CHAPTER - II

THE MODIFICATION
MADE IN THE EXISTING
SUGAR MILLS TO
IMPROVE THE MILLING
PERFORMANCE.
 THE MODIFICATION MADE IN THE EXISTING SUGAR MILLS TO
IMPROVE THE MILLING PERFORMANCE.
The measure of performance of sugar milling plant is judged by the quality of the
final bagasse discharged by the last mill and going to boiler. The whole performance
of milling plant is the collective effect of the performance of all units in the plant The
units are as underra: -
1) Cane preparation unit: -
Cane preparatory sets such as cutter, leveler, heavy-duty shredder, fixed
hammer type fibrizer / swing hammer type fibrizer, etc. The performance of cane
preparation is checked by the analysis of prepared cane, which is entering into 1st mill.
2) 1st mill - Primary mill: -
Its performance is checked by the analysis of the bagasse leaving the 1st
mill The primary extraction is calculated from the analysis of the bagasse of 1st mill for
its pol and moisture % bagasse and analysis of juice from 1st mill discharge roller for
its brix pol and purity. The calculations of primary extraction need to know the pol and
fibre % cane.
3) 2nd, 3rd & 4th mill: - (For 4-mlll tandem): -
Mill extraction of each mill can be calculated by analysis of bagasse of each
mill for its pol and moisture % and analysis of juice of the delivery roller of each mill for
its brix, pol and purity.
4) The whole extraction of the milling plant: -
It is calculated from the analysis of the final bagasse leaving from the last mill
(going to boiler) for its pol & moisture %, cane analysis for its pol & fibre% and
analysis of the last expressed juice for its brix, pol & purity.

The following parameters are being considered for higher milling performance151
1. Fresh and clean cane,
2. Preparatory Index to about 85 %,
3. Primary Pol Extraction to about 75 %,
4. Proper juice drainage from feed and discharge sides of individual mills,
5. Arcing of mill rollers,
6. Minimizing Re-absorption factor,
7. Better Mill Setting,
8. Hydraulic pressure at specified range,

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9. Provision of pressure feeding devices (UFR, GRPF, TRPF)- to avoid bottleneck at
the mill opening, increase capacity as well as extraction,
10. Imbibition system & imbibition water temp. - increase extraction, Imbibition % fibre
to about 250 %.
11. Automation in milling tandem - increase crushing capacity.

Following is the list of modifications done in milling tandem:

1. Modifications in the preparatory devices of the sugar cane plant to improve the
preparatory index of the mill.
2. Modification in the existing milling tandem to increase the crushing capacity of
the sugar mill.
3. Modification in the grooving of mill roller & hydraulic system in the existing mill.
4. Modification in the mill setting & trash plate profile on the basis of fibre % cane
by different methods.
5. Improvement in efficiency of the mill using Under Feed Roller / Grooved Roller
Pressure Feeder/Toothed Roller Pressure Feeder & speed of mill roller.
6. Modification in the compound imbibition system & temperature of the imbibition
water.

2.1 Modifications in the preparatory devices of the sugar cane

plant to improve the preparatory index of the mill.
Sugar cane which is quite long & surround from the sugar factory. These
sugarcanes are transported from the fields to the factory by means of Railways,
Trucks, Trolleys, Tractors and Bullock carts, etc. It is desirable to transport the cane to
mill within 24 hours from its cutting time.
Before sending the cane to the mills for extracting the juice, it is chopped &
pulverized into very small pieces to enable the mills to extract the maximum. Sugar
cane sticks with node & rind portion with fibrous part pith inside the rind portion.
Preparation means to open maximum cells inside the pith fibrous portion. Fine
preparation of cane is done with various cane preparatory devices and these are

measured in terms of:

Fine cane preparation is measured in terms of:
1. Preparatory index
2. Bulk Density
3. Better Feed ability to the mills.

9
- -
2.1.1 Following combinations have been used in preparation of cane[33):
a) One or two sets of knives followed by a two roller crusher,
b) One or two sets of knives followed by a three roller crusher,
c) Leveller & cutter,
d) Kicker, Leveller & Cutter
e) Kicker, Leveller & reversed Cutter with split carrier,
f) Kicker, Leveller & reversed Cutter with stationary knives in the cutter hood,
g) Kicker, Leveller, Cutter & shredder now,
h) Leveller & Fibrizer.

Cane Carrier with feeder table on both side Fig, 2.1.1

2.1.2.1 Cane Kicker (Equaliser):-

The term equalizer or kicker is used to describe equipment designed to even
out the distribution on the carrier, and to level the layer of cane to certain extent.
An equaliser a shaft placed across the carrier, carrying curved arms, and
rotating in such a direction that the arms moving against the direction of cane
movement on cane carrier. Line diagram of cane equalizer is as shown in fig. 2.1.2.

- 10
-
 One cane kicker set of all steel construction with raised side plates of 6 mm
thick and 10 mm thick deflector plate at top to be mounted on the first cane carrier. It
shall have minimum 24 arms suitably welded to 450 mm diameter central hollow pipe
of equivalent strength.
The diameter over the tips of the arms shall be 1200 mm. Arms shall be made
out of angle iron (two angle iron welded in such a way that they form a paramedical
shape). The kicker set shall be directly coupled to a 40 BHP Squirrel cage electric
motor through an enclosed reduction gears so that the speed of the kicker shall be
between 50 to 70 rpm. Shaft shall be supported on heavy duty double row self
aligning spherical bearings of minimum 100 mm bore. The clearance between the tip
of kicker arms and tip of the cane carrier slats shall maintained as per standard.
The Cane -carrier slots is given by the formula.
1000 x C
h= [E. Hugot33]
60xp x L x d

Where, h = Clearance in mm. C = Crushing rate in TCH.

L = Width the cane carrier in meters, p = Speed of the cane carrier in m/min
d = bulk density of cane feed to the knives, Kg/m3

Power required for cane carrier is generally 25 to 35 % of cane crushed. The

shaft of cane equaliser will be set at a height that the distance between the ends of
the arms and the carrier slats is slightly less than the height h given in the above
equation.

