Saving energy in cotton gins

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

Submitted to: Plant Management Network
Publication Type: Proceedings
Publication Acceptance Date: 7/19/2018
Publication Date: 7/23/2018
Citation: Funk, P.A., Hardin Iv, R.G., Terrazas, A.A. 2018. Saving energy in cotton gins. Plant Management Network. Available: http://www.plantmanagementnetwork.org/edcenter/seminars/cotton/SavingEnergy/.

Interpretive Summary: Energy costs represent 20% of the total cost of cotton ginning, with electricity cost varying from $1.62 to $21.58 per bale and fuel costs from $0.23 to $9.07 per bale. Because there is a large difference between facilities there is probably room for improvement. Fuel and electricity consumption were measured through energy audits in commercial cotton gins. The facilities that made the best use of energy per unit processed were considered better. Material handling with air accounted for more than half of the electricity used. We recommend sealing leaks in air ducts, minimizing turbulence before and after fans, reducing pressure drops by simplifying flow paths, and using mechanical conveyors where practical. Fuel consumption can be reduced by insulating the hottest ducts, minimizing the distance between burners and cotton pickup points, and adding automatic controls with temperature sensing in locations recommended by ASABE Standards. Using energy efficiently improves environmental stewardship and stakeholder economic sustainability.

Technical Abstract: Energy costs represent 20% of the total cost of cotton post-harvest processing, with electricity cost varying from $1.62 to $21.58 per bale and fuel costs from $0.23 to $9.07 per bale; this large disparity indicates opportunity for improvement. Fuel and electricity consumption were quantified in commercial cotton gins to elucidate industry best practices. Because pneumatic conveying represents about half of the electrical energy consumed, recommendations focus on sealing leaks in air ducts, minimizing turbulence before and after fans, reducing pressure drops by simplifying flow paths, and using mechanical conveyors where practical. Fuel consumption can be reduced by insulating the hottest ducts, minimizing the distance between burners and cotton pickup points, and adding automatic controls with temperature sensing in recommended locations. Environmental stewardship and stakeholder economic sustainability are both served through improved energy utilization.