Energy Efficiency Assessment in a Textile Dyeing Facility: A Case Study

This study presents the results of a comprehensive energy audit conducted at an industrial textile dyeing facility in Türkiye with the aim of evaluating its energy performance and identifying energy efficiency improvement potentials. Electricity and natural gas consumption patterns were analyzed using historical production and energy data, field measurements, and on-site observations. The audit focused particularly on thermal energy systems, including steam boiler operation, heat distribution lines, and auxiliary equipment, as well as electrical systems such as lighting. Flue gas analysis, thermal imaging, and energy monitoring were employed to determine system efficiencies and quantify energy losses. Based on the audit findings, three main energy efficiency measures were proposed: recovery of waste heat from boiler flue gases, insulation of uninsulated piping and installation elements, and conversion of conventional lighting systems to high-efficiency LED luminaires. The results indicate that natural gas accounts for more than 90% of total energy consumption, highlighting the critical importance of improving thermal systems. The proposed measures demonstrate significant energy saving and economic benefits, with simple payback periods ranging between 0.6 and 3.9 years. The findings confirm that systematic energy audits constitute an effective and economically feasible approach for reducing energy consumption, operating costs, and greenhouse gas emissions in energy-intensive textile dyeing facilities.