Energy uses for cotton ginning in Australia

Ginning is an energy intensive process. This paper evaluates the energy usage inside cotton gins in Australia. Benchmark electricity use for the years 2007 and 2008 was found to range between 46.5 and 58.55 kWh (167.4–210.8 MJ) per bale, with the average being 52.3 kWh (188.3 MJ). The electricity consumption for different gins was positively correlated with bale numbers produced. Electricity and gas usage comprised of 61% and 39% of total energy use respectively. A method for the detailed monitoring of energy performance in cotton ginning is developed and described. From the detailed monitoring carried out at two gin sites, it was suggested that changes in trash content and degree of moisture in the module and lint quality produced did not have significant influence on electricity usage. 57% (74) of motors inside the gin operated at less than 60% loading. Overall, cotton handling was found to be the largest energy user and accounted for nearly 50% of power use in both gins. Packaging and handling together used 70% of total power required. With the installation of capacitor banks, all gins monitored had an overall power factor of higher than 0.81. It was estimated that 60.38 kg of CO2-equivalent emissions were produced by energy usage for ginning one bale of cotton.

► Electricity use was between 167 and 211 MJ per bale, with 61% as electricity and 39%. ► At two gin sites, 57% of motors operated at less than 60% loading. ► Cotton handling accounted for 50% of power and handling 20%. ► Gins with capacitor banks installed had an overall power factor greater than 0.81. ► 60.4 kg CO2-e were emitted from energy used for ginning one bale of cotton.