BOCM Feasibility Study (FS) 2014 – Final Report

MOEJ/GEC BOCM Feasibility Study (FS) 2014
Summary of the Final Report“Waste Heat Recovery and Utilization in Textile and Garment Factories”(Implementing Entity: PEAR Carbon Offset Initiative, Ltd.)
1．Overview of the Proposed JCM Project
Study partners

Kurose Chemical Equipment Co. Ltd. (Japan)
Tex Master Buying Solution (Bangladesh)

Project site

Bangladesh

Category of
project

Energy saving
The project is to install heat exchangers for recovering waste heats from wastewaterof textile dyeing process and applying the heats to warm up fresh water required fortextile dyeing process.
The project targets three Bangladesh textile and garment factories. The factory are

Description ofproject

Hams Garments Ltd., Giant Textile Ltd. Delta Composite Ind. Ltd located Gazipur
district of Dhaka Division.
The core technology is the heat exchanger that will be provided by Japanesemanufacturer, Kurose Ltd. and other related equipment such as pumps and control
panels are planned to adjust from Japan. The local partner is Tex Master Buying
Solution, a local consultant and buying house.

Japan
Expected project
implementer

PEAR Carbon Offset Initiative, Ltd.
Giant Textile Ltd. (GTL)

Host country

Hams Garments Ltd. (Hams)
Delta Composite Ind. Ltd (Delta)

Initial investment
Annualmaintenance cost
Willingness toinvestment（Thousand yen）

Date ofgroundbreaking

September 2015

1,800 (Thousand yen)

Construction
period5 months

Date of projectcommencement

February 2016

106,200

The target factories aretaking interests in the
project

Financial plan ofproject
GHG emission
reductions

50% of the total cost is from factories and rest of 50% is from the subsidy of JCM
2,397 (t CO2/year)
1) Reduction of fossil fuel consumption due to reduction of steam consumption(2,397 t CO2/year)

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BOCM Feasibility Study (FS) 2014 – Final Report

2. Study Contents(1) Project development and implementation
1) Project planning
The study (feasibility study) approximately estimates the total cost for the three factories is 106.2 million
Japanese yen (including custom taxes). Among them, the heat exchangers cost 25 million Japanese yen,control panels cost 14.4 million Japanese yen, pumps cost 20.5 million Japanese yen, local construction,
piping and wiring works cost 14.5 million and rest of equipment cost 12.5 million Japanese yen. Annual
maintenance fee is 1.8 million Japanese yen. Among the total cost, GTL shares 28.5 million Japanese yen,Hams shares 29.8 million Japanese yen and Delta shares 47.9 million Japanese yen. The table 1 in below
shows the costs in detail. However, the cost does not include margins of Japanese entities involved in the
project implementation.
Table 1 Estimated Cost
Heat
Wiring and Submersive
exchanger piping work water pumpTK
Hams

8,510,000

US$

70,917JPY

8,920,000

US$

74,333-3,939,773

4,247,483

2,064,236

4,094,400

294,750

1,147,000

4,071,574

1,400,000

29,769,215

32,83135,396

17,202

34,120

2,456

9,558

33,93011,667

248,077

6,756,637

12,007,035

3,597,634

6,188,200

699,880

1,482,000

6,578,950

1,700,000

47,930,336

56,305100,059

29,98051,568

5,832

12,35054,825

14,167399,419

3,817,933

4,247,483

2,328,236

4,094,800

01,147,000

3,883,504

1,400,000

28,518,955

31,81635,396

19,402

34,1230

9,558

32,363

11,667

237,658

20,502,000

7,990,106

14,377,400

994,630

3,776,000

14,534,027

4,500,000

106,218,506

170,850

66,584

119,8128,289

31,467

121,11737,500885,154-2,506,850

JPY

7,600,000

US$

63,333TK

Total

4,436,400

TK
GTL

Other
(instruction,
test operation)