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Modifications in Cane Equalizer or Cane Kicker:
Modifications in cane equalizer are diameter increased, power increased,
speed increased, direction of rotation changed. [Data supported to problem, solution &
improvement are discussed in later chapters.]
Problem:
1. Cane preparatory index was poor.
2. Bearings failure was more serious.
3. Any small imbalance of knife assembly may cause considerable vibrations.
Solution:
1. Knife set no. 1 its length increased, stronger hubs and bigger shaft fixed. Its
clearance decreased 320 to 240 mm.
2. Knife set no. 2: stronger hubs and bigger shaft fixed.
3. Both knife sets; a) Spherical roller type bearings changed to cooper split
bearing design with bigger shaft, b) Foundation drilled by a special type boring
machine and bigger size stronger bolts fixed.
Improvement:
1. Cane preparation index is improved.
2. Bearings failure is eliminated.
3. Vibrations are now minimal.
4. Working of the knife sets is now quite smooth and satisfactory.

2.1.2.2 Cane Knives:-

Before 1920, many factories did not posses knives. The actual purpose of the
revolving knives is to cut the cane into small chips so that the hard rind and node are
broken up and the soft pith, which contains most of the juice, will be more affectively
treated by the following crusher or mill pressure.
The cane knives then perform two functions and have two advantages:
1) They favour the capacity of the mills,
2) They assist the extraction of the mills by breaking the rind of the cane and so
facilitating its disintegration and extraction of its juice.
Cane Knives consists of two sets, one is a leveller while other is cutter which is
driven by electric motor. Leveling knives serve primarily to level down the tangled
volume of cane on the carrier into one even and compact mass. In cutting knives
(Cane cutter) are used essentially for the purpose of cutting and slicing the cane into
small bits or pieces. First set of cane knives is placed on a concrete foundation.
Second set of foundation is placed on a steel structure.
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 Cane knives are mainly used to slice and level down the bulky mass of cane to
an even and reasonable depth and thereby ensure a uniform feed to the first milling
unit. This device consists of a horizontal shaft carrying a series of curved knives,
arranged spirally and rotating at high speed in a vertical plane.
The power requirement of the knives is given by the following formula:
p
P = 0.0025 x K x C x f x n x—------------------------ [E.Hugot33]

Where,
P= Power required by the knives in HP. K=Preparation of cane cut (P.l) 0.8 rough.
C=Crushing rate in TCH. f = Fibre per unit area cane.
n= Speed of the rotation of knives. R= radius of the cutting angle in cm.
P’= Pitch of the knives in cm.
The power required by the cane knives or cutter depends upon the following factors
[Hugot33]:

1. Crushing rate 2. Fibre %cane

3. Nature of the Fibre (Hard / soft). 4. No. of blades.
5. Speed of the rotation. 6. Pitch of the knives.
7. Radius of the cutting circle. 8. Cane preparation required.
9. The clearance.
In principle the device consist of a horizontal shaft carrying a series of curved
knives, arranged spirally and rotating at high speed in a vertical plane.
Cane knives are designed to meet the following important requirements:
1) A knife set should be well balanced in order accomplish the duty of leveling or
cutting with the minimum power.
2) Knife blades should be individually detachable, so that they can be quickly and
easily removed for replacing.
3) Knives should be of simple design without any complicated fastenings.
4) The blades are to be of superior quality steel, homogeneous through out, so that
knives of high grade steel will retain their sharp cutting edge for a longer period.
Different types of cane knives differ from one another, in connection with the
method of fixing the blades. Now a day these are obsolete.
1. Meinecke knives.
2. Ramsay knives.
3. Mirrless knives.
4. Searby knives.

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2.1.2.2.1 Method of utilizing knives:
F. Maxwell distinguishes two types of knives|8):
1) The Leveller knives which are required mainly to even out the layer of cane. They
are arranged to work with a high clearance and in consequence leave a large
proportion of uncut.
2) The Cutting knives: This second effect is found, when only two sets of knives are
installed; first at the bottom of the sloping portion of carrier, second at immediately
after the first or at the head of carrier. This second set knives cut layer of cane
which the first set of knives has not touched, and delivers the cut cane in smaller
and thinner pieces.
Cane Leveler:
One cane leveler set having not less than 32 knives secured to cast steel hubs
of IS:1030 grade 26/52 mounted on a forged steel shaft of 200 mm diameter of 40C8
quality or equivalent at knife holder seat. The diameter over the tips of knives shall not
be less than 1600 mm. The knife shaft shall be supported at 180 mm bore, heavy duty
seif aligning double row spherical roller bearings with adopter / withdrawal sleeve in
cast steel plummer blocks. The knives shall be of special shock resisting steel having
stellited / carbide cutting edges, hardness 45 to 48 HRC and tanned into the hubs
eliminating the shear on the bolts which shall be of EN8 steel or of equivalent strength
with nyloc nuts. The knives shall conform to IS: 8461-1977. A suitable flywheel of C. I.
grade 20 duly machined and well balanced shall be provided at the other end of the
shaft. [V.Haridas6]

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 Cane leveler set shall be driven by a continuously rated drip proof screen
protected slip ring motor of 250 HP and 587 RPM synchronous speed at a total slip of
15 percent. It shall be directly coupled by means of flywheel type coupling capable of
transmitting 250 HP continuously. The motor shall be complete with starter and
protection switch gear etc.
The knife set shall be installed on the inclined portion of the carrier and be
provided with a suitable device for adjusting clearance in between the knives tips and
slats from 200 to 250 mm. The knife set shall be totally enclosed by suitably reinforced
hood of 10 mm thick mild steel plate attached to the cane carrier frame work and
provided with suitable swing flaps and bolted doors at top of the hood.
2.1.2.2.3 Clearances for two knives set:
The clearance adopted for the first set should be approximately one-quarter of
the height of the layer of the cane. The first set is then given a high clearance and with
high pitch of leveller knives provided. The clearance for first set is 50 mm, for second
set of knives with a clearance of 50 mm, more often 25 mm or even as 10 mm & pitch
is 22 - 25 mm.

