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BY SUMIT BHATI
DY. MANAGER-ENGG.
Triveni Engineering & Industries Ltd. Sugar Unit- Ramkola, Kushinagar (U.P.)
OBJECTIVE OF MILLING
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Maximum possible extraction of sucrose Minimum extraction of non sugars Minimum sucrose in final bagasse Optimum moisture in final bagasse Optimum power/ energy consumption
CANE MANAGEMENT
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Quality cane supply 1. Minimum extraneous matters and binding materials 2. Clean and fresh Uniform supply of cane to avoid reduced crushing situation
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PREPERATION OF CANE
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Optimum cane preparatory Index as 85 Long fibrous preparation Avoid excess of cane preparatory devices Avoid dusting of cane
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CANE PREPARATION
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Good cane preparation Improve Bulk density and higher number of juice open cells Make easy to extract free juice Improve mill extraction Reduction in power consumption Improve feedability to mills Lower down mill opening Lower mill speed Lower hydraulic loading Effective imbibition Lower down reabsorption
HYDRAULIC LOAD
a. To be decided by Specific Hydraulic loading (SHP ) SHP = F/ 0.1LD Where F = Total load on top roller (Tons) L = Length of roller (Mt.) D = Dia. Of roller (Mt.) b. To curb excessive lift of top roller
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15 Roller 240 220 230 250 275 Above values of SHP are in tons/ft2 Nitrogen gas pressure in accumulator should be in the range of 70 to 90% of the hydraulic pressure. Nitrogen gas pressure should never be higher than the oil pressure
This is the maximum fibre load to be given to a milling tandem This is influenced by type of feeding devices Optimum range of SFL is 20kg/m3 to 25kg/m3 for mills with D chute and UFR Optimum range of SFL is 27kg/cm3 to 30kg/m3 for mills with GRPF/TRPF
REABSORPTION
Speed of bagasse is lesser than roller surface speed when it comes in contact to rollers gripping zone and reaches equal to roller speed at neutral plane. The speed of bagasse is higher than roller speed between neutral plane and axial plane. This phenomenon of excess speed causes the extrusion of bagasse which gives higher volume of bagasse than the escribed volume generated by the opening between the rollers called Reabsorption
REABSORPTION FACTOR
The ratio of actual volume of bagasse emerged to escribed volume generated by the opening between rollers at axial plane is known as reabsorption factor
RF CALCUL ATIONS
RF RF RF RF 1ST Mill 2ND Mill 3RD Mill 4TH Mill 0.75+ 0.0052V + 0.01F 0.65+ 0.0052V + 0.01F 0.60+ 0.0052V + 0.01F 0.60+ 0.0052V + 0.01F
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Poor cane preparation Higher surface speed Higher hydraulic loading than required Inefficient juice drainage Roller polishing Increase in pressure
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Relative positioning of three rollers (Top, Feed & Discharge) Trash plate properly drawn and positioned Setting of feeding devices Proper setting of scrapers knives
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MILL SETTINGS
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60
MILL SETTING
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0 1 b f x H
wt. of bagasse after each mill (W) (kg/hr)= TCHxfbx1000 TC Fibre% bagasse Where fb fibre % cane Assume bagasse density after each mill (d ) in kg/m3 I II III IV 1200 1210 1220 1230
MILL SETTING
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Diameter of mill roller Mill rpm Mill roller length Bagasse density
MILL SETTING
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Mill Ratio
Feed/Discharge 2.0 to 1.80 1.75 to 1.6
UFR setting
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Speed Ratio for UFR= 1.1 Average speed of UFR = Mill speed + UFR speed 2 Fibre Compaction (kg/m3 )= 85 to 120 UFR work opening= Fibre/minx1000 V x L x Fibre compaction Where V = surface speed of UFR (mt./min) L = Length of UFR (mt )
Average speed for D chute = Mill speed + UFR speed 2 Fibre Compaction (kg/m3 ) 50 to 85 D chute opening = Fibre/minx1000 V cosF x L x Fibre compaction Where V cosF = L = Surface speed of UFR (mt./min) Length of UFR (mt )
GRPF/TRPF SETTING
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GRPF SETTING 1. Speed ratio (A) 1.2 to 1.4 2. Volumetric ratio (B) 1.3 to 1.5 TRPF SETTING 1. Speed ratio (A) 1.0 to 1.2 2. Volumetric ratio (B) 2.0 to 3.0
Normal value of inlet pressure chute angle is 21 degree Normal value of out let angle of pressure chute is 45 degree Divergence angle of pressure angle varies from 5 to 7 degree Pressure chute should be symmetrical to the axis joining mid point of PF opening and mill feed opening
PRIMERY EXTRACTION
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SECONDARY EXTRACTION
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Low purity extraction Extraction based on imbibition efficiency Extraction of more non sugars High power consumption
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IMBIBITION
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By cold water By hot water Preferably by hot water Optimum temperature of hot water 70oC.
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MILL SANITATION
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To avoid bacterial growth Rapid growth of Luconostics in acidic and Low Brix juice Regular steaming Regular chemical spray - 30-40 ppm shock dosing under extreme conditions - 10 ppm for regular dosing Chemicals 1. Quaterrery Ammonium salts 2. Carbonates bases Thrust area 3. Bleaching powder
Not to monitor lift of top roller It is assumed that top roller lifts only that value considered during mill setting calculations Normally actual lift of top roller during operation is higher than considered in mill setting calculation Higher thickness of cane/bagasse blanket passes through mills due to excessive lift of top roller This leads to poor extraction of sucrose and results in higher sugar loss in final bagasse Hydraulic load applies on top roller simply by assumption/experience It is seldom to consider the lift of top roller while deciding the hydraulic pressure To compromise with mill performance due to power constrain
Plotting of Brix curve for feed and discharge side To monitor lift of top roller Analysis of bagasse leaving the mills for free pol and total pol Measurement of temperature of juice on feed and discharge Measurement of pol for bagasse leaving a mill and juice from back roller of same mill
Pol percent final bagasse Brix of last expressed juice Primary extraction (PE) Reduced mill extraction (RME)
There is seldom preventive/predictive maintenance No records of individual equipments No records about repair of equipments No proper training programme No proper house keeping works No separate inspection cell Lack of motivation among staff
Right selection of equipments and their components Correct orientation of wrongly placed equipments Quality repair during off-season Planning and scheduling of various jobs Equipment cards Provision of stand by equipments
PREVENTIVE MAINTENANCE
CONSTANT MONITORING ON OPERATIONAL PARAMETERS THROUGH SYSTEMATIC INSPECTION SO AS TO TAKE TIMELY REPAIR/REPLACEMENT OF COMPONENTS UNDERGOING WER AND TEAR TO AVOID DOWNTIME DUE TO FAILURE
Preventive maintenance cell with proper motivation Proper inventory to be maintained Categorization of plant and machinery Analysis of wear and tear and evaluation of service life
PREDICTIVE MAINTENANCE
IT IS MORE ADVANCE ON STREAM NON DESTRUCTIVE TESTING WITH A VIEW TO AVOID UNNECESSARY SHUT DOWNS BY TAKING FULL HELP OF TROUBLE PREDICTING AND TROUBLE SHOOTING TEST INSTRUMENTS