
Year of Manufacturing 2007
Rated Capacity (kVA/kW) 1287Kva/1030Kw
Fuel Use Natural Gas
Rated Power Factor (cos phi) 0.8
Altitude (M) 1000
Rated Frequency (Hz) 50
Rated RPM 1500
Rated Voltage (V) 400
Rated Current (A) 1857
Excitation Voltage (V) 25
Excitation Current (A) 6.63
Max. Temperature Rise (deg.C) 105
Insulation Class H
Max. Ambient Temp.(deg.C) 40
Operation Schedule (h/day) ACT STANDBY MODE

Manufacturer Jenbacher/Austria
Model JMS420GSNL
Generator S/N 1078256
Rated Capacity (kVA/kW) 1770/1415
Altitude (M) 1000
Rated RPM 1500
Rated Current (A) 2598.1
Insulation Class H
Operation Schedule (h/day) 24

Model JMS420GSNL
Rated Power Factor (cos phi) 1
Rated RPM 1500
Insulation Class H
Page | 58
Model JMS420GSNL
Altitude (M) 1000
Rated RPM 1500
Insulation Class H

Model JMS420GS-NL
Altitude (M) 1000
Rated RPM 1500
Insulation Class H

Model JMS420GS-NL
Altitude (M) 1000
Rated RPM 1500
Insulation Class H
Page | 59
Generator S/N
Altitude (M) 1000
Rated RPM 1500
Insulation Class H
Model JMS420GS-NL
Generator S/N
Product Identification Number
Year of Manufacturing
Altitude (M) 1000
Rated RPM 1500
Insulation Class H
EGB-01 Particulars Info
Manufacturer Shangdong Huatuan Boiler Co.Ltd.
Type Waste Heat Recovery Boiler
Model Q11/438-2.0-1.0
Product Code R15-125
Evaporation Capacity (t.h) 2
Heat Exchange Area (m2) 172.5
Working Medium Exhaust Gas
Max. Working Pressure (Mpa) 1
Product Net Weight (Kg) 8020
Design Temperature (deg.C) 187
Model Q15/515-3.0-1.0
Page
Operation | 60 (h/day)
Schedule 24
Model Q15/515-3.0-1.0
Max. Working Pressure (Mpa) 1.06

Model Q11/438-2.0-1.0
Total Gas
Production Production (Kg) NG Con Generator Generation NG Con Generator Generation NG Con Boiler (m3) - NG Con Boiler Total Gas
Month Production (Ton )2021 Production (Kg )2021 Consumption-
(Ton) 2022 2022 (m3) -2021 (KWh) -2021 (m3) -2022 (KWh) -2022 2021 (m3) -2022 Consumption-2021
2022
January 2,288.77 2,288,770.00 2,441.66 2,441,660.00 1405943 5397836 1472582 5677396 2300 52 1408243 1472634
February 2,087.06 2,087,060.00 2,216.62 2,216,620.00 1257887 4870284 1335761 5158193 0 107 1257887 1335868
March 2,349.69 2,349,690.00 2,444.78 2,444,780.00 1429866 5537728 1552252 5988295 54 50 1429920 1552302
April 2,310.15 2,310,150.00 2,094.34 2,094,340.00 1470599 5618620 1477105 5670320 26 141 1470625 1477246
May 2,334.75 2,334,750.00 2,145.92 2,145,920.00 1539127 5831717 1550421 5957795 363 0 1539490 1550421
June 2,133.62 2,133,620.00 2,037.89 2,037,890.00 1485828 5619651 1393676 5765391 139 946 1485967 1394622
July 1,571.42 1,571,420.00 1,761.21 1,761,210.00 1135420 4291607 1367372 5275149 62 5382 1135482 1372754
August 2,227.19 2,227,190.00 1,984.06 1,984,060.00 1542901 5833746 1570477 5861393 292 0 1543193 1570477
September 2,247.06 2,247,060.00 1,740.92 1,740,920.00 1454326 5516077 1206670 4641040 121 0 1454447 1206670
October 2,406.55 2,406,550.00 1,723.04 1,723,040.00 1531544 5804738 1254873 4826435 129 0 1531673 1254873
November 2,351.58 2,351,580.00 1,832.44 1,832,440.00 1463156 5610956 1477754 5031356 30 1628 1463186 1479382
December 2,450.90 2,450,900.00 2,103.73 2,103,730.00 1482939 5732247 1325052 5640495 78 2989 1483017 1328041
26,758.74 26,758,740.00 24,526.61 17199536 65665207 16983995 65493258 3594 11295 17203130
Month Natural Gas (m3)-2021 Natural Gas (m3)-2022 Production-2021 Production-2022 Energy Mj-2021 Energy Mj-2022 SEC (MJ/KG) 2021 SEC (MJ/KG) 2022
January 1408243 1472634 2288770 2,441,660 54893312.14 57403273.32 23.98 23.51
February 1257887 1335868 2087060 2,216,620 49032435.26 52072134.64 23.49 23.49
March 1429920 1552302 2349690 2,444,780 55738281.6 60508731.96 23.72 24.75
April 1470625 1477246 2310150 2,094,340 57324962.5 57583049.08 24.81 27.49
May 1539490 1550421 2334750 2,145,920 60009320.2 60435410.58 25.70 28.16
June 1485967 1394622 2133620 2,037,890 57922993.66 54362365.56 27.15 26.68
July 1135482 1372754 1571420 1,761,210 44261088.36 53509950.92 28.17 30.38
August 1543193 1570477 2227190 1,984,060 60153663.14 61217193.46 27.01 30.85
September 1454447 1206670 2247060 1,740,920 56694344.06 47035996.6 25.23 27.02
October 1531673 1254873 2406550 1,723,040 59704613.54 48914949.54 24.81 28.39
November 1463186 1479382 2351580 1,832,440 57034990.28 57666310.36 24.25 31.47
December 1483017 1328041 2450900 2,103,730 57808002.66 51767038.18 23.59 24.61
Total NG Total NG
NG Con Generator NG Con Generator NG Con Boiler (m3) - NG Con Boiler
Month consumption consumption (m3)-
(m3) -2021 (m3) -2022 2021 (m3) -2022
(m3)-2021 2022
January 1405943 1472582 2300 52 1408243 1472634
February 1257887 1335761 0 107 1257887 1335868
March 1429866 1552252 54 50 1429920 1552302
April 1470599 1477105 26 141 1470625 1477246
May 1539127 1550421 363 0 1539490 1550421
June 1485828 1393676 139 946 1485967 1394622
July 1135420 1367372 62 5382 1135482 1372754
August 1542901 1570477 292 0 1543193 1570477
September 1454326 1206670 121 0 1454447 1206670
October 1531544 1254873 129 0 1531673 1254873
November 1463156 1477754 30 Page | 611628 1463186 1479382
December 1482939 1325052 78 2989 1483017 1328041
User supplied data GHG emissions (tonnes)
Fuel type Amount of Units Heating value All GHGs
Source ID Sector (e.g., solid fossil) Fuel fuel (e.g., kg or kWh) basis CO2 CH4 N2O (tonnes CO2e)
2021G Manufacturing Gaseous fossil Natural gas 17199536 metre3 32420.437 5.779E-01 5.779E-02 32451.933
2021B Manufacturing Gaseous fossil Natural gas 3594 metre3 6.775 1.208E-04 1.208E-05 6.781
2021G Manufacturing Gaseous fossil Natural gas 65493258 metre3 123452.172 2.201E+00 2.201E-01 123572.103
2022B Manufacturing Gaseous fossil Natural gas 11295 metre3 21.291 3.795E-04 3.795E-05 21.311
Appendix-5: Energy Auditor certificate
Page | 62
THE END
Page | 63