T
!■«■■■■ 1 4
;nr cx

-4 -4
-

r-^-----
———as? rhrju±L
----- f— I ! i XT ijjiimr
[61
Various Models of Cane knives suggested

Fig. 2.6 Pictorial view of Cane Leveller & Cane knives

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-
2.1.2.3 Shredders:-
As the name denotes, the object of shredder is to shreds the cane into very
small pieces, its work that in effect increases the capacity and extraction of mill. The
first, shredder, introduced and invented in Louisiana, was the Abrasion shredder.m
Principle of Shredder: -
The process of shredding, as applied to the preparation of cane, involves high
speed ranging from 159 to 1200 rpm. It is placed before the mills and after preparation
device (knives):m
Types of Shredder: -
1. The disc shredder or Abrasion shredder
2. Swing Hammer shredder or Searby shredder
3. Morgan cane disintegrator.
1. Disc Shredder: -

Abrasion Principle In Disc Shredder

Swing Hamer Principle in shredder

Fig. 2.1.2.3.1 Abrasion Principle in Disc Shredder & Swing Hammer Principle
Principle: - This type is based on the abrasional principle or torsional shredding
according to which the cane is prepared between two toothed rollers moving at
different speeds and is thereby makes cane into shreds[8!.
2. Searby Shredder: -
Principle: -This shredder designed on the swing hammer and this shredder is also
known as Swing hammer Shredder. Around 45% of the power consumed in cane
preparation and 55% power is consumed in milling to tandem171.
3. Morgan Cane Disintegrator: -
The Morgan Cane disintegrator is a modification in cane preparatory machines.
Its construction not like traditional and not like a centrifugal pump or blower. It makes
necessary for the canes to be feed to this disintegrator in short lengths, and machine
is therefore preceded by knives for this purpose.181171
Principle: - The machine consists of a high speed disc, fitted on both outer sides with
radial curved blades, and revolving inside a fixed casing fitted on both inner sides with

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straight radial blades. The short canes are fed into center opening in the inner casing
and are thrown by centrifugal force towards the periphery being shredded as they
pass between the fixed and moving blades.
The disintegrator driven by electric motor, steam turbine or engine, the driving
unit is directly coupled to the machine with flexible couplings. This disintegrator firstly
installed at Central Hershey, Cuba with capacity 140 TCH and they rated up to 180
TCH, 300 Hp
While selecting suitable preparatory devices, the following factor is to be considered.
1. Preparatory index. 2. Cost and maintenance.
3. Foreign material entry. 4. No. of mills in tandem.
FLETCHER-SMITH / TONGAAT HULETT HEAVY DUTY SHREDDER
The FS/TH heavy duty
shredder as shown in
fig. 2.7 ruptures a high
percentage of sucrose
bearing cells in the cane
and simultaneously presents
the raw material to the
extraction plant in long fibre
Fig. 2.7 Fletcher-Smith / Tongaat Hulett Heavy Duty Shredder

Increases sugar extraction from either conventional crushing mills or a diffuser.

• High preparation index (90 % plus consistently).
• Efficient energy consumption (steam or electricity).
• Robust fabricated design.
• Flexible operation and excellent feeding characteristics.
• High mechanical reliability assisted by magnetic iron separator on conveyor belt
feeding shredder.
• Excellent fibre particle distribution.
• Higher bagasse densities.
• Improved final bagasse moistures and polarization.

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 Heavy Duty

Fig. 2.8 Schematic Diagram of Heavy Duty Shredder >91013>

2.1.2.4 Fibrizer:
2.1.2.4.1 Fibrizer Fixed Hammer Shredder (Cane Mincer)191012131
One set of fibrizer of all steel construction having not less than 44 hammers
mounted at the head of the first cane carrier. The weight of each hammer shall not be
less than 15 kg. The rotor shaft shall be heavy duty minimum 330 mm diameters. At
the hubs and minimum 240 mm diameter at the
bearing journal and shall be of 40C8 quality or
equivalent. The hammers shank shall be minimum
25 mm thick and minimum hardness 600 BHN. The
hammers shall be secured to 50 mm thick cast steel
hubs mounted on the shaft and will be of special
shock resisting alloy steel and tenoned into the hubs
eliminating the shear on the bolts of EN8 steel or of
equivalent strength with check nuts or nyloc nuts [12].
The deflector plate shall be minimum 18 mm
thick, mild steel and rear chute minimum 12 mm thick
mild steel with 2.5 mm thick stainless steel lining.
The anvil plate should be 75 mm thick and Fi92 9 Flbri2er A™

- IS-
serrated type. Anvil plate shall be machined and hard faced having a hardness of
minimum 500 BHN.
The rotor shall be supported on two numbers heavy duty self aligning double
row spherical roller bearings with adapter / withdrawal sleeve. The diameter over the
tips of hammers shall be minimum 1650 mm when running at 690 rpm at 80% turbine
speed. A matching flywheel at both ends of the shaft duly machined and well balanced
shall be fitted to reduce the peak load to 160 percent of the full load.
The fibrizer rotor shall be completely covered by reinforced mild steel fabricated
hood made out of 12 mm thick plate attached to the cane carrier frame work and will
be complete with deflector plate. Fixed type mild steel fabricated anvil plate, anvil
suspension gear, front adjustable cover, rear chute, bolted doors on the top of the
hood, cast steel / fabricated plummer blocks with water cooled pedestals and grease
lubricated bearings. Provision shall be made for adjusting the clearance.
The Fibrizer shall be driven by a steam turbine with forced feed lubrication
system capable of developing continuously minimum 700 BHP at 80% of its rated
speed when supplied with stream at normal parameters and all hand operated over
load valves in closed position.
Two hand operated overload valves to be provided in the turbine to control the
steam flow in such a way that the turbine develops minimum 775 BHP with one valve
open and minimum 850 BHP with both valves open at 80 percent of its rated speed
when supplied with steam at normal parameters during initial stage.
The steam turbine shall have necessary space, grooving and machining in the
steam casing for addition of nozzles and throttle valve at sugar factory site for
increasing the development of power by the turbine to minimum 1000 BHP at 80% of
its rated speed when supplied with steam at normal, parameters and both hand
operated overload valves closed. No other changes should be required in the turbine

for increasing the power from 1000 BHP to 1200 BHP under normal conditions for the
ultimate capacity of 3500 TCD.
The steam turbine shall be designed for operation for the following ranges of steam

parameters [9, io 12,13].

Inlet Steam Pressure Inlet Steam temperature Exhaust Steam Pressure
Maximum 32 kg/cm2.g Maximum 390 *€. Maximum 1.5 kg/cm2.g

