Mill Material Balance

12.1.2

The Evaluation

The result of computer calculation with the use of the same input as for the example in Chapter IX
is shown on Sheet-II (Evaluation) that is for the overall and individual performance of each mill,
such as:

The Material Balance, overall and individually (page 1).

The overall performance of the tandem (page 2).

The individual performance of each mill (page 2).

The actual versus the projection of Brix Curves (page 3).

The approximate mill power (HP) required (page 4).

XII-3

Mill Material Balance

M I LL M A T E R I A L B A LA N C E
SUGA R FACTORY : E X A M P LE
M I LL TRA I N
: 2 CC + 5 MILLS
CANE QUALI TY
% pol =

Mass
kg/hr.

%
brix

10.32
Brix
kg/hr.

E V A LUA TI O N O F P E R F O R M A N C E
CA P A CITY
:
4,351.0 TCD
PERIOD
:
X
M I LLING SEA SON :
1977
D a t e : Last date
% brix =
13.41
% fibe r =
16.07

%
pol

Pol
kg/hr.

M I LL I
- J u ic e in
- Fiber
Total in
Extracted juice
- Bagasse juic e
- Fiber
Total bagasse

152,158
29,133
181,291
68,761
83,397
29,133
112,530

15.98

24,311

12.30

18,709

13.41
17.46
14.80

24,311
11,969
12,342

10.32
14.05
10.89

18,709
9,631
9,078

10.97

12,342

8.07

9,078

M I LL I I
- J u ic e in
- Fiber
Total in
Extracted juice
- Bagasse juic e
- Fiber
Total bagasse

146,898
29,133
176,031
86,185
60,713
29,133
89,846

12.25

17,994

8.97

13,174

10.22
12.48
11.98

17,994
10,723
7,271

7.48
9.29
8.55

13,174
7,982
5,192

8.09

7,271

5.78

5,192

M I LL I I I
- J u ic e in
- Fiber
Total in
Extracted juice
- Bagasse juic e
- Fiber
Total bagasse

112,703
29,133
141,836
63,501
49,202
29,133
78,335

9.10

10,260

6.48

7,303

7.23
8.90
9.37

10,260
5,652
4,609

5.15
6.45
6.52

7,303
4,096
3,207

5.88

4,609

4.09

3,207

M I LL I V
- J u ic e in
- Fiber
Total in
Extracted juice
- Bagasse juic e
- Fiber
Total bagasse

93,235
29,133
122,368
51,990
41,245
29,133
70,378

6.33

5,903

4.38

4,087

4.82
5.75
7.07

5,903
2,989
2,914

3.34
4.06
4.79

4,087
2,111
1,977

4.14

2,914

2.81

1,977

M I LL V
- J u ic e in
- Fiber
Total in
Extracted juice

76,373
29,133
105,506
44,033

3.82

2,914

2.59

1,977

2.76
2.94

2,914
1,295

1.87
2.00

1,977
881

5.01

1,619

3.39

1,096

2.63

1,619

1.78

1,096

- Bagasse juic e
- Fiber
Total bagasse

32,340
29,133
61,473

The Computer Program

Density
kg/dm3

Volume
dm3/hr.

Page : 1

E v a l u a t i o n:

