Abstract
ABSTRACT This article shows how carpet dyeing plants at Shaw Industries have achieved significant energy reductions as an extension of water conservation and water heating reductions in 2007–2008. Those savings came from the following: 1. Water conservation—both water reuse and reductions in quantity 2. Rinse water temperature reductions 3. Waste-water heat recovery The impact of these is discussed, and the overall plant performance is presented. Savings for both total water and total energy have exceeded 20% in some plants. The article includes a process description for the continuous dye line and typical energy and water inputs for each step of the process. Specific changes are itemized, then the revised energy/water inputs for the line are presented. Finally, one plant's total energy per unit of production over the course of two years shows the impact of the improvements on total plant performance.
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