Normal 30 kg/cm2.g Normal 370° C. Normal 1.0 kg/cm2.g

Minimum 25 kg/cm2.g Minimum 350° C. Minimum 0.5 kg/cm2.g

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 The turbine shall be so designed that it suffers no damage if the exhaust
pressure occasionally goes down to atmospheric pressure and/or live steam
temperature goes up to 400 T).
The turbine shall develop minimum 700/1000 BHP even when steam pressure
at the stop valve is 25 kg/cm2 and temperature 350°C and both overload valves are

open. The specific steam consumption at 80% of its rates speed and on normal steam
operating parameters shall not exceed 11.0 kgs / BHP / Hour while delivering
700 BHP at the initial crushing capacity of 2500 TCD.
The turbine should have 200 percent starting torque and 160 percent stalling
torque capability. Ail the mechanical components of the steam turbine, coupling etc.
shall be designed to transmit 1200 BHP continuously at 80 percent of its rated speed.
The turbine shall be coupled to a suitable enclosed reduction gear box of hardened
and ground gears designed to transmit 1200 BHP continuously at 80 percent of
turbine rated speed and an ambient temperature of 45 Deg.C with a minimum service
factor of 1.70. The gear box shall be coupled to the fibrizer shaft through oil lubricated
gear type coupling / bibby type coupling, capable of transmitting 1200 BHP
continuously. The gear box shall be designed as per relevant DIN/IS/BS/AGMA
standard. Necessary cooling arrangement for the gear box shall be provided. The
gear box ratio shall be such that the speed at the output shaft of the gear box shall be
690 rpm at 80% of the rated speed of the steam turbine.
The speed regulation of the turbine (droop characteristic) shall not exceed 15%
at 1200 BHP full load. The turbine shall be provided with variable speed type hydraulic
or mechanical governor capable of full governor control from 105% down to 60% of
the full rated speed of the turbine. The turbine shall be complete with high pressure
stop and emergency valve, steam strainer, steam traps, sentinel valve, main oil pump,
auxiliary Electric motor driven oil pump, hand operated standby oil pump oil cooling
system consisting of two numbers oil coolers with necessary pipes and valves so that
one of the two coolers can be cleaned when the turbine is working on load, steam and
oil temperature and pressure gauges, gauge type spot mounted bearing temperature
indicators for turbine and gear box, one local / direct mounted speedometer and one
remote reading tachometer, oil pockets with stem type thermometers in the live steam
inlet and exhaust steam outlet lines, steam flow meter for measuring the steam
consumption of the turbine, servomotor for remote speed control etc. Necessary oil
reservoir, duplex micronic felt / self - cleaning oil filters, oil strainer, inter-connecting oil
water and steam pipe work with valves and non-return valves, etc. and arrangement

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for automatic starting of auxiliary oil pump in case of low oil pressure shall be
provided. The following safety devices shall be provided for the turbine:
i) Over speed trip with audio visual alarm.
ii) Low oil pressure trip with audio-visual alarm.
iii) Power failure trip.
iv) Remote operated manual trip with audio visual alarm.
v) Manual trip knob / handle on turbine.
Special maintenance tools for the turbine shall be supplied along with the
turbine. One remote control panel fitted with stop push button temperature and
pressure gauges, turbine speed indicator push buttons for raising and lowering the
turbine speed and push button for starting of auxiliary oil pump shall be provided.
The Fibrizer consists of a heavy duty forged Key-wayed hubs to which

the hammers are solidly bolted (Hence easily replaceable if damaged) Hammer

or arm used in factory as shown in fig 2.9. The rotor assembly consists of

double row self aligned bearings, a fly wheel and a flexible coupling. Each

hammer tip consists of a hammer head. The hammer blades are made up of

Special alloy to withstand wear and tear.

The anvil is serrated, hinged and spring loaded. Spring tension and the

gap between anvil and the rotor tip could be adjusted even during operation.

The cane is forced into the rotor by the cane carrier. The hammer tips

revolve at a peripheral speed of 3000 to 5000 meter/minute. The whole mat of

interwoven uncut cane is lifted by the upward strokes of the hammers and

thrown over the rotor against the slide-plate located above the serrated anvil. It

creates the cane anvil i.e. the anvil created by the cane itself as the layer is

pressed against the rotating rotor by the action of the feeding carrier.

The cane is partly shredded at the cane leveler. Anvil is thrown over the

rotor at a high velocity. The velocity is reduced to zero upon impact at the top of

the back slide. Then the cane slides down towards the anvil. The velocity at the

anvil entrance is 1000 fl/min compared to the velocity of hammer heads of

12000 to 15000 ft/min. Hence the high velocity heavy hammer hitting the slow

moving bed of the partly uncut cane disintegrates the cane further and throws it

back again at the anvil plate. The cane emerges from the anvil in the final stage

of readiness for feeding to the mills.

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 In Fibrizer, the small pieces of cane are impacted by hammers of fibrizer this is
done to open the cells of cane, which are containing the juice. Fibrizer consists of a
rotor rotating in the casing and driven by the steam turbine.
On this rotor little keys fit hubs. Hammers of cast steel with abrasion and
impact resistance hard facing fitted at the tip of the hammer are used for beating the
cane. The casing has a grate made up of the cast steel with separated configuration,
hinged and spring loaded to adjust the space between the hammer tips and anvil
anytime during working of fibrizer. It has a speed of 750 RPM. The cane feed to the
fibrizer are lifted by upward motion and fit against the anvil plate by the hammers.
The angle between centre line cane carrier sprockets, to the vertical of centre
line of fibrizer will be 38s to 45a, and should not less than 389. If it is less than 38s then
feeding will be less. If it is more than 45s then feeding will be more.
Generally for 2500 TCD plant (Data collected from factory): -
1. The size of the shaft at the bearing is 250mm (minimum).
2. Number of Hammer = 44 to 60.
3. Weight of the Hammer = 12-18kg.
Anvil Plate: -
The span of Anvil plate 160s.
For box type anvil plate size of box 225 x 100 x 100mm. If the sizes of box increases
jamming occurs. Hammer weight will be 15 - 18kgs.
Deflector plate it is provided to present recirculation of prepared cane.
Serrated type anvil of angle =90s.
Pocketed type anvil with wrap angle =160 s-1809.
Clearance should be minimum =90 -120 mm.
Clearance at the bottom = 30mm (Maximum) ~ 5mm (minimum) generally, 30-15 mm.
Drive; - Power required = 1.5 to 1.7 Hp/ton of fibre /hr.
Drive may be of electrical or Turbine with minimum 750-1000 HP and the peripheral
speed should be 5000 - 5500 m/min.
Pocketed type anvil plate with wrap angle=1609-1809.
Drive should be 1000HP minimum.
Fixed type Hammer: -
Clearance between Anvil plate and hammers tip = 50-70mm.
Power should be 30-40 HP/TFH.
Swing type Hammer power should be =50-60HP/tfh.

