1. Optimizing the Ring Diameter of Ring Spinning Machines

Objective: Reduce energy consumption of spinning machines
Principle: Reducing the ring diameter decreases the weight of the bobbin and rotational resistance, thereby reducing the motor load.
Solution: Select the minimum feasible ring diameter based on yarn count (e.g., 38cm/36cm instead of 40cm) and adjust machine speed to compensate for capacity changes.

2. Installing Variable Frequency Drives (VFD) for Humidification System Fans

Objective: Reduce energy consumption of the humidification system
Principle: Adjusting fan speed to match actual humidity requirements avoids energy waste caused by fixed-speed operation.
Solution: Install VFDs on the humidification system fan motors and dynamically adjust flow based on sensor feedback.

3. Application of Counter-Current Washing Technology

Objective: Reduce water and steam consumption in wet processing
Principle: Washing water flows from the last tank to the first tank, utilizing residual heat and chemicals step by step.
Solution: Modify the water flow direction in continuous washing machines to adopt a counter-current washing design, reducing the need for fresh water and heating.

4. Cold Pad-Batch Dyeing System

Objective: Reduce dyeing energy consumption and chemical usage
Principle: Dye fixation is achieved through prolonged stacking at low temperatures, avoiding high-temperature steam consumption.
Solution: Replace traditional high-temperature dyeing machines with cold pad-batch equipment, optimizing chemical formulations and stacking time.

5. Recovering Waste Heat from Dyeing Wastewater

Objective: Reduce thermal energy waste
Principle: Use plate heat exchangers to recover heat from high-temperature wastewater and preheat fresh or process water.
Solution: Install heat exchangers at the dyeing machine outlet to transfer waste heat to the inlet water pipeline.

6. Humidity Control of Exhaust Air in Stenters

Objective: Reduce drying energy consumption
Principle: Real-time monitoring of exhaust air humidity using sensors reduces excessive air heating.
Solution: Install automatic exhaust control systems to dynamically adjust fan speed and exhaust volume.

7. Compressed Air System Leakage Repair

Objective: Reduce compressed air energy consumption
Principle: Repairing leaks reduces compressor load and operating time.
Solution: Regularly use ultrasonic detectors to identify leakage points and replace aging pipes and fittings.

8. Replacing Traditional Motors with High-Efficiency Motors

Objective: Improve motor system efficiency
Principle: High-efficiency motors reduce internal losses and improve energy conversion efficiency through optimized design.
Solution: Prioritize replacing motors with over 2000 hours of annual operation (e.g., pumps, fans) with IE3/IE4 high-efficiency models.

9. Steam System Condensate Recovery

Objective: Reduce boiler fuel consumption
Principle: Recovering high-temperature condensate for direct use in boiler feedwater reduces heating energy consumption.
Solution: Install condensate recovery pipelines and storage tanks at the outlets of drying cylinders, dyeing machines, and other equipment.

10. Replacing Steam Drying with Radio Frequency Drying Technology

Objective: Reduce yarn drying energy consumption
Principle: Radio frequency technology generates heat through molecular friction, directly acting on moisture and avoiding environmental heat loss.
Solution: Adopt radio frequency dryers in the yarn drying process to replace traditional steam heating systems.

11. Automatic Chemical Dosing and Distribution System

Objective: Reduce chemical waste and wastewater treatment energy consumption
Principle: Precise control of chemical usage avoids overuse and repeated washing.
Solution: Install automated chemical dosing equipment integrated with flow meters and PLC control programs.

12. Upgrading Factory Lighting Systems

Objective: Reduce lighting energy consumption
Principle: High-efficiency lighting (e.g., LED or T8 fluorescent lamps) and smart controls minimize ineffective lighting time. 

Solution: Replace traditional T12 fluorescent lamps with LED lighting and install light + motion sensors in workshops for time-based control.