Indonesian textile manufacturer increases productivity using distributed power for cogeneration
Two GE Jenbacher J320 gas engines from Navigat Energy, working in tandem with an absorption chiller, have given Indonesian textile manufacturer WinnerSumbiri Knitting (WSK) a more cost- effective, efficient and lower-emissions power supply.
WSK is a leading manufacturer of fabric and textiles for the garment industry, producing over 1.2 million meters of high quality fabric each month. Headquartered in Indonesia, the company uses some of the most sophisticated and modern knitting machineries, as well as advanced capabilities in dyeing, finishing and printing facilities. Due to WSK’s rapid growth in recent years, its facilities now run for 24 hours each week day and require new infrastructure to support the expanded operations, including new energy efficiency needs.
GE’s gas engines, installed in 2007, each supply about 1 MW of power and have more than 60,000 combined hours of successful operation. Prior to installing the engines, WSK had been experiencing production difficulties because their old power supply was unstable and costly. In addition, WSK had been using older diesel generators for intermittent onsite power needs that were less friendly to the environment and also less efficient.
The solution: cogeneration technology
WSK opted for Navigat Energy’s natural gas solution to power its factory, and two years later, the efficiency of the Jenbacher units was augmented by installing an absorption chiller that created a true cogeneration plant, also known as: Combined Cooling, Heating and Power (CCHP). The chilled water from the cooler offsets the extremely harsh, warm Southeast Asian climate by cooling the manufacturing hall, which preserves the quality of the knitting equipment and the manufactured goods themselves.
The GE Jenbacher gas engines now run 24 hours a day, seven days a week, in order to sync with the factory’s operating schedule. Since the electrical needs of the facility are only about 1.3 MW, WSK usually runs one engine at a time. This protects the engines from overuse and assures that excess power capacity is available when needed. In addition to that, WSK recovers 450 TR (~213.75 kW) of chilling from the waste heat of the gas engine and the peak boiler. This means a great cost saving, since almost a half of their power needs are covered by the CCHP technology.
- Reliable power and cooling for a 24/7 production environment
- Excellent efficiency and environmental savings by capturing waste heat from engines
- More than 60,000 hours of successful operation with minimal maintenance needed
- Recovered waste heat saves more than $100,000 in annual cooling costs (based on Nov. 2014 cost figures)
KEY TECHNICAL DATA:
|Number and type of GE units:||2 x GE J320 gas engines; 1 x absorption chiller|
|Generating capacity:||~2 MW|
|Electrical efficiency:||Up to 70 percent|
|Commissioning:||2007 (engines); 2009 (chiller/CCHP)|