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Swing type Hammer: -
No. of Hammer should be: - 70(minimum) -120(maximum).
Weight of the each Hammer = 12-18kg.
Clearance between Anvil plate and hammers tip = 35 -45 mm.
2.1.2.4.2 Heavy duty swing hammer fibrizer offer many advantages in cane
preparation and milling plantI9,10,11,1Z1:
• Preparatory Index for better feed ability to mills,
• Long fibres for better feedability to mills,
• Increased mill extraction,
• Reduced maintenance

Fig. 2.10 Swing Type Hammer Fibrizer

Heavy Duty Swing Hammer Fibrizer with various sizes as per requirement of
sugar mill;
01500 x 1000, 01750 x 1400, 02000 x 1830, 02200 x 2040, 02200 x 2300,
01750 x 1220, 02000 x 1700, 02000 x 1980, 02200 x 2140, 02200 x 2540
2.1.2.5 Preparation of Cane: -
After knives cane preparation is done up to 65% -70% P.l. (Preparatory Index),
after a conventional shredder 78%-85% and after a heavy-duty shredder 86%-92%
exceptionally we have to obtain up to 94%-95% preparatory index.
P.l. means “number of cells for extraction” (Preparatory Index).
Pol extracted by washing (cold).
P.l. can be calculated by: - p .i. = ................................................................ x 1 00
Pol extracted after disintegration.

Extraction on washing is determined on samples of 500g in 3.5 lit of water

with agitation for 20mm. The mean of 6 determinations is taken.

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 Extraction of disintegration is determined on similar samples (500g in 3.5 lit)
disintegrated for 10 min in a ‘Varigator’ machine. The mean of 3 determinations is
taken.
Improvement in extraction due to Shredder (e)[33):
For knives: - For Searby Shredder: -
3 7.5 Where, e = Gain in the extraction,
£ =--------- % £ =---------- % N=No. of rollers in the tandem,
N-6 N-8
For example,
For knives For Searby Shredders
e = 0.6 % for 11 rollers. e = 2.5 % for 11 rollers,

e = 0.375 5 for 14 rollers. £ = 1.5 % for 14 rollers.

e = 0.33% for 15 rollers. £=1.0 % for 15 rollers.
From above it is clear that shredder is more beneficial for a shorter tandem .In
a long tandem, where the action of the successive mills of it self produces a very
complete disintegration; its relative effect by shredder is much less. For long tandem,
these preparatory index if 94% then these preparatory devices will improve in only
remaining 6% only (for 100% achieving).
Relationship between power and P.l. (preparatory index): -
The efficiency of preparation depends essentially on the power expended to obtain it.
Relation between P.l. and power is given in formulai33i: -
P.l. = 63.7 (w)009

Where,
w= kW / Ton of fibre /hr, (A good P.l. is obtained with 50-80 Kw / TFH.)

2.2 Modification in the existing milling tandem to increase the

crushing capacity of the sugar mill.
“The capacity of a train of mills is the quantity of the cane which that trains is
capable of treating in unit time “1331
This capacity depends upon the following factors1331: -
01) Fibre % cane and nature of the Fibre.
02) Degree of preparation of cane by the preparatory devices such as knives, leveler,
Cutters, shredder, fibrizer etc.
03) Pressure feeding devices like - under feed roller, GRPF, TRPF, etc.
04) Number and size of the roller in the milling tandem (Number, diameter, Length).
05) Surface speed of the mill ratios.

- 24 -
06) Method of grooves of the mill rollers.

07) Gaps or openings between the roller on different are technically called as mill setting.

08) Hydraulic pressure.

09) Design of the mill such as improved design self-setting mill, 5 roller mills etc.

10) Imbibition % Cane and temperature of water.

11) Degree of the extraction desired to be achieved.

12) Method of the rollers, roughness of the surface and grip on the bagasse.
13) Maintenance of the mill.
14) Skill of the people etc.

2.2.1 Mill Capacity Calculations:

There are a large number of formulae for the calculation of the capacity of a
milling tandem. Mill Capacity formulae1331:
1. Noel Deer formula.
2. K. S. Arnold formula.
3. Hugot formula.
4. N.S.I. formula,
5. Tromp formula.
6. Maxwell formula.
From the above we know only some of the formulae, which are as follows: -
1. Noel Deer Formula:
O.SxnxLxLxDxD
f ................................. ............. [Deerr Noel'4]

Where, n=No. of roller, D=Roller diameter, L= Roller length,

f= fibre per unit cane.

2. K .S. Arnold Formula: u/Wual fjre % cane

TCH= 1.1 x;rxDxLxN......... .......... [EHugot33] D=Rollerdiameter,
L = Roller length,
This formula is at 15% fibre and 7.5-m/min-roller speed. v=Roller speed m/min,
15 V
TCH =1.1 x j x D x Lx N x.......x ........
f 7.5
3. Hugot formula:

0.9xCxnx(l - 0.06xnxD)xLxDxDxVN
TCH [E. Hugot33]

Where, C=1.1 to 1.5 = coefficient of preparatory index of devices,

f = Actual fire % cane, D = Roller diameter,
L = Roller length, V = Roller speed m/min,
n = roller speed rpm, N = No. of roller,

-25 -
4. N.S.i. formula:

C = 4.3 x D x L x N............ ..................... ^

For 10.62 m/min roller surface speed and at 15% fibre.
Where, D=Diameter of the roller, m.
L= Length of the roller, m.
N= No. of roller in tandem.

5. Tromp formula:
- [Tromp L A.7]
O.OSxOxDxLxNxM
„ “ TCH
B
Where, D= Diameter of the roller, m. L = Length of the roller, m.
N =No. of Compression in mill. B = Bagasse % cane.
M= Coefficient of preparatory devices = 1.25 to 1.1.

2.3 Modification in the grooving of mill roller & hydraulic system in

the existing mill.
Originally mill rollers were smooth, but with the function of grooves, it is found
that the capacity of such mill is comparatively high despite in the same dimension and
speed, bagasse is broken up well, thereby extraction of juice is increased.

2.3.1 Types Roller Grooving: -

The roller shell is provided with circumferential grooves of V section in order to
improve the grip of the rollers on the cane and to give improved juice drainage.121
Dimensions of the grooving vary considerably, ranging from 6.35mm to at least
38.2mm. Pitch, and from 35° to 36° in angle of grooving.133113211,1
Deep narrow grooves, known as Juice grooves or Messchaert grooves (after their
inventor) are often provided at the base of the V grooves shown in Fig. 2.3.1. The
object of these is to provide a channel for the juice to escape without passing through
the mat of entering and compressed feed.

Proper operation of juice grooves are required so as not to fill it with bagasse,
otherwise bagasse does not provide passages for escape of juice.

