In the global apparel industry, carbon emission issues are becoming increasingly severe. According to statistics, the apparel industry accounts for 10% of global carbon emissions, second only to the oil industry, making it the second-largest source of pollution. To address this challenge, green manufacturing has become a crucial development direction for clothing factories. Choosing the right industrial boiler plays a vital role in energy saving and emission reduction.
Industrial boilers are essential equipment in the manufacturing process, used to heat water or produce steam. However, traditional coal, natural gas, or oil-fired boilers generate large amounts of carbon dioxide and other greenhouse gases, posing threats to the environment and human health. Opting for energy-efficient and environmentally friendly boilers can not only reduce carbon emissions but also help companies save on energy costs and improve production efficiency.
This article includes the basics and importance of industrial boilers, analyze the advantages and disadvantages of different types of boilers, and provide recommendations for selecting the right industrial boiler for clothing factories. Through this information, we aim to assist apparel manufacturers in making informed decisions on their path to achieving carbon neutrality.
Fashion Industry’s Carbon Emission Commitments
Facing the carbon emission challenge, major fashion companies like H&M and GAP signed an agreement in 2019, committing to reduce carbon emissions by 30% by 2030 to meet the United Nations' carbon emission targets. The Sustainable Apparel Coalition, led by H&M and GAP, further increased this target, aiming for a 45% reduction by 2030. At the COP26 Climate Change Summit in 2021, 130 fashion companies pledged to achieve carbon neutrality by 2050. Since manufacturing supply chains contribute 96% of the apparel industry's carbon footprint, clothing factories have a responsibility to meet this goal. Selecting the right boiler can significantly contribute to reducing the carbon footprint of factories.
Basics and Importance of Industrial Boilers
Industrial boilers are used to supply thermal energy in manufacturing processes, primarily for heating water or generating steam to meet the thermal energy demands of various industrial processes. These boilers are widely used in chemical, petroleum, food processing, apparel manufacturing, paper, and power generation industries. Industrial boilers must comply with safety and environmental requirements and require regular maintenance and inspections to ensure safe operation.
Common Types of Boilers
Boilers can be classified based on different usage needs and structural characteristics to ensure optimal performance and efficiency in various applications. Below is a detailed classification based on thermal energy utilization, including the advantages and disadvantages of each type of boiler.
1. Steam Boilers: Steam boilers are the most common type of boilers in the industrial sector, primarily used to generate steam. They work by burning fuel to produce heat, which converts water in the boiler into steam. The advantage of steam boilers is their ability to produce high-pressure steam, suitable for industrial production processes requiring large amounts of steam, such as paper mills and power plants.
Advantages:
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Pros: High efficiency: Can quickly produce large amounts of steam, suitable for high-demand industrial processes.
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Versatile: Can be used for power generation, heating, and driving mechanical equipment.
Disadvantages:
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High cost: Initial equipment and operating costs are high.
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Complex maintenance: Requires specialized maintenance and operational skills.
2. Hot Water Boilers: These boilers are specifically used to produce hot water, commonly applied in central heating and hot water supply systems, such as schools and hospitals. Hot water boilers operate at lower pressure and have higher safety levels, providing immediate heating and energy savings.
Advantages:
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Versatile: Suitable for heating, domestic hot water supply, and some industrial processes.
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Low operating cost: Only need to heat water to a certain temperature without reaching steam generation, reducing operating costs.
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Easy to operate: Relatively simple operation and easy maintenance.
Disadvantages:
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Limited application: Cannot be used for high-temperature industrial processes requiring steam.
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Lower thermal efficiency: Compared to steam boilers, thermal efficiency may be lower.
Common Boiler Structural Features
1. Vertical vs. Horizontal Boilers: Vertical boilers are arranged vertically, occupying less floor space and being easy to install, suitable for small-scale applications. Horizontal boilers are arranged horizontally, offering higher efficiency and easier maintenance, suitable for large factories and power generation facilities. These structural types have their advantages in different application scenarios and should be selected based on specific needs.
2. Water Tube vs. Fire Tube Boilers: In water tube boilers, water flows through the tubes, and combustion gases generate heat in the combustion chamber, heating the water through the outer walls of the tubes to convert it into steam. These are suitable for chemical industries, textiles, and paper manufacturing. Fire tube boilers have combustion gases pass through tubes, suitable for low-pressure and capacity applications. Both designs cater to different industrial needs, providing corresponding performance and efficiency.