1.07138
1.60000
1.13146
1.07788
1.06608
1.60000
1.16689

142,020
18,208
160,228
63,792
78,228
18,208
96,436

M I LL I
Dk =
L=
n=
h=
i=
Vedo =
Ved =

10.02
21.33
268
0.4123
2.20
74,154
70,331

r=
r' =
m=
h' =
K=
HKej =
kB =

1.3712
1.3590
0.3378
0.3910
2.28
80.47
1.089

1.05550
1.60000
1.11850
1.05646
1.05414
1.60000
1.18526

139,174
18,208
157,382
81,579
57,595
18,208
75,803

M I LL I I
Dk =
L=
n=
h=
i=
Vedo =
Ved =

10.23
21.33
244
0.3633
2.00
60,737
56,154

r=
r' =
m=
h' =
K=
HKej =
kB =

1.3499
1.3477
0.3443
0.3359
2.80
74.44
1.016

1.04234
1.60000
1.12272
1.04191
1.04288
1.60000
1.19802

108,125
18,208
126,333
60,946
47,179
18,208
65,387

M I LL I I I
Dk =
L=
n=
h=
i=
Vedo =
Ved =

10.21
21.33
216
0.2779
2.00
41,048
48,959

r=
r' =
m=
h' =
K=
HKej =
kB =

1.3355
1.3364
0.3543
0.3315
2.58
72.47
0.978

1.03085
1.60000
1.12623
1.02889
1.03332
1.60000
1.21085

90,445
18,208
108,653
50,530
39,915
18,208
58,123

M I LL I V
Dk =
L=
n=
h=
i=
Vedo =
Ved =

10.20
21.33
191
0.2614
2.00
34,108
43,986

r=
r' =
m=
h' =
K=
HKej =
kB =

1.3214
1.3253
0.3631
0.3371
2.47
70.61
0.908

1.01772
1.60000
1.13142
1.01772

75,043
18,208
93,251
43,266

M I LL V
Dk =
L=
n=
h=

10.34
21.33
193
0.2462

r=
r' =
m=
h' =

1.3010
1.3010
0.3615
0.2875

1.01772
1.60000
1.22983

31,777
18,208
49,985

i=
Vedo =
Ved =

2.00
32,907
38,421

K=
HKej =
kB =

2.43
68.03
0.771

XII-4

Mill Material Balance

M I LL M A T E R I A L B A LA N C E
S U G A R F A C TO R Y : E X A M P L E

CA P A CITY

M I LL TRA I N
: 2 C C + 5 M I LLS
C A N E Q U A LI TY
% pol =

10.32

I m b ib it i o n w a t e r :

M ix e d ju ic e :

La s t m ill b a g a s s e :

E x t r a c t io n ' s :

R a t io o f ju ic e p u r ity
Crystal:

Sym b o l

Date

La s t d a t e

16.07

V a lu e

crushed, total
c r u s h in g d u r a t io n
crushed per hour
juic e c o n t e n t
weighed, total
weighed per hour

Q
jg
Qj
gnt
Gi
G ij

4,351.0
24.00
181,291
83.93
843.1
35,128

% fiber
% cane
on bagasse 1
on bagasse 2
on bagasse 3

g is
g it
g ia 1
g ia 2
g ia 3

120.58
19.38
0
0
0

on bagasse 4
weighed, total
weighed per hour
% cane

g ia 4
Gnm
Gnmj
gnmt

pol
brix
purity
total per hour
% cane

pol
brix
fib e r c o n t e n t
dry matter
juic e t o f ib e r
juic e lo s s in b a g a s s e
B rix m ill # 1
B rix t o t a l
sugar
s u g a r o n 1 2 ,5 % f i b e r

- can be expected
- in m ix e d ju ic e
- l o s s i n b a g a s s e ( r e l a t iv e )

Page :2

E V A L U A TI O N O F P E R F O R M A N C E
4,351.0 TCD
PERIOD
:
X

M I LLI N G S E A S O N :
1977
% b r ix =
13.41
% fibe r =

A CTUA L P E R F O R M A N C E
D e s c r ip t i o n
Cane:

Unit
TCD
hours
KCH
% cane
Tons
kg/hr.
%
%
%
%
%

Ta r g e t
4,800.0
24.00
200,000
83.93
1,581.3
65,887

fibe r
cane
G ij
G ij
G ij

205.00
32.94
0
0
30

100
3,718.7
154,946
85.47

% G ij
Tons
kg/hr.
% cane

70
4,800.0
200,000
100.00

pnm
bnm
HKnm
Gal
g a lt

11.40
14.69
77.62
61,473
33.91

%
%
%
kg/hr.
% cane

10.04
12.60
79.68
65,887
32.94

pal
bal
kf
zk
nss
gnhs
H P B -I
H P B -t
HPG
H P G 1 2 ,5
PSHK
kt
knm
khar

1.78
2.63
47.39
50.03
111.01
31.84
49.23
93.34
94.14
95.44
94.51
9.08
8.59
5.38

%
%
%
%
%
% fibe r
%
%
%
%
%
% cane
% cane
%

0.94
2.58
48.78
51.36
105.00
32.97
53.40
93.67
96.99
97.66
97.44
9.08
8.99
1.05

I N D I V I D U A L P E R F O R M A N C E
M I L L N O : --------------->
I
II
III
IV
V
E x t r a c t io n :
- J u ic e
En =
45.19
58.67
56.34
55.76
57.66
N o r m a l v a lu e =
> 60
> 60
> 60
> 60
> 60
- Pol
Ep =
51.48
60.59
56.09
51.64
44.55
- B rix
Eb =
49.23
59.59
55.08
50.64
44.43
C o m p r e s s io n r a t i o :
K =
2.28
2.80
2.58
2.47
2.43
N o r m a l v a lu e = 2 , 4 - 3 , 3 2 , 6 - 3 , 5 2 , 6 - 3 , 3 2 , 5 - 3 , 2 2 , 4 - 3 , 0
J u ic e e x t r a c t e d b y f e e d o p e n in g
y =
-0.14
0.71
0.44
0.31
0.25

%
%
%
%

m e a n in g = n o e x ' t i o en x t ra c t e de x t ra c t e de x t ra c t e d
e x t ra c t e d
l =
-0.10
-0.13
0.25
0.35
0.19
%
m e a n in g =
safe
safe
danger danger
safe
no-void density
da =
1.1669
1.1853
1.1980
1.2108
1.2298 kg/dm3
a b s o r p t io n a b ility fa c t o r
r =
1.3712
1.3499
1.3355
1.3214
1.3010
ditto, norm a l
r' =
1.3590
1.3477
1.3364
1.3253
1.3010
% cane
gat =
62.07
49.56
43.21
38.82
33.91
%
pol
pa =
8.07
5.78
4.09
2.81
1.78
%
brix
ba =
10.97
8.09
5.88
4.14
2.63
%
dry matter
zk =
36.86
40.52
43.07
45.54
50.03
%
inde x
c =
0.41
0.52
0.60
0.66
0.76 k g / d m 3
loading
q =
161.98
174.26
197.24
223.27
217.97 gr/dm 2
re d u c e d lo a d in g
q' =
123.18
129.80
147.20
166.80
160.63 gr/dm 2
N o r m a l v a lu e = 1 2 0 - 1 3 0 g r / d m 2 e s c r i b e d ro l l e r s u r f a c e
% bagasse
kf =
25.89
32.43
37.19
41.40
47.39
%
N o r m a l v a lu e = 2 5 - 3 5
%
28-38
32-42
37-47
45-50

R o lle r s h e l l d e f l e c t i o n
Bagasse: F ib e r :
-

The Computer Program

XII-5

Mill Material Balance

M I LL M A T E R I A L B A LA N C E
SUGA R F A C TO R Y : E X A M P LE
M I LL TRA I N
: 2 C C + 5 M I LLS
C A N E Q U A LI TY
% pol =

10.32

THE B RIX CURVES

C A P A CITY
:
4 , 3 5 1 . 0 TCD
PERIOD NO.
:
X
M I LLI N G S E A S O N :
1977
D a t e : La s t d a t e
% brix =
13.41
% fibe r =
16.07

V a l u e f o r -------------->
% brix, expected ----------->
% brix, a c t u a l ---------------->

M ill I
16.02
17.46

M ill I I
9.82
12.48

M ill I I I
5.60
8.90

M ill I V
3.10
5.75

Page : 3

M ill V
1.90
2.94

20
19
18
17
16
15
14

<---------- % brix ---------->

13
12
11
10
9
8
7
6
5
4
3
2
1
0
Mill I

Mill II

Mill III

Expected Curve

The Computer Program

Mill IV

Mill V

Actual Curve

XII-6

Mill Material Balance

M I LL M A T E R I A L B A LA N C E
SUGA R FACTORY : E X A M P LE
M I LL TRA I N
: 2 CC + 5 MILLS
CANE QUALI TY
% pol =

10.32

P O WE R C A LCULA TI O N
CA P A CITY
:
4,351.0 TCD
PERIOD NO. :
X
M I LLING SEA SON :
1977
D a t e : Last date
% brix =
13.41
% fibe r =
16.07