-26 -
 Mill rollers are made of cast iron and are fitted on the steel shafts by heating
and shrinking the rolls on the shaft. The mill roller shafts are of special rolls on the
shaft. The mill roller shafts are of special type of tensile steel for the heavy-duty
performance required in a milling plant. In order to improve the feedability of the
prepared cane to the mills, and at the same time increase the area of crushing surface
and also make available channels for quick drainage of the juice extracted in each
mill, the mill rollers have circumferential V-shaped grooves. The grooves of the 3-roller
in a set of 3-roller mill are so arranged that the grooves of the top roller, mesh with the
grooves of the 2 bottom rollers (i.e., feed roller and discharging roller).
The angle of the grooves and pitch of the grooves vary depending on the
experience of the different milling experts, according to HUGOT, generally an angle of
50° pitch and the depth of groove for the 1st mill is 1 Vz X 2”, for the 2nd mill 3A “x 1"
and for the 3rd, 4th mill 3/8” X Vz” are ideal. Thus the blanket becomes finer and finer
towards the end of the milling tandem, the pitch and depth of the grooves on the mill
rollers, reduces.
2.3.2 Function of Grooving1331: -
1. To press and squeeze the prepared cane 1st mill of bagasse in other mills for Juice
extraction.
2. To drain the juice effectively from the mill.
3. To mill the bagasse further to get the uncut juice cells broken to help to increase
the extraction in the following mill.
4. To drive the bagasse through the mill effectively.
5. Earlier mills prepare bagasse (Coarse grooving) and later mills extract the Juice
(fine grooving).
A groove has three distinct factors for identification:
1) Pitch. 2) Groove depth. 3) Groove angle.
2.3.3 TYPES OF GROOVES: -
1. Circumferential grooves. 2. Differential grooves.
3. Messchaert grooves. 4. Chevron grooves.
Originally, mill rollers were smooth and such rollers exist in some countries. But
in India and other country rollers with fine, coarse grooving observed which depends
on to mill equipment, rate of grinding required, cane varieties available, the texture of
fibre (%), and the hardness of cane. [33) The section of grooves forms isosceles
triangles with an apical angle 55e-60s, depth of groove, pitch of groove. It describes by
the figure of grooves “grooving of h X P".

27
- -
Pitch (p): - The pitch is the distance, which separates axes of two successive teeth.
Height (h): - The depth or height, is the distance from the top to the bottom if the teeth,
measured perpendicular to the axis of the roller.
2.3.3.1 Circumferential Grooves: -
It is universal type of grooving and it is also called as ‘V’ grooving. It is formed
by grooving the roller with notches on complete circles, in planes perpendicular to its
axis of the roller. This type of groove over all surface of roller circumference as shown
in figure.

Fig. 2.3.3.1 Pictorial View of Mill Roller grooving Sugar Factory.

Apex angle (a) is 559 -609. Depth or height (h) is slightly less than pitch (p). When the
angle is 609, the height (h) is 0.80 of the pitch (p) in mill roller.
Pitch does not depend upon the size of the mill. Below 1”, pitch (25mm) does
not give better results. The small landing and high breakage and hence frequent
reshelling of mill will be unavailable.13311161
Landing: - For 5% of pitch or 10% of pitch.
0.45 x p
5% of pitch depth =.............. -..................................... (A)
T ana/2
0.4 x p
10% of pitch depth =................................-.................(B)
Tana/2
In practice angle of groove of top and bottom rollers kept identical.
To avoid leaving sharp and fragile edges the exteriors point of isosceles triangle made
by teeth are small surfaces of about 2-4mm of top rollers and 3.5mm on bottom rollers
called flank of teeth. The grooving of the 3 rollers of a mill is arranged in such a way
that the teeth of the top roller mesh with the grooves of the two bottom rollers.

- 28 -
 Fig. 2.3.S.2 Details of Mill Roller grooving with arcing on teeth1161

2.3.S.2 Differential grooves: -

Same engineering adopt identical grooving on all mill rollers from the extraction point
of view while others favour differential as by these juice handling capacity increases.
The wear and tear of grooves in case of differential groove is more than in the case of
identical grooving121I33].
2.3.2.1 Types of differential grooves: -
1. Fine grooves - 5 -20mm pitch.
2. Medium grooves - 25-30mm pitch.
3. Coarse grooves - above 80mm pitch.
The grooves generally decreased from the first to last mill because for two reason.
1. Coarse groove in first and second mill helps in capacity of mill more.
2. The bagasse becomes finer and finer as it proceeds from the first mill towards last
mill due to the fine grooving towards last mills, they breaks bagasse and due to
this extraction of juice up to last mill.
Size of grooving in differential Tandems (in mm): -

Is1 mill IInd mill IIIrd mill IVth mill Vth mill Vl,h mill

12 roller 20x26 20x26 10x13 10x13 - -

15 roller 20x26 20x26 10x13 10x13 10x13 -

18 roller 20x26 20x26 10x13 10x13 10x13 10x13

Angles of groove (degree): -
Feed -50a, Top -50s, Discharge -50s.
Lotus Roller: -
Apart from good juice drainage, there is an increase in capacity due to less
slippage usually caused by entrapped juice [E.Hugot33].

- 29 -
"Conventional shell with vertical holes for drainage is called a lotus roller”. In Lotus
roller taper nozzle is provided to reduce to jamming.
WIL design: Each groove will have nozzle for higher size pitch rollers. The
nozzles are divergent type to avoid blockages. This also helps to reduce slippage and
re-absorption.
Lotus rollers are employed only at top because no advantage is experienced in
feed and discharge rollers Lotus roller will help to create more extraction and capacity.
In case of last mill, Lotus rollers are not prepared and hole sizes varies from 2.6 mm
to 5mm diameter.
Advantages of arrangement of differential grooves in the point of view milling
process1331: -
a) Efficient juice drainage through low-pressure zone at feed roller: -
The weight of bagasse at discharge roller is reduced due to the maximum juice
drainage at feed roller. Thereby the opening at discharge roller is reduced giving
higher discharge at low power.
b) There is effective shear action to the bagasse layers in the groove due to
differential groove due to differential speeds of the tip and bottom of the groove
and extra depth at bottom roller grooves. This will effect in tearing of unbroken
juice cells in the bagasse. This helps to improve the extraction of the following mill.

For 4 - mill tandem.

For Ist and IInd mill: -
Pitch- 65/75 mm (according to mill size)
Grooves angle -Top- 55s to 60e, Feed -30® to 35s, Discharge-40sto45s.

For IIIrd mill: -

Pitch- 35 / 40 mm.
Groove angle- Top-55s to 60®, Feed- 35®-40®, and Discharge-45 ®.

For IVth mill: -

Pitch- 40-45 mm.
Groove angle- Top-55®, Feed- 40® and Discharge-55®.

