Boiler Guide for Sizing Industry|How to select boiler type in the sizing industry?

Steam is one of the necessary energy sources in the textile printing and dyeing production process, and the steam comes from a steam boiler. In the previous article, we outlined the application of the boiler to the various processes of textile printing and dyeing, including: pretreatment, sizing, bleaching, dyeing, and drying,almost every link will be applied to the boiler. Today we will introduce in detail, the challenges encountered in the sizing production line, as well as the boiler application and selection.

What are the textile sizing production equipment?

Boiler, warping machine, sizing machine, air compressor, sizing tank, starch, pva, nano wear-resistant agent and other auxiliary materials. Among them, the sizing machine uses steam from a heating boiler such as a steam boiler or a hot water boiler to sizing.

Common problems in the sizing process:

1.The brittleness of sizing is too high

2.The running cost of sizing is high

3.The sizing service guarantee system is not perfect

1.The brittleness of sizing is too high

The brittleness rate is an important indicator for assessing the quality of sizing. The high brittleness rate seriously affects the quality of the sizing. Appropriate sizing rate and moisture regain improve the weaveability of the yarn and reduce the brittleness of the warp yarn during weaving.

Sizing rate

The sizing rate is the percentage of the dry weight of the warp yarn after sizing to the dry weight of the original warp yarn before sizing. If the sizing rate is too high, the surface sizing is too high, the yarn elasticity decreases, and the elongation reduction rate increases, and it is easy to produce falling sizing and brittle ends during weaving. At the same time, the slurry consumption is large and the sizing cost increases. The sizing rate is too low, the sizing is lightly sized and fuzzing, the opening of the loom is unclear, and the warp yarn breakage increases, which affects production.

It can be seen that the sizing rate is very strict, too high or too low will affect the weave ability of the thread.

Moisture regain

Sizing moisture regain refers to the percentage of moisture content to the dry weight of sizing. Excessive moisture regain will cause unclear weaving openings, and too small moisture regain will cause brittle ends.

In actual production, the fluctuation of moisture regain should be less than ±0.5%, and the moisture regain qualification rate should be controlled at 90%. Press-out moisture regain: The percentage of water content in the sizing to the dry weight of the sizing before entering the drying room after exiting the sizing roller.

Weave ability

In addition to the weaving conditions, sizing weaving is mainly affected by the quality of the original yarn and the sizing process. In order to reduce the rate of warp yarn breakage, improve weaving efficiency, and produce high-quality products. The warp yarn needs to be sized to achieve reinforcement, wear resistance, stretch retention and hairiness fit. About 38% of warp yarn breaks are caused by the sizing process.

2.The running cost of sizing is high

The current production status of "high investment, high cost, high risk, and high pollution" has always been a bottleneck in the sizing industry, which has severely restricted the survival and development of enterprises.

1. Energy cost

In sizing enterprises, water, steam, electricity, and fuel energy costs account for about 43% of the total cost. Among them, steam cost is the main cost, second only to the cost of slurry.

2. Environmental protection costs

Sizing is one of the main pollution sources in the textile industry. About 40% of the pollution sources in the textile industry are generated by pulp and boiler exhaust gas. Improper treatment of boiler exhaust gas will cause serious pollution and increase the environmental protection investment of enterprises.

3. Labor cost

The content covered in labor cost is diverse and complex, including worker wages, personal insurance, skills training, etc.

4. Maintenance cost

Long commissioning cycle, high failure rate, long-term maintenance, etc. will cause excessive maintenance costs and reduce the market competitiveness of the product.

3. The sizing service guarantee system is not perfect

The stable and efficient production of sizing is inseparable from the support of production equipment services. A good service system can provide a strong guarantee for the sizing process. At present, many equipment manufacturers can't keep up with their services. Once the equipment fails and stops running, it will cause a shutdown due to equipment maintenance, which will have a bad impact on the brand.

How to solve the problems in the sizing process?

To solve the above problems in the sizing process, it is actually not difficult. Through more than 30 years of boiler service experience in the sizing industry, EPCB concluded that the important factors affecting the yarn brittleness are the sizing temperature, drying efficiency, Heat source stability, as long as these problems are solved, the brittle fracture rate of sizing will be controlled, thereby improving the quality of sizing.

1.Control sizing brittleness rate:

Stable slurry water temperature

According to the temperature requirements of the sizing, the basic standard of 70-80℃ for semi-cooked pulp and 97-99℃ for cooked pulp, EPCB has passed many years of repeated research and experimentation, and has visited the customer site for many times, and automatically adjusted the main steam pressure of the boiler. The technology of the system circuit and the measuring range of the pressure transmitter is researched and upgraded, and the sizing can be uniformly increased to 96% on the basis of providing a stable and continuous temperature demand.

