Saving energy in cotton gins

Authors: Funk, Paul; HARDIN, ROBERT - Texas A&M University; TERRAZAS, ALBERT - New Mexico State University; Yeater, Kathleen

Submitted to: National Cotton Council Beltwide Cotton Conference
Publication Type: Proceedings
Publication Acceptance Date: 2/4/2019
Publication Date: 5/16/2019
Citation: Funk, P.A., Hardin, R., Terrazas, A., Yeater, K.M. 2019. Saving energy in cotton gins. National Cotton Council Beltwide Cotton Conference, January 8-10, 2019, New Orleans, Louisiana. p. 359-362.

Interpretive Summary: Energy costs have increased more than other variable costs of ginning. Consuming fuel and electricity also impacts the environment. Reducing the amount of energy used in post-harvest processing will increase the sustainability and decrease the cost of the cotton supply chain, improving farm economics. This paper presents energy conservation principles for cotton gins by combining results from electricity and fuel use audits conducted over the past decade. Electrical energy can be conserved in many cases by improving or replacing pneumatic conveying systems. A thoughtful assessment of materials handling requirements followed by a careful economic analysis is required before replacing pneumatic conveying systems with mechanical conveyors. Where pneumatic conveying is more desirable than mechanical, savings might be realized by repairing, modifying, or replacing duct runs that have high pressure losses from leaks caused by wear or damage, short bend radius elbows, inefficient fan inlets, or lengthy runs. Fuel consumption can be minimized by repairing leaks and adding insulation to hot air ducts, especially before the seed cotton mix point, and placing burners as close to the mix point as possible without risking a cotton fire. Electricity and fuel use can also be reduced through maintenance and operating decisions that minimize downtime and maximize throughput.

Technical Abstract: Energy costs have increased more than other variable costs of ginning. Consuming fuel and electricity also impacts the environment. Reducing the amount of energy used in post-harvest processing will increase the sustainability and decrease the cost of the cotton supply chain, improving farm economics. This paper presents energy conservation principles for cotton gins by combining results from electricity and fuel use audits conducted over the past decade. Electrical energy can be conserved in many cases by improving or replacing pneumatic conveying systems. A thoughtful assessment of materials handling requirements followed by a careful economic analysis is required before replacing pneumatic conveying systems with mechanical conveyors. Where pneumatic conveying is more desirable than mechanical, savings might be realized by repairing, modifying, or replacing duct runs that have high pressure losses from leaks caused by wear or damage, short bend radius elbows, inefficient fan inlets, or lengthy runs. Fuel consumption can be minimized by repairing leaks and adding insulation to hot air ducts, especially before the seed cotton mix point, and placing burners as close to the mix point as possible without risking a cotton fire. Electricity and fuel use can also be reduced through maintenance and operating decisions that minimize downtime and maximize throughput.