Blog Post By : Karun Tyagi
Introduction
The textile industry is a major consumer of fossil fuels, relying on diesel, furnace oil, LPG, and natural gas for processes such as steam generation, thermic fluid heating, and power backup. With rising fuel costs, increasing carbon emission regulations, and India’s push for renewable energy adoption, textile mills must explore biofuels as sustainable and cost-effective alternatives.
India’s transportation sector has already seen the benefits of ethanol blending, biodiesel blending, and compressed biogas (CBG) to reduce dependence on imported fossil fuels. The same principles can be applied to the textile industry, ensuring energy security, lower emissions, and operational cost savings.
This article explores:
- The role of ethanol, biodiesel, and CBG in textile processing
- Technological modifications required for their adoption
- Comparison of these biofuels with conventional fuels
- A roadmap for implementation in textile mills
The Need for Biofuels in the Textile Industry
Current Energy Consumption in Textile Mills
- Steam Boilers – Used in dyeing, scouring, bleaching, and finishing
- Thermic Fluid Heaters – Used for drying, curing, and heat-setting
- Diesel Generators (DG Sets) – Used for power backup in textile clusters
- Direct Firing in Stenters – Used for fabric finishing
These processes primarily depend on fossil fuels, making the textile industry vulnerable to oil price volatility and environmental regulations.
How Biofuels Can Help?
Ethanol blending → Replaces furnace oil & diesel in boilers & heaters
Biodiesel blending → Replaces diesel in boilers & DG sets
CBG → Replaces natural gas & LPG for steam generation & power
Biofuels in Textile Processing: Use Cases & Technology Modifications
1. Ethanol Blending in Textile Mills
Ethanol is a renewable biofuel derived from sugarcane, molasses, and agricultural waste. India is already implementing 20% ethanol blending (E20) in petrol, and its use can extend to industrial heating applications.
Use Cases:
- Can replace diesel and furnace oil in textile boilers and thermic fluid heaters
- Reduces carbon emissions and fuel costs
Necessary Technological Modifications:
| Component | Current Technology | Modification for Ethanol |
|---|---|---|
| Boilers & Burners | Diesel/Furnace oil burners | Minor tuning for ethanol combustion |
| Storage Tanks | Steel tanks | Corrosion-resistant tanks for ethanol storage |
| Piping & Seals | Standard rubber seals | Ethanol-compatible materials to prevent degradation |
| Control Systems | Diesel combustion calibration | Adjusted air-fuel ratio for ethanol burning |
Flex-Fuel Concept for Boilers: Similar to how automobiles use flex-fuel engines that switch between ethanol and petrol, multi-fuel boilers can be adapted to seamlessly switch between diesel, furnace oil, and ethanol based on availability.
2. Biodiesel Blending in Textile Mills
Biodiesel is made from vegetable oils, animal fats, and used cooking oil, making it a sustainable drop-in replacement for diesel.
Use Cases:
- Can be used in boilers, thermic heaters, and DG sets
- Works as a direct replacement for diesel (B20, B50, B100 blends)
Necessary Technological Modifications:
| Component | Current System | Modification for Biodiesel |
|---|---|---|
| Boilers & Heaters | Diesel/Furnace oil burners | No major changes for B20-B50 blends |
| Diesel Generators (DG Sets) | Runs on 100% diesel | Minor tuning for biodiesel combustion |
| Fuel Storage | Diesel storage tanks | Similar storage, but B100 needs extra filtration |
| Fuel Filtration | Basic filtration | Additional water separation required for B100 |
Easy Integration: Biodiesel requires minimal modifications compared to ethanol and CBG, making it a practical first step for textile mills transitioning to biofuels.
3. Compressed Biogas (CBG) in Textile Mills
CBG is a purified version of biogas (90% methane), produced from agricultural waste, industrial effluents, and food waste. It can directly replace LPG and natural gas in textile processing.
Use Cases:
- Can be used in boilers, steam generation, and thermic fluid heating
- Reduces dependence on imported LPG and natural gas
Necessary Technological Modifications:
| Component | Current System (LPG/Natural Gas) | Modification for CBG |
|---|---|---|
| Boilers & Heaters | Gas burners | New injectors for CBG |
| Gas Storage Tanks | LPG/NG storage | CBG storage at high pressure |
| Pipelines | Standard gas pipelines | Reinforced pipelines for CBG |
| Power Backup (Gas Generators) | Runs on LPG/NG | Modified for biogas injection |
Circular Economy Model: Textile mills can set up in-house CBG production units by utilizing effluent sludge, cotton waste, and sizing chemicals, ensuring waste-to-energy conversion.
Comparing Ethanol, Biodiesel, and CBG for Textile Processing
| Parameter | Ethanol Blending | Biodiesel Blending | Compressed Biogas (CBG) |
|---|---|---|---|
| Primary Application | Boiler fuel (diesel replacement) | Boiler & DG set fuel | Steam & LPG/Natural gas replacement |
| Carbon Reduction | Moderate | Moderate-High | High |
| Infrastructure Requirement | Burner & storage tank modifications | Minor modifications for high blends | New storage & gas pipelines |
| Cost Savings | Moderate | Moderate (depends on feedstock) | High (if produced in-house) |
| Government Incentives | Ethanol Blending Program | National Biodiesel Mission | SATAT Scheme |
| Scalability | High | High | Medium (depends on waste availability) |
Implementation Roadmap for Textile Mills
Step 1: Pilot Testing
Identify the primary fuel consumption areas in the plant
Conduct pilot trials with B20 biodiesel in DG sets
Test ethanol blending in boilers (start with 10% ethanol)
Establish a CBG sourcing or production model
Step 2: Equipment Modifications & Adaptation
Retrofit burners and injectors for ethanol & biodiesel compatibility
Install new fuel storage systems where required
Upgrade pipeline networks for CBG adoption
Step 3: Full-Scale Adoption
Transition to multi-fuel boilers and power systems
Establish long-term biofuel procurement agreements
Work with government agencies for subsidies & incentives
Conclusion: The Future of Sustainable Fuel in Textiles
The textile industry must adopt a multi-fuel strategy, combining ethanol blending, biodiesel, and CBG to achieve cost savings, carbon reduction, and energy security.
Biodiesel (B20-B100) → Best for boilers and DG sets
Ethanol Blending (E10-E20) → Works for boilers and heaters
CBG → Best for steam generation and replacing LPG/Natural Gas
The time to transition to biofuels is NOW! Textile mills should start pilot trials, adapt equipment, and integrate biofuels for a sustainable, cost-effective future.
Image by: Freepik
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