2,586,850

JPY

TK
Delta

Ancillary
Export packing
Control board Auto valve Flow meterequipment
freight-

9,530,100

Total
JPY 25,030,000 14,514,342(3 factories)US$
208,583
120,953-

Regarding financing, the target factories will responsible 50% of the total cost correspondingly and therest 50% will be adjusted from the subsidy of BOCM. In order to realize implementation of the project, aninternational consortium that consists of Toyota Tsusho Corporation, PEAR and target factories is planned tobe established. The consortium is responsible for project implementation and also MRV implementation.
In the consortium the Toyota Tsusho is a representative entity and response for financing and managementof the project. PEAR is responsible for MRV implementation including methodology development,
monitoring plan development. Construction time is tentatively planned to be September 2015 and operation
time is to be February 2016. However, the final implementation plan in detail will be completed discussing
with factories by confirming their investment concern.

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BOCM Feasibility Study (FS) 2014 – Final Report

MRV implementation
and reporting

Ministry ofEnvironment

International Consortium (Project implementer)
GEC

Pumps,
Control
PanelsBear 50% of the cost

Third
party
Reporting

Monitoring
Emission Reduction Calculation 
Monitoring

Other factories 

Delta Composite Ind. Ltd.

Construction

System operation and monitoring Constructor

Hams Garments Ltd.

Provide heat exchanger andsupport installation
Construction
order
Local

System operation and monitoring 

Giant Textile Ltd.

Heat exchanger order 

System operation and monitoring 

System management 

System operation and monitoring 

BOCM/JCM subsidy(up to 50%)

KuroseVerifying

Toyota Tsusho Corporation
Representative implementer and conduct financing andproject management

PEAR
MRV management

QC/QA

Other equipment
order Provide equipment andsupport installation 

Figure 1 Project Implementation Scheme
Through the project, target factories can save energy and then corresponding cost for the energy. Energy
savings (natural gas) from the project are 335,728 m3/year, 471,352 m3/year and 783,097 m3/year for GLT,
Hams and Delta respectively.
5 Tk/m3, 8 Tk/m3 and 10 Tk/m3 different scenarios of natural gas prices are taken for economic analysis of
the project. Here 5 Tk/m3 is the current price for natural gas. Bangladesh government is considering
increasing the price of natural gas. At the moment, it is decided to double the price for domestic natural gas
use. Though it is clear that the price of industrial gas use will also be increased in the future; however, it’s
timing and range are not clear yet.

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BOCM Feasibility Study (FS) 2014 – Final Report

Table 2 Information of Project Energy Saving Impact Calculation

The economic analysis for each factory respecting for varies gas prices are given in the tables below.

Table 3 Economic Analyses

10 Tk/m 3
8 Tk/m 3
5 Tk/m 3
Hams Delta GTL Hams Delta Hams Delta
IRR
39% 42% 23% 25% 27% 13% 15%
Payback period (year) 2.4
2.3
3.8
3.5
3.3
5.3
5
Net benefits (million)
46
79
24
27
48
13
24
Gas Price

The results of economic analysis from the perspective of target factories in the table above show the
payback periods for the gas price in 10 Tk/m3 are very attractive. For the gas price in 8 Tk/m3, the figures
also seem acceptable. In the case of current gas price (5Tk/m3), except GTL that uses CNG with the price of
10Tk/m3, payback periods are within 6 years that are not attractive for factories. However, it is clear that thegas price will be increased in the near future that makes the project feasible for factories for long term.
Moreover, there is a loan scheme from IDCOL (Infrastructure Development Company Limited) for
projects that promote renewable energy and energy efficiency. Factories are able to have loans up to 60% of
the total investment with an interest rate of at least 9% under the scheme. Economic analyses for the case of
60% loans with 10% interest rate are shown in the table 4 below.
Table 4 Economic Analyses (for the case of loan)