P O WER CA LCULA TION

Description
M ill hydraulic pressure
Diameter of hydraulic p iston
M e c h a n ic a l efficiency, total
Roller shaft diameter, average
Roller shaft length
Top roller mean diameter
Roller length
Roller rotation
Reduced fiber loading
Cross section area of hydraulic piston
Hydraulic force
Top roller weight
Total pressing load
Bagasse coeffic ient of fric t ion
Circumferentia l forc e
P o we r required for milling, average
Specific power requirement

12.1.3

Unit
kg/cm2
mm
%
mm
mm
mm
mm
rph
gr/dm2
cm2
kg
kg
kg
m
kg
PK
HP/ton fiber

M ill I

M ill I I

M ill I I I

M ill I V

Page : 4

M ill V

180
182
182
206
210
330
330
330
330
330
86
86
86
86
86
420
420
420
420
420
4,220
4,220
4,220
4,220
4,220
1,002.0
1,023.0
1,021.0
1,020.0
1,034.0
2,133
2,133
2,133
2,133
2,133
268
244
216
191
193
123.18 129.80 147.20 166.80 160.63
854.87
854.87
854.87
854.87
854.87
307,751 311,171 311,171 352,204 359,043
16,943
17,555
17,496
17,467
17,881
324,694 328,726 328,667 369,671 376,924
0.3378
0.3443
0.3543
0.3631
0.3615
109,677 113,175 116,437 134,228 136,247
398
382
347
354
368
13.67

13.11

11.92

12.14

12.62

Notes for Evaluation

After a material balance for a mill tandem made completely as shown above, the next step is to
define the performance evaluation together with the comments and recommendations.
The evaluation for the performance of a mill tandem can be made in 4 (four) main items:

Overall for the whole tandem.

Individually for each unit of mill.

Comparing the Brix Curves.

Power required for the milling.

The criterions used for the evaluation, both the overall and individuals of a mill tandem is shown
above (see the sheet on page-2).
The main points essentially evaluated for overall performance of a mill tandem are comparing the
actual figures achieved during operation with the planned figures made by the projection, such as:

The crushing capacity.

The imbibition water % fiber as well as % cane.

The mixed juice % cane and its purity (HK).

The Computer Program

XII-7

Mill Material Balance

The last mill bagasse for its quantity (in %cane), %pol, %Brix and the dry matter. Also the
juice in bagasse %fiber (nss) and the loss of juice %fiber (gnhs).

The results of extraction for Brix in mill#1 (HPB-I), the total Brix by the tandem (HPB-t) and
the sugar extraction (HPG).

The ratio of juice purity (PSHK).

The expected crystal obtained (kt) by and contained in mixed juice (knm) and the relative
crystal loss in the last mill bagasse (khar).

While the main and essential items, which should be evaluated individually for each mill, among
other things are the followings:
a. Extractions
There are 3 (three) extractions in milling:
Juice extraction,

Pol extraction, and

Brix extraction.

The juice extraction is good when the value is more than 60% for each mill, and gradually
decreasing for the ensuing mills. The same criterion applies for the value of Pol and Brix
extractions.
b. Compression Ratio
The compression ratio (K) is a ratio between the no-void volume of the incoming material and
the escribed volume of the delivery opening, and is a barometer for the pressing work of the
milling in a unit of mill.
The value of the compression ratio depends on the ability of the respective mill rollers in use.
A good roller material enables maintaining a good compression ratio wills also obtaining
optimal fiber index (c).
c. Is juice extracted by the feed opening ?
As it was expressed in Chapter VII, that if the value of y = positive, then juice is really
extracted by the feed opening. But likewise, if the value of y = negative, it is concluded in
average that the feed opening of the respective mill does not extract any juice.
The value of y also indicates the presence of slip when a rather high value is defined. Generally
speaking a heavy slip is presence, if too many juice extracted by the feed opening compared to
the juice extracted by the delivery opening.
Beside of no extraction made by the feed opening when the value of y = negative, it also
indicates in average that the feeding of the respective mill is less and not stable.
The normal value of y is between 0.10 0.30. It means the juice volume extracted by the feed
opening is about 10% 30% from the volume of juice extracted by the delivery opening. Then
it is suggested that the most extraction should due by the delivery opening to avoid the
occurrence of heavy slip in a respective mill. The condition will be achieved when the ratio
The Computer Program