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SECTION-1

1.1: BADSHA TEXTILES LTD. - A CONCISE OVERVIEW

Infrastructure and Cutting-Edge Technology:

1.2: A SUMMARIZED PORTRAIT OF PROCESS

11. Documentation and Records: Comprehensive documentation is maintained throughout the

1.3: THE PRESENT POWER LANDSCAPE OF BADSHA TEXTILES LTD.:

1.4: ENERGY USE ANALYSIS AND BENCHMARKING

1.4.1: Establishment of base year consumption

Table-1 : Energy Consumption status

ENERGY ALL GHGs

Figure-1: Energy consumption share breakdown

1.4.2 Energy consumption and production pattern

1.4.3 Specific energy consumption (SEC)

Figure-2: Specific Energy Consumption status

To address these observations, we recommend crucially focusing on energy efficiency measures to

2.1 ENERGY UTILIZATION FRAMEWORK

Badsha Textiles Ltd.: A Model of Sustainable Energy Integration

Electrical Energy Generation: Powering Progress

Waste Heat Recovery: Maximizing Efficiency

A commitment to sustainability is demonstrated through the waste heat recovery system. It

Thermal Energy Generation: Ensuring Consistency

Environmental Responsibility: Minimizing Footprint

At Badsha Textiles Ltd., a commitment to environmental responsibility is upheld. Natural Gas is

Figure-3: Schematic diagram of existing cogeneration systems.

Figure5-: Generator consumption generation and demand profile

Observations and Analysis:

Table-: Measured Generator flue gas data

Figuer-6: Sample operating profile

Table-2 :Measured Flue Gas data

Measured Parameter Symbol Unit Gen # 01 Gen # 02 Gen # 03

Oxygen Content O2 % 9.2 10.1 10.3

Gen # 04 Gen # 05 Gen # 06

Table-3: Composition of Natural Gas

Composition Unit Value

Particulars Unit Gen-1 Gen-2 Gen-3 Gen-4 Gen-5 Gen-6

Particulars Unit Gen-7 Gen-8

Table-5: Generator Plant Output Base Case

Parameters Unit GEN-1 GEN-2 GEN-3 GEN-4 GEN-5 GEN-6

Parameters Unit Gen-7 Gen-8

Generator Air-Fuel Ratio:

•Fortunately, under the present operating conditions, the generators achieve an

• By carefully managing excess heat and implementing appropriate heat recovery

2.5: WASTE HEAT RECOVERY AND UTILIZATION

i) Recovery of High-Temperature Waste Heat from Exhaust:

ii) Recovery of Waste Heat from Cooling Circuits:

Figure: Diagrammatic View of the Transition from Waste to Energy

Table-6:Status Overview of Harnessing Exhaust Waste Heat

Genset-1 Genset-2 Genset-3 Genset-4

Genset exhaust Heat Loss % 43.13 43.09 42.95 42.79

Parameters Unit Gen-1 Gen-2 Gen-3 Gen-4

Parameters Unit Gen-5 Gen-6 Gen-7 Gen-8

Figure-9: Electrical system parameter

Table-8: System operating parameters status

Voltage Profile (V) Current Profile (A) Frequency

Active Power Profile (kW) Apparent Power Profile (kVA)

Reactive Power Profile (kVAR) Power Factor Profile

Addressing these recommendations will usher in a discernible improvement in power quality,

2.7: ENERGY PERFORMANCE AT DEMAND SIDE

Intelligent Temperature Management: Implementing smart temperature control for heating