Cotton Gin Electrical Energy Use Trends and 2009 Audit Results

Abstract

Cotton gin energy costs have risen more than other operating costs. Energy audits were conducted in 20 U.S. cotton gins representing a range of capacities in six states. The average participating saw gin used 39.5 kWh to process a bale. The average roller gin used 62.6 kWh. Gins have become larger, from a connected power of 570 kW (764 hp) in 1962 to over 2237 kW (3000 hp) today. Energy costs are a larger proportion, 20% of the total cost of ginning, compared to 6% to 10% of the total in the 1970s, even though energy consumed per bale processed is less, approximately 73% of the electricity consumed in 1982. Connected power and energy consumption were allocated to five categories: seed cotton cleaning, ginning, lint cleaning, bale packaging, and materials handling. Materials handling accounted for the largest portion, over half of the electricity consumed by a gin, as it has since the 1960s. Since the 1980s, the power and energy allocated to ginning has decreased slightly, and that allocated to lint cleaning has decreased significantly. Best practices still include: operating at full capacity, avoiding down time, minimizing materials handling, and improving electric motor efficiency.