E−Report for balancing Sahkari chini mill ltd

Milling Plant:

The Factory is having 6 no. of mills of size 700 mm x 1300 mm. It is having
only one set of knife along with a shredder/fiberizor. The mills are provided wi
th GUFR and donelly chute. The milling tandem of the factory is capable of crush
ing 145 tch.The plant could be rated at 3190 TCD.The power required for driving
each mill is 280 BHP.
Cane Unloader:
The cane unloader be provided with 4 no. of grabs. The grab to have a capacity
of lifting 2 tons at 20 lifts/hr.The crane to have 4 Tons SWL capacity. A gantry
length of 50 meters be provided.
Cane Carrier:
The width of the cane carrier will be 1300 mm. The depth of the cane carrier wi
ll be 2600 mm. Cane carrier shall be driven by 45 bhp motor.
Feeder Table:
A 5m x 7m feeder table be provided. The feeder table drive would be 20 bhp.The
Feeder table however is an optional item for a sugar plant.

Cane Kicker and Cutters:

A cane kicker having 42 arms driven by 30 bhp motor be provided.However this ki

cker is an optional item for the sugar plant.
A cane leveller having 24 arms driven by 230 bhp motor or a cane cutter having
42 arms driven by 320 bhp motor be provided.
Fibrizor and Shredder:
A cane fiberizor having 33 hammers of 15 kg each driven by 910 bhp motor be pro
vided with leveller or a cane shredder having 110 hammers of 18 kg each driven b
y 640 bhp motor be provided with cane cutter. The cane leveller and shredder com
bination shall be better for energy conservation.

Carriers:

The rake carrier drive would be 25 bhp.

Rake type intermediate carries shall be driven by 25 bhp motors.

A bagasse carrier of width 1000 mm having a carring capacity of 60 tons of baga

sse per hour be provided with a drive of 50 bhp motor. Bagasse elevator be drive
n by 40 bhp motor. RBC be driven by 40 bhp motor.
Boiler and Turboalternator:
Total minimum boiler capacity of 85 tons/hr be provided along with a power tur
bine of 3990 kva.

Juice Heaters and Evaporators:

It is assumed that the factory is getting 120 deg cent exhaust steam for heatin
g purposes.It is assumed that vapour bleeding arrangement is there as per the fo
llowing scheme.

For clear juice heating from 95 to 112 deg C 4610 Kgs of exhaust vapour at 120
deg C would be required.For sulphited juice second heating from 90 to 103 deg C
3530 Kgs of vapour from 1st body at 111 deg C would be required.For sulphited ju
ice heating from 65 to 90 deg C 6590 Kgs of vapour from 2nd body at 100 deg C wo
uld be required.For second raw juice heating from 50 to 70 deg C 5230 Kgs of vap
our from 3rd body at 85 deg C would be required.For first raw juice heating from
25 to 50 deg C 6620 Kgs of vapour from 3rd body at 85 deg C would be required.
All the five juice heaters shall be of 210 m sq HSA.Optional−One additional jui
ce heater of same capacity as standby may be provided.
Vapour required for A and B pan boiling 16530 kgs/hr.
The quantity of water to be evaporated 116000 kgs/hr.
Quad of 1740, 1120, 960, 540 m sq HSA be provided.
The Quad bodies which are above 500 HSA if required may be split into two bodie
s for parallel operation.

Vapour bleeding:

From 1st body to A and B pans and SJH−2.

From 2nd body to SJH−1.
From 3rd body to RJH−1 and RJH−2.

Clarification plant:

The juice sulphiter receiving tank capacity 150 HL. The Sulpher furnace burnin
g area required 3.65 sq meter. Two air compressors of 540 m cube/hr capacity del
ivering air at 1 kg/cm sq would be required. Lime slaker capacity 1090 Kgs/hr wo
uld be required. The filteration area of the vacuum filter required would be 100
m sq. Total holding capacity of the clarifier would be 5400 HL. Syrup sulphiter
working capacity 60 HL.

Pan Floor:

15 no. of syrup molasses tank of 180 HL capacity are required. 6 nos. of vacuum
pan of 50 tons capacity could be provided. One seed crystalliser of 35 tons cap
acity be provided. One vacuum crystalliser of 40 tons capacity be provided.
Crystalliser Floor:
Four air or water cooled crystalliser for A−massecuite having 60 tons capacity
are required. Four water cooled crystallisers for B−massecuite having 60 tons ca
pacity would be required. Seven water cooled crystallisers for C−massecuite havi
ng 60 tons capacity be provided.
Centrifugal machines:
Flate bottom centrifugal machines doing 14 cycles per hour for handling 3830 kg
/hr of A−massecuite. C−foreworker continuous machines for handling 27 tons/hr C−
massecuite and B/C afterworker machines for handling 43 tons/hr B and C massecui
te.

Sugar melter and magma mixer of capacity 13 tons/hr be provided.

Sugar elevator and sugar grader of capacity 10 tons/hr be provided.

Spray pond:

660 no. of spray nozzles be provided along with two spray pumps of 3190 m cube
/hr capacity with 10 m head.

Trees required for CO2 absorption:

 The sugar factory shall produce 44 tons/hr bagasse having 20.4 tons of carbon i
n it all of which could be converted to CO2; releasing 75 tons/hr CO2 in the atm
osphere as long as the factory is in operation. Therefore the factory would requ
ire minimum 31565 m2 of plant leaf area to absorb CO2 produced per day. So appro
ximately 51 no. of big trees are to be planted which will need minimum 20400 m2
of plantation area.

Pumps required for this Sugar plant crushing: 3190 TCD

Mill House No. Standby Capacity m3/hr Head m

Mill House juice pump 5 1 38 12
Mixed juice pump 1 1 96 12
Screened juice pump 1 1 96 15
Imbibition water pump 1 1 38 50
Weighed juice pump 1 1 96 60
Boiling House
Juice heater condensate pump 5 1 38 suitable
Phosphate slurry pump optional suitable suitable

Clarification House
Sulphited juice pump 1 1 134 60
M.O.P pump 1 1 2.9 20
Mud liquidating pump 1 1 32 20
Clear juice pump 1 1 96 30

Filter House
Filterate pump 1 1 suitable suitable
Cake Wash pump 1 6.4 30
Injection water pump 1 10 20
Mud recirculation pump 1 1 16 18
Vacuum pump 1 8.0(m3/min) 20inches
vacuum

Evaporators
Syrup extraction pump 1 1 26 30
Condensate extraction pump 5(max.) suitable suitable
As many as no. of evaporaters
Caustic soda pump 1 16(l/sec) 10
Syrup pump 1 1 26 20
Main condensate receiver
Condensate pump 1 1 32 30
Condensate pump 1 13 30
Injection water pumps
For evaporators 1 1 287 22
For pans 6 590 22

Miscellaneous
Melt pump 1 19 30
Molasses pump 1 1 10 suitable
Molasses recirculation pump 1 128 30
Service water pumps 1 1 128 30
Acknowledgement:
There have been many people who have indirectly/directly contributed to the mak
ing of this report without whose contribution this work would have remained inco
mplete, I heartly thank them.
 Shri D.Mukherjee
email− deepankar68@gmail.com

25/10/2010−Rev−9 Report taken on−− Time and Date: Sun Nov 28 19:58:52 2010