For IVth mill Tandem: -

First 3 mills as above (1st, 2nd, S^mill).
Last 2 mills as above (3rd and 4th mill).

30
- -
2.3.S.3 Messchaert grooves: -
Messchaert grooves had the simple but fruitful idea of providing an outlet for
the juice by circumferential grooves around the feed roller at intervals as shown in fig.
2.3.S.3. The Messchaert grooves are provided on the feed roller only. These grooves
also known as juice grooves invented and applied in Hawaii. The only objective of this
groove Improvement of extraction” by providing “adequate juice drainage area”. The
groove of 5/6 mm width, 20/25 mm deep are normally provided at the root of every
groove of feed roller.1171
The fine bagasse enters the juice grooves must be removed at each revolution
of rollers but must not be removed with the bagasse from the mill, as it would carry
much juice with it. For this reason, special scrapers are provided for the juice grooves,
which drop the bagasse into the juice tray. With this type of grooving pol loss
bagasse% cane improving the mill extraction.

Advantages!,8!: -
1. Maximum juice drainage is facilitated specially in factories with pressure
feeding devices.
2. Eliminates re-absorption.
3. Permits to go for higher rate of imbibition 250 %.
4. Complete scraping of the bagasse on the grooves is possible by increasing
the length of the teeth in the trash plate.
5. Metal to metal contact is eliminated at trash plate tip of the teeth by which
specific load on the trash plate is reduced.
6. They improve the capacity as well as extraction.
Disadvantagest18!: -
1. Strength of roller is decreased.

-31 -
 2. Roller with discharge grooves suffers more damage from foreign bodies.
2.3.5.4 Arcing[18): -
Arcing of roller is another improved technology adopted presently. The roller
surface can be roughened to increase the coefficient of friction by arcing. This will
further improve the gripping and eliminate slippage (Mechanical interlocking) and thus
improves feeding characteristics.
Advantages[18!: -
1. Increased crushing capacity 5 to 10 %.
2. Increased extraction by 0.5 to 1.0 %.
3. Reduction in moisture by 1 to 2 units.
4. Imbibition rate can be increased 230 to 350%.
5. Increase roller life.
Precaution in Arcing(1SI: -
1. Choose proper electrode.
2. Arcing done at proper position, speed («10 m / min) and voltage to achieve
proper deposit.
2.3.3.5 Chevron Grooves: -
Messchaert have their special object, the improvement of extraction chevrons
have the sole object of improving the feeding of the bagasse.
These are notches cut in the teeth, in a sequence, which describes a helix from
the center to each end of the roller. The angle of the chevrons with a longitudinal line
on the rollers varies with 10-20 and is generally 18a.
The pitch is 20-25 cm or better 1 /10th of the circumference, (i.e., 10 chevrons
on the roller) depth equals to the one-third the depth of the main grooving.
Chevrons are placed only on top roller and feed rollers only. They are never
placed on the delivery rollers because: -
a) They would not be any use, the delivery roller being in a way force-fed by the trash
plate and the feed roller.
b) As bagasse is not compressed between rollers having chevron groove.
Groove Angle[19]: -
• Usually grooves possess 30a to 60a.
• Equal angle for universal grooving.
• Differential angle for differential grooving.

-32 -
 TOP HOLLER

Fig. 2.3.S.4 Axial Juice Drainage Device

Problem: [Data supported to problem, solution & improvement are discussed in later
chapters.]
1. After changing the underfeed roller with TRPF in first mill and last mill we
experienced improved performance with lot of juice flooding above the top
roller.
2. Sometimes gain in extraction was lost by over flow of flooded juice to the mill
bagasse.
Solution:
1. Modifications by drilling four sets of holes in the top roller flanges as in lotus
roller in top roller.
2. Additional juice guard ring were fabricated and welded to the drilled top roller.
As shown in above figure.
3. We experienced that guard ring used to jam with fine cane pieces and plugged
the drain holes of the top flanges. Hence installed finger type knife scrappers.
Improvement:
1. Drain holes on top roller flanges and juice guard rings always remained clear.
2. Juice drainage is efficient and juice flooded on top rollers is minimized.
3. Milling feed ability is improved to maximum extent.

2.3.4 Hydraulic System: -

The system of hydraulic pressure exerted on top rollers of mills is so
designed as to maintain constant pressure irrespective of the volume of cane or
bagasse passing through the mill. In modem mills the pressure is transmitted to
the top roller journals from hydro-pneumatic accumulator by a system of piping
conveying oil under high pressure. A typical accumulator is a cylinder containing
- 33 -
nitrogen filled in inflated bladder, which gets compressed or dilated when the
hydraulic ram on the top of roller journals, is lifted or falls due to the variations in
the quantities of cane or bagasse. The accumulators are provided at both the
ends of the mills in close proximity to the hydraulic ram and are equipped with
indicators of lift which help regulate pressure on mills. The maximum lift of top
rollers ranges for 20 mm. to 35 mm. The hydraulic system comprising
accumulators, oil-piping etc is designed for pressures of 250-300 kg/cm2.
Pressure increased towards the next mill and total pressure on projected area of
roll journal (length x diameter) should be in the range of 100 to 115 kg/cm2
according to E. Hugot.[33]
The various types of accumulators are as follows; -
1. Dead weight Accumulator.
i
2. Air-oil accumulator with air reservoir.
3. Individual air-oil Accumulator.

Hwhaulic SiimIb
n

Fig. 2.3.4.1 Old Hydraulic System used in Sugar Factory

2.3.5 Total Hydraulic pressure or Load: - (t.h.p)

Total hydraulic pressure or load on the top roller is the number of tons
obtained by multiplying the total area of the two pistons in m2 by the oil pressure
expressed in kg/cm2 (g).
TT
Fh = “"“"X Dram * Phyd Where, Dram = diameter of ram of piston,
4 Phyd= Hydraulic pressure.
Specific hydraulic pressure: - (S.H.P)
This is the figure obtained by assuming the t.h.p uniformly distributed over a
rectangular plane surface of length equal to that of the rollers and width equal to one
tenth of their diameter.

34
- -
 t.h.l. Fh
S.H.P. = --------— = -------—— Kg/ cm2
0.1 (LxD) 0.1 (LxD)
Where, L = length of roller in cm, D = Diameter of roller in cm,
t.h.l. = Fh = Hydraulic load.
Influence of the trash plate: -
The certain amount of pressure (P) is absorbed by the trash plate.
Around 20%-30% of the total hydraulic load is the load taken by trash plate.
Cooling water required for mills: -
Hydraulic load = Area of Journal x Hydraulic Pressure.
7T
---------- x (0.325)2 x 270 kg/cm2
4
Hydraulic Load = 22.87 x 10000.
Hydraulic Load = 228752 kg.