XII-8

Mill Material Balance

between feed and delivery work opening (i) actually sets referred to the value defined by the
projection of the material balance (the Projection Program).
d. Is there any deflection made by the top roller ?
Among the 3 (three) rollers in use, the top roller is attaining the most pressing work in a unit of
mill (attaining the pressing due in the feed and the delivery openings). Because the top roller
supported by two upper halves of the top metals, then a slight deflection will occur on the shaft
and the roller shell as well. The roller shafts made of forged steel material, while cast iron or
cast steel is for the roller shells. Based on the different materials, roller shell deflection should
be intensely monitored to prevent the roller breakage during the course of milling.
The different between the actual work opening (calculated) and the work opening when set, and
then divided by the roller length will show the value of deflection made by the roller. The limit
value of deflection (maximum) for the roller shell made of cast iron/steel is around 0.22%. If
the average value of deflection exceeding the limit, it is definitively concluded that the roller
works in danger. The occasion would not happen, if the setting of the respective mill done
precisely according to the calculation made by the projection program of the material balance.
Especially when the centers to center distances between the rollers were not checked during the
setting of mills to prove its accuracy, or, if the roller lift (hydraulic lift) sets exceeding or higher
than the dimension determined by the calculation (the material balance).
e. Everything related to bagasse
Items evaluated in bagasse among other things are:

The no-void density (da). It is best when the value gradually increasing from mill#1 to the
last mill.

The absorption ability factor (r). Its value should gradually decrea-sing from mill#1 to the
last mill.

The value of normal absorption ability factor (r) also gradually decreasing.
The bagasse percentage to cane (gat) gradually decreasing.

%pol (pa) and %Brix (ba) also gradually decreasing.

The dry matter (zk) is best when gradually increasing.

f. Everything about fiber

The evaluation should be at least focused to the followings:

The fiber index (c).

The fiber index normally expressed in kg/dm3 of the volume escribed by the delivery work
opening is to know the fiber true density when pressed or milled under the rollers. If the
value obtained from the calculation of mill material balance compared to the value from the
table (see the Java Method of Mill Setting, E. Hugot third edition 1986, page 201-203), then
well know the true capability of the roller shell material in use. The higher the value of
fiber index, meaning the best material for the roller is and that has the character of building

The Computer Program

XII-9

Mill Material Balance

up raw grain surface. Therefore the value of its fiber index obtained from the calculation
also indicates the capability of the respective mill.

The fiber loading (q).

The fiber loading expressed in gram/dm2 of the roller surface is to know the rate of average
fiber distributed to the roller surface during the pressing of cane or bagasse under the
rollers. It is also to know the difference when compared to the value obtained from the table
(see the Java Method of Mill Setting, E. Hugot, third edition 1986, page 201-203).
For the mills driven by reciprocating steam engines, where the roller rotations decreasing
from the first to the ensuing mills, the values of fiber loading gradually increasing. But it is
not the case with mills driven by steam turbines or by electric motors. Steam turbines have
nominal speed, where the efficiency could be achieved optimally. Thus for the mill tandem
with steam turbine or electric motor drives, the rotation of the rollers should be set based on
the nominal speed of the steam turbines or the electric motor respectively.
When steam turbines used for the tandem, the fiber loading should refers to the capability of
the normal 30 mills or it is usually called the reduced fiber loading (q), whereas if the
value lies between:
120-130 gram/dm2 is normal. It means the respective mill is sufficient when provided
only with an ordinary feeder roller for the feeding device.
130-140 gram/dm2, besides of feeder roller the respective mill also needs to be provided
with a Donnelly chute to perform a reasonable feeding.
140-160 gram/dm2, the mill needs to be provided with a light duty pressure feeder.
150-170 gram/dm2, the mill needs to be provided with a heavy-duty pressure feeder.

The fiber percentage to bagasse (kf).

The value gradually increasing from mill#1 to the ensuing and up to the last mill, but it
should also be compared with its value normally achieved.

The Computer Program

XII-10