Two BROAD single-stage steam chillers turn zero-pressure steam left over from Kejriwal’s continuous polymerisation line into chilled water for POY and FDY yarn production.
Textile sector application
Synthetic textile plants run three linked processes: CP (continuous polymerisation), POY (partially oriented yarn) and FDY (fully drawn yarn). The CP stage produces heat that can drive cooling for the downstream POY and FDY lines, whether it is available as steam, hot water from the heat-transfer-medium (HTM) system, zero-pressure steam from CP, or exhaust from on-site power generation.
At Kejriwal, the CP stage releases zero-pressure (0 kg/cm²g) steam at 100–105 °C that the plant had no use for and was venting through the CP vapour chimney.
The BROAD solution
BROAD installed two single-stage steam absorption chillers, rated 800 TR and 400 TR, that take this waste steam as their only heat source. They deliver chilled water at 7 °C (returning at 12 °C) to cool the POY and FDY processes, with cooling water circulating between 33 °C and 38 °C through the plant’s cooling towers.
Because the chillers are thermally driven, the cooling comes from heat the plant already had, instead of from electrically driven compressors.
Unique value to the customer
The installation avoids around 850 kW of electrical load and saves about ₹5.5 crore on the electricity bill every year. The project paid for itself in roughly 7 months.
Chiller details
- Chiller type
- Single-stage steam absorption chiller
- Cooling capacity
- 800 TR × 1 + 400 TR × 1
- Heat source
- Zero-pressure steam after CP (100–105 °C)
- Models
- BDS121XIII-0.0-38/33-7/12-200 · BDS242XII-0.0-38/33-7/12-400
- Chilled water
- 12 °C → 7 °C
- Cooling water
- 33 °C → 38 °C
- Condensate
- 95 °C
Download the full case study
Specifications, process diagram and savings in one PDF (241 KB).