Constant and rapid drying efficiency

For the drying needs of sizing, in order to provide efficient and stable heat energy, EPCB has customized the design of boiler materials and structure, and continuously upgraded them, so that the furnace temperature can be rapidly increased and kept constant. At the same time, the design of the three-pass boiler can maximize the thermal efficiency and increase the drying efficiency by 30%.

Continuous and uninterrupted heat supply

During the drying process of the sizing machine, steam needs to be supplemented in time in the drying cylinder of the drying room. In order to obtain sufficient steam, it is necessary to continuously add water to the boiler. The EPCB is equipped with a fully automatic control system through the boiler to ensure that the boiler produces stable The steam pressure and temperature ensure 24h continuous and uninterrupted heat source.

2. Reduce operating costs

1.Choose the most advanced and cost-effective high-efficiency boiler operating system, which can reduce energy costs by 30%.

2. Tailor the most economical and environmentally friendly auxiliary equipment configuration plan to reduce the enterprise's environmental protection investment and improve economic benefits.

3. The use of high-quality standard auxiliary equipment, and advanced PLC and DCS control technology, can remotely guide services, greatly reducing maintenance times and maintenance costs.

3. Choosing a reliable boiler manufacturer can provide high-quality services from all the production, and provide a strong guarantee for the sizing process.

Which boiler is used in the sizing industry?

The sizing machine uses steam provided by industrial boilers such as steam boilers or hot water boilers to sizing. In the sizing industry, boilers are usually used in different production processes, such as: providing stable and continuous temperature requirements during the sizing process, and providing efficient and stable thermal energy for the drying of sizing.

Types and specifications of boilers suitable for the sizing industry

According to the current applications in the textile industry, natural gas steam boilers are the most widely used. Sizing boilers mainly include gas fired fire tube steam boiler and gas fired water tube boiler, in addition to biomass fired water tube boiler.

Gas Fired Fire Tube Steam Boiler

Capacity: 1~30 tons/hour

Fuel: heavy oil, diesel, natural gas, liquefied petroleum gas, city gas, coke gas, etc.

This series steam boiler flue gas three-pass wet structure, achieving high thermal efficiency (98%). This is a fire tube boiler with low water quality requirements and a failure rate of less than 0.1. Adopting world-class burners, PLC automatic control cabinet and safety interlocking device, the operation is safe and convenient.

Gas Fired  Water Tube Steam Boiler

Capacity: 4~35T/h

Fuel: diesel, natural gas, heavy oil, liquefied petroleum gas, compressed natural gas, fuel oil, biogas, city gas, methane gas, etc.

This series steam boiler is also a three-pass flue gas wet structure. The evaporation capacity and working pressure are the same as the wns gas-fired steam boiler. This is a water tube boiler. The size and cost are slightly larger than that of the wns gas-fired steam boiler. Some large enterprises use gas. In the case of more than 10 tons, the gas fired water tube steam boiler is often selected, which has high steam quality and sufficient steam.

Biomass Fired Water Tube Steam Boiler

Capacity: 2~25t/h

Fuel: wood, bagasse, straw, rice husk and other biomass fuels.

Biomass fuel has low pollution, is renewable and has low cost. This double drum boiler adopts membrane wall and automatic feeding system, which has the advantages of high thermal efficiency (97%), large output, high steam quality and low operating cost.

How to choose a suitable boiler for the sizing industry?

1. Determine the capacity of the boiler.

First, we must clarify the total load range;

The second is the peak situation, including the duration of peak load, the frequency of peaks, that is, the periodicity of peaks. After understanding the total load needs and peaks, you can consider the choice of equipment capacity and number of units. In the selection, we should also consider the issue of accidental shutdown reserve.

2. Determine the heating medium.

Generally, the sizing industry uses steam boilers for production. If a large amount of hot water is needed, a steam boiler and a hot water boiler should be used at the same time.

3. Determine the boiler heating parameters, including pressure, temperature, etc.

To understand how big a boiler is needed for a sizing machine, it is necessary to know the specific steam or hot water demand, pressure value, temperature and other conditions.

4.Determine boiler efficiency.

In order to save operating costs, the boiler should have high thermal efficiency, by maximizing the fuel utilization rate, reducing the use of water resources, and saving more operating costs for sizing enterprises.

5. Determine environmental protection solutions.

By configuring low-nitrogen burners, various dust collectors and other auxiliary equipment, reduce harmful gas emissions and reduce environmental protection maintenance costs for sizing enterprises.

Conclusion:

At present, the sizing industry has two challenges: high energy consumption (water, heat, electricity); high pollution (waste water, exhaust gas, waste residue). Therefore, energy saving and emission reduction have become an indispensable means for sizing enterprises to reduce overall operating costs. Through more than 30 years of experience in boiler design and development in the sizing industry, EPCB starts from the customer's first use site, and provides a one-stop service from pre-sales to after-sales, ensuring that you can buy the most suitable products for you.

EPCB, your private boiler system expert!