Gas Price

10 Tk/m 3
8 Tk/m 3
5 Tk/m 3
Hams Delta GTL Hams Delta Hams Delta
IRR
79% 98% 41% 44% 49% 15% 19%
Payback period (year) 2.9
2.7
4.9
4.5
4.2
7.8
7.1
Net benefits (million)
38
89
16
19
35
5
11
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BOCM Feasibility Study (FS) 2014 – Final Report2) Permits and Licenses for the project development and implementation
According to the Environmental Conservation Rules, 1977, textile and garment factories belong to red
category that requires EIA for implementation the kind of projects. However, this project targets factories
that are holding Environmental Clearance Certificates and then there is no need to conduct any EIA
additionally. Furthermore, the system being introduced under the project is a close system that will notgenerate any kind of solid or liquid wastes and pumps in the system also works with the pressure lower than
0.005MPa and then no risk even if pipe clogging happen. However, even that keeping in mind to report tothe department of environment before starting the construction.

3) Advantage of Japanese technology
The core technology of the system is the heat exchanger of Kurose. The heat exchanger is spiral heatexchanger without distance piece that is a patented product of Kurose.
Say heat exchanger, there are several types. The spiral type is apt for heat collection from wastewatercontaining solid and gelled substances. Though, tubular heat exchangers had a history of being applied in
textile industry. At present, it has been seen seldom in the field due to its nature of low efficient and spaceconsuming. Plate type heat exchanger had been applied widely in China. However, prompt clogging withtextile scraps and pastes make its maintenance cost high from repeated breaking down and assembling forcleaning. In most factories they exist in a dormant state for many years. Even in China where labor cost is
not so high they have been abandoned from many years.

Figure 2

Figure 3

The figure 2 and 3 below shows structure of the spiral heat exchanger. Generally, there are distance pieces
between flow channels as shown in the figure 2. However, in the case of liquids with long thread line/fibers,
the spiral heat exchanger with the distance pieces easily occurs clogging.
On the other hand, Kurose has developed a spiral heat exchanger without distance pieces (refer to figure3) that is low fouling and easy to clean. Compare to tubular heat exchangers, it has advantages of highefficiency, low maintenance and space saving.
It is costly compare to the plate type heat exchangers. It has been widely applied at wastewater treatment
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BOCM Feasibility Study (FS) 2014 – Final Reportplants in Japan. Along with the increasing of energy cost, an increased number of chemical factories andpaper mills have been applying the spiral heat exchangers without distance pieces.
Moreover, the heat exchangers are been highly appreciated by domestic textile factories that started toapply the technology. Regarding the spiral heat exchanger, the domestic (Japan) market share is nearly 100%.
In overseas, it is also high valued. For example it has acquired U stamp of ASME (American Society of
Mechanical Engineers), manufacturing licenses in China and Korea.
In Bangladesh, there are cases of application of tubular and plate heat exchangers in textile and garment
factories. However, there has been no any case for application of heat exchangers for recovering waste heatof wastewater from dyeing sections.
For the project the spiral heat exchanger without distance pieces is selected for application due to aptnessof the technology for the project. The project will be the first case of applying such a kind of technology in
Bangladesh Textile and Garment factories.
It is clear that the project will realize energy saving through the technology. It is expected that the projectwill contribute to sustainable development in Bangladesh textile industry by expanding the technology
among the factories.

4) MRV structure
Parameters are selected carefully from the perspective of developing a methodology that is simple,
transparent and conservative as well compare to methodologies of CDM. As a result, the following 4
parameters are selected for monitoring ex post of the project.
No.1：Temperature of the feed water (hot) to dyeing machines after the project (°C)
No.2：Temperature of feed water (fresh) to heat exchanger after the project (°C)
No.3：Amount of the feed water (hot) to the dyeing machines after the project (t/y)
No.4：Amount of the electricity consumption of the system after the project (MWh/y)For measuring the No.1 and No.2, temperature measurement system that has functions of datatransmission through frequency conversions will be installed to ensure continuous data collection andrecording. For the parameter No. 3, flow meters with data transmission functions will be installed to promise
continuous data collection and recording. A dyeing master (or an assigned person for the task) in eachfactory will collect the data recorded automatically once a week and record them into data sheets prepared
beforehand.
For the parameter No.4, power meters are installed to control panels of the system introduced to measureaccumulated power consumption of the system. A dyeing master (or an assigned person for the task) in eachfactory will read power meters and record the figures after each shift. Factories managers will collect all data
once a week and record them into data sheets prepared beforehand. All meters with sensors will be inspected,
maintained and calibrated regularly as per specifications, guidelines from makers.
QA/QC system is very important to ensure reliability of a monitoring. As situations in each factory are
different, it is hard and inappropriate to develop a uniform QA/QC system for all factories.
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Concrete