3. Tubular boiler: Operating similarly to water tube boilers, water flows through the pipes, and combustion gases generate heat, heating the water through the outer walls of the tubes to produce steam. Without steam drums, they are compact and have short start-up times. Suitable for small to medium-sized factories and residential or commercial use, these boilers are ideal for general steam demands. However, they cannot handle sudden large steam demands and are suitable for food factories, restaurants, hospitals, hotels, and schools.
Steam Applications in Apparel Production
Fabric Dyeing and Finishing: This process involves adding pigments or dyes to the fabric to provide color to clothing. Dyeing usually takes place during yarn production or fabric weaving, requiring specific heat and humidity provided by steam.
Fabric Pre-Treatment: In garment factories, fabrics typically undergo pre-treatment, such as relaxing and pre-shrinking. Relaxing involves heating and moistening to remove shrinkage and tension from the fabric, making it more natural and soft. Pre-shrinking involves heating and shrinking the fabric to achieve the desired shape in advance.
Garment Ironing: In the ironing stage, steam is an essential tool for ironing clothes. Using steam provides appropriate heat and humidity during the ironing process, maintaining consistent shape and size, and eliminating wrinkles for a neater, smoother finish.
Common Boiler Fuel Choices
Common boiler fuels include electricity, coal, natural gas, oil, and biomass, each with its cost and environmental characteristics. Some fuels are cheaper but have a significant environmental impact, while others have superior environmental performance but are relatively expensive. Therefore, companies need to balance cost and environmental benefits when selecting boilers based on specific needs and environmental conditions.
Electric Boiler
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Pros: High efficiency, low emissions, no air pollution, saving energy costs.
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Cons: High initial investment cost, but lower long-term operating costs.
Oil Boiler
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Pros: High combustion efficiency, suitable for various industrial applications, relatively low cost.
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Cons: Emits high levels of carbon dioxide and other harmful gases, significant environmental impact.
Gas Boiler
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Pros: High efficiency, space-saving, high production efficiency, relatively low cost, stable heat and power.
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Cons: Still emits carbon dioxide and greenhouse gases, requiring the selection of low-carbon fuels and improved combustion technology to reduce emissions.
Biomass Boiler
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Pros: Uses renewable biomass resources, reduces carbon emissions, decreases reliance on petroleum and harmful fuels.
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Cons: Production, collection, and transportation processes may emit carbon, requiring the selection of efficient biomass resources and regular maintenance.
Coal Boiler
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Pros: High combustion efficiency, can provide large amounts of heat energy, low cost.
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Cons: Emits large amounts of carbon and pollutants, harmful to the environment and health, requiring improved combustion technology and air cleaning technology to reduce emissions. It is recommended to avoid use and switch to alternative energy sources or advanced emission control technologies.
How to Choose the Right Industrial Boiler for Manufacturing Factory
When selecting boilers for garment factories or textile industries, consider the following factors:
1. Energy Efficiency: Choose high-efficiency boilers to minimize energy consumption and reduce carbon emissions.
2. Equipment Capacity: Select boiler capacity that meets your production needs to avoid wasting space or energy.
3. Control Functions: Choose boilers with good control functions to ensure accuracy and consistency in the production process.
4. Reliability: Choose reliable boilers to avoid unnecessary downtime and production interruptions.
5. Maintenance and Upkeep: Choose boilers that are easy to maintain and upkeep to lower long-term operational costs.
6. Environmental Protection: Choose environmentally friendly boilers to help comply with environmental regulations and improve the environment.
7. Supplier: Choose reputable suppliers to get high-quality products and excellent service.
Conclusion
In recent years, the apparel industry has been striving to transition to cleaner, more sustainable energy. The Fashion Industry Charter for Climate Action commits to achieving carbon neutrality by 2050. Energy consumption is a key factor in greenhouse gas emissions in the apparel manufacturing industry. By adopting energy-efficient boilers, the industry is working to reduce the energy intensity of heating and steam processes, further decarbonizing. Choosing the right industrial boiler can help textile companies reduce their carbon footprint and energy costs. With over 30 years of experience in industrial boiler manufacturing, OSHIMA is here to assist. If you want to learn more, please contact us.
