Comparative Study of Energy Consumption Patterns in Nigerian Synthetic Fibre and Natural Fibre Textile Plants

Energy cost constitutes one of the largest operational expenditure components for Nigerian textile manufacturers, and understanding consumption patterns across production process stages is essential for targeted efficiency interventions. This study comparatively analyses energy consumption patterns in synthetic fibre production plants and natural fibre textile plants operating in Nigeria, drawing on case study data from facilities in Lagos and Kaduna states. Energy audits were conducted at six plants, three synthetic fibre and three natural fibre processing, recording electrical and thermal energy consumption by process stage over a three-month monitoring period. Specific energy consumption per kilogram of output was calculated for each production process, and energy performance benchmarks were developed. Energy intensity indices were compared between plant types and against international benchmarks from comparable economies. Results show that synthetic fibre plants consumed an average specific electrical energy of 2.8 kWh/kg of output, compared to 1.4 kWh/kg for natural fibre processing plants, reflecting energy-intensive polymer melting, extrusion, and spinning operations. Dyeing and finishing stages were identified as the most energy-intensive unit operations across both plant types, accounting for 38 to 52 percent of total energy use. Air compressor systems and auxiliary motors were identified as the most significant sources of energy waste in both plant types, with motor efficiency ratings below 75 percent in most facilities. The study recommends investment in motor efficiency upgrades, heat recovery from exhaust steam in dyeing operations, and installation of energy management monitoring systems across Nigerian textile operations to reduce energy intensity by an estimated 25 to 35 percent. Keywords: energy consumption, textile plants, energy efficiency, synthetic fibre, Kaduna