BOCM Feasibility Study (FS) 2014 – Final Reportmonitoring plans for the factories will be developed in due course of implementation process. In the study, amonitoring and MRV scheme shown in the figure 4 is developed in a general way.

Figure 4 Monitoring and MRV Scheme5) Environmental integrity and Sustainable development in host country
As mentioned before, textile factories belong to red category that requires EIA for project implementation.
However, this project targets textile and garment factories that already held Environmental Clearance
Certificates.
Therefore there is no need to conduct any EIA additionally. Furthermore, the system being introduced
under the project is a close system that will not generate any kind of solid or liquid wastes and pumps in thesystem also works with the pressure lower than 0.005MPa and then no risk even if pipe clogging happen.
However, even that keeping in mind to report to the department of environment before starting theconstruction.
Moreover, the project will save energy (natural gas consumption) in Textile and Garment industry that isa pillar industry of Bangladesh. Then the project is seen to contribute to improve energy supply and demand
and then sustainable development by contributing energy security of Bangladesh.
At present, Bangladesh is suffering from lack of natural gas supply that causes difficulty of gaining gas
connection for new factories and gas consumption limitation for existing factories. The project that covers 3
factories can save 1.2 million m3 of natural gas annually and expansion of the project to more factories canpromise further saving a far larger amount of natural gas.

6) Toward project realization (planned schedule and possible obstacles to be overcome)The schedule for future works is given as follows.
February 2015
March 2015
April 2015

Completion of the feasibility study
Site visit
Confirm factories investment willingness
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BOCM Feasibility Study (FS) 2014 – Final Report

May 2015
Confirm and establish BOCM project implementation system
June 2015
Apply for BOCM implementation project
September 2015 Project start
October 2015
Verification of MRV methodology
December 2015 Project registration application for BOCM joint Committee
January 2016
System operation start
Implementation of technology transfer (operation, maintenance and management)
Capacity building for MRV implementation
February 2016 Start monitoring
March 2016
Completion of the report for BOCM project.
Tasks:In order to implement the project as per the schedules, there are some tasks need to be cleared.
The first is the financing. In the study, it is planned that the factories will responsible for financing 50%of the total cost. With the gas price of 10 Tk/m3, the project incurs enough benefits to motivate factories’
willingness to invest. However, if price rise will not be realized or postponed, the projects’ benefits will
shrink by a large margin and factories’ willingness to investment will drop as well. For this, it needs todiscuss and negotiate with factories taking several cases into consideration. IDCOL’s (Infrastructure
Development Company Limited) loan for renewable and energy efficiency promotion projects is considered
as an option if factories have difficulties of adjusting their own funds. In a word, it is necessary to confirm
the factories’ willingness to invest as soon as possible.
The second is technical risks. If the construction of tanks, installment of equipment, piping and wiring canmeet technical standards expected is an issue of taking into consideration. It requires developing construction
specs in detail, confirming final schedules and costs before implementation. Moreover, it needs to establish asystem for construction process management and ensuring QA/QC together with local consultants.
Furthermore, the factories will operate the system of waste heat recovery and application. So it needs toensure technical transfers including system maintenance and management prior to project operation.
Together with capacity building for MRV, it is important to increase awareness of managers toward
maintenance and calibration of monitoring equipment.
Except the issues mentioned above, there is no any big risk that poses an impediment for project
implementation. Based on designs in detail and closely working stakeholders, strive for realization of theJCM project as soon as possible.

(2) JCM methodology development
1) Eligibility criteria
The following eligibility criteria are identified for the methodology application.
Criterion 1

Waste heat (heat from dyeing waste water) recovery from dyeing and finishing process inthe existing or new textile and garment factories.

