Assessment of energy efficiency and environmental impacts of cotton processing pneumatic systems for sustainable manufacturing

This research examines the environmental and operational impacts of cotton handling processes on pneumatic conveying systems, particularly in the context of transporting raw cotton to gins, which are recognized as a fundamental component of the cotton textile industry. The study examines the impact of pipe diameter on air velocity, energy consumption, and system efficiency. Theoretical analysis shows that increasing pipe cross-sectional area results in increased air and energy consumption, while diameter optimization can significantly reduce energy consumption. Despite using a larger-than-necessary pipe diameter (d = 0.4 m) to prevent clogging and ensure stable air mixture formation, the results indicate that improved uniform cotton feeding can allow the use of narrower pipes without compromising flow performance. This contributes to increased energy efficiency, reduced operating costs, and a reduced environmental impact—key factors in developing more sustainable and environmentally responsible cotton handling systems in the textile industry.