Criterion 2

Spiral heat exchanger without distance pieces is applied for heat recovery.
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BOCM Feasibility Study (FS) 2014 – Final Report

Criterion 3

Targeting factories with dyeing capacity more than 10 ton/day

The heat exchanger is the spiral heat exchanger without distance pieces that will be customized to thefactories. The technology is the first trail for textile and garment factories in Bangladesh. The technology
ensure reduction of steam consumption in dyeing process that in turn results in reduction of fossil fuelconsumption of boilers that provide steam for dyeing process in the factories. The project image is shown in
the figure 5 below.

Figure 5 Image of the Project2) Calculation of GHG emissions (including reference and project emissions)
The reference emission is the emission from consumption of fossil fuel to gain the same amount ofenergy utilized from waste heat recovery system. It is determined as follows.
[(Temperature of feed water in the project) - (Temperature of feed water in the case of without project)] ×（The amount of the feed water in the project）×（the specific heat of water）/(boiler efficiency)×（CO2 emission
factor the fossil fuel that is used to provide energy for dyeing and finishing process）.
For the boiler efficiency, 1.0 is applied. For CO2 other parameters, lower values between upper and lower
values are applied for conservativeness.
The equation is give as follows
𝑅𝐸! = (𝑇!   −    𝑇!" )×W!!   ×F! ×1
×EF!"#,!"#$   ×10!!
Ef

RE! :

Reference emission [tCO2/y]

T! :Temperature of feed-water in the project [°C]T!" :Temperature of feed-water in the case of without the project [°C]W!" :The specific heat of water [kJ/kg °C]

F! :The amount of the feed-water in the project [t/y]I-20

BOCM Feasibility Study (FS) 2014 – Final Report

Ef:  Boiler efficiency [ratio]

EF!"#,!"#$： CO2 emission factor the fossil fuel that is used to provide energy for dyeing and finishingprocess [tCO2/TJ]
On the other hand, project emission is calculated based on the amount of electricity consumed by thewaste heat recovery system and electricity CO2 emission factor.
PE! = EC!",! ×EF!"!#
PE!     :	 	 	
 	 Project emissions [t CO2/y]
EC!",!   :	
  Electricity consumption by the waste heat recovery system [MWh/y]𝐄𝐅𝐞𝐥𝐞𝐜     : 	 CO2 emission factor of electricity [t CO2/MWh]In Bangladesh, the most textile and garment factories have captive diesel or gas generators for power
generation while grid power supply is not stable. For CO2 emission factor of power generation, respective
emission factors of grid and captive power generator could be used if the proportion of each is available.
However, it is usually difficult to identify the proportion. Thus, emission factor of diesel generator, which is
the highest emission factor, is used to calculate CO2 emission for the conservativeness in the methodology.
Among the 3 factories, two factories are using diesel generators regularly. The rest factory is using diesel
generators as back up in the case of power outage.
The emission reduction is calculated as follows.
ER ! = RE! − PE!
ER ! : Emission Reductions [t CO2/y]
RE! :Reference emissions [t CO2/y]

PE! :Project emissions [t CO2/y]

3) Data and parameters fixed ex ante
The source of each data and parameter fixed ex ante is listed as below.
Parameter

Description of data

SourceEf

Boiler efficiency

1.0 is used for conservativenessEF!"#,!"#$           CO2 emission factor of the fuel used for steam

2006 IPCC Guidelines for National

generation

Greenhouse Gas Inventories. Table 1.4,

Natural gas：54.3 t CO2/TJ (54.3–58.3)

Chapter 1, Volume 2.

CO2 emission factor of electricity：0.8

Emission factor of diesel captive

tCO2/MWh (Diesel captive power plant)

power is used for the

EF!"!#               

conservativeness (Table I.F.1,
Small Scale CDM Methodology:
AMS I.F., Ver.2)
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BOCM Feasibility Study (FS) 2014 – Final Report

Emission factor of the grid is 0.67
tCO2/MWh (Official data of
Bangladesh Government).

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