2.4 Modification in the mill setting & trash plate profile on the basis
of fibre % cane by different methods.
“MILL SETTING” is an important in accessing the performance for achieving
high extraction of sugar contained in sugarcane. Mill setting means, the selection of
optimum opening between the feed and top roller, opening between the top and trash
plate. This means adjusting the feed and delivery opening and setting of the trash
plate, the dimensions of these openings depend on many factors, particularly the
quantum of the prepared can per blanket of fibre passing through each unit time,
speed of the mills and other factors. Though precise calculations are necessary to
determine the optimum openings to obtain highest mill efficiency, the adjustment is
more an art based on the experience of the Mill Engineer. The delivery feed opening
in a 3-roller mill is usually lesser than the feed opening. Trash plate setting is also very
important in determining these openings.
“Setting” a mil consists of selecting the most favorable relative positions to be
given to the 3- rollers and trash plate, in order to obtain the best extraction results.
Every mill has a provision for adjustment permitting to be made to the position at rest
of each of the two lower rollers relative to the top roller. The relative positions with the
mill empty determine those when operating, when the top roller lifts against the
hydraulic pressure, under the thrust of the bagasse.

- 35 -
 Adjustment of settings is a delicate and important operation. A good setting is
indispensable for obtaining good operation of the mill, that is, regular operation without
choking and with a suitable extraction
Setting of feed and delivery openings; -
The front roller is a feeding apparatus. If they are made equal, either the output
is low or pressure is very poor due to large opening.
This is very important section of the sugar factory: from preparatory section,
cane is forwarded to the milling section.
Pressure in milling: -
The pressure was developed by the layer and dropped when it increased it was
decreased.
The greatest disadvantage was associated with the passing of foreign bodies if
the piece of iron or steel was big of too hard the housing gave way.l22]

This led to search for some more flexible arrangement hence development of
mills with pressure applied by springs. This system still adopted still in small mill or
crushers. After this next development is the hydraulic, pressure which is very
important to maintaining a constant pressure independent of the lift of the roller.
Pressure and volume relationship: -
(Static compression or static pressure test)
To investigate relationship of pressure and degree of compression. Let us
consider a certain quantity of loose bagasse i.e., not compressed.
For example, the bagasse comes in contact in one of the latter mills. For this we have
to add some quantity of water in loose bagasse by means of spray. The volume of
loose bagasse is small in changed, but weight is increased by quantity of water is
applied.
The relationship between pressure and volume at higher-pressure range is
PV5 =Constant. ----------------- [E.Hugot33]

This is position applied at delivery roller where higher pressure and decrease in

volume of bagasse.
After further study, Hugot give unit. In figure, hydraulic press, with cylinder with
3 inch in diameter in which prepared cane varying in size pressed at known pressures
and the volume of bagasse measured.
Then there will be found that volume of bagasse is decreased rapidly at first,
with removal of juice, until the pressure reached approximately 1000 PSI after which
the pressure rises more rapidly, so that at higher pressure gave only a small reduction

36
- -
in volume, with a consequently small increase in extraction of juice. New results of
Deer’s in the form of
70
P=-------------- [Ps 1000/ (10C) ---------------------[E.Hugot33]
(10C) 6

Where, P =pressure exerted on the bagasse in kg/cm2 [Psi].

C = Compression of bagasse.
h Volume of compressed bagasse
C = —— = —---------------------------------------------------------- [E.Hugot33]
H Volume of the loose bagasse
Firstly studied by Noel Deer14 and conclusion on this study is given by Bullock20
that this study is disadvantage that it is at static pressure conditions. After that for
practical study in industry they used this is basis from which to study of pressure in
milling.
Phenomenon influencing pressure in mills1331 [32]: -
Let’s consider that bagasse passing between mill rollers travel at a speed equal
to the peripheral speed of the rollers.
Let us consider a layer AB of prepared cane or bagasse entering a mill as
shown in fig.2.4.1.
Let us visualize vertical equidistant bands A, B, C, D etc. When these bands
approach the rollers, they will be proceedings forward due to friction between roller
surface and prepared cane /bagasse layer.
These bands at first bends backwards due to narrow space between rollers due
to tendency of going backward they forms pockets in the middle layer.
This material consists of solid fibre and liquid juice. Under influence of pressure,
the cell -walls burst the juice tends to escape towards the zone of lower pressure and
flows backwards through the fibrous mass towards the free exterior spaces M and N.
At N it escapes to the juice pan at M it cannot escape except by transferring the whole
bagasse layer where it is not yet under pressure. So the layer at there is saturated
with juice increased proportion of juice therein and consequently the proportion, which
is tapped and carried on towards the opening.1931
Fibre having natural tendency like "Sponge” .At high pressure it will drops juice
contain in it and as low pressure sucks juice at low pressure, this tendency of fibrous
mass is called ‘permeability of fibrous mass'.
When this permeable fibre comes at very high pressure zone starts PQ neutral
plane(not shown in fig 2.4.2) and at 00’ again pressure decrease forward then there
is decrease pressure, liquid will then obviously be thrown forward on dry and
-37-
compressed bagasse .Due to its natural tendency juice is again entrapped or
reabsorbed by the bagasse. For this extraction of juice in milling train, more amount of
energy is expended.
This disadvantage is a matter of the nature of materials and would be difficult to
overcome.

Fig. 2.4.1 Three Roller Mill with Trash Plate Setting

The maximum pressure takes place not at the axial plane 00’ but in an earlier
plane in neighborhood of 00’, called the “neutral plane PQ not shown in fig 2.4.1”.
The pressure is increased maximum up to PQ plane and it is probably
practically constant between neutral plane and the axial plane and falls off rapidly
beyond the latter.
The neutral plane PQ may be located at 25-50 mm before the axial plane 00’.
The squirting of juice (sprinkle) start at neutral plane and finishes just after the axial
plane. The juice flow at a high velocity through the near the layer 00’. It is possible
that practically juice passes through fibrous mass at a velocity only 10, 20 or 50%
higher than that of the rollers. In discharge roller, it is supposed that squirting takes
place is like “extrusion” of solid-liquid material under pressure through the delivery
opening.
Re-absorption factor; -
“It is ratio of the volume of bagasse at axial plane to the escribed volume
generated by the opening between rollers and rotations of the rollers.”1331
VB
Therefore, r = --------, r >1 to avoid slippage.
VE

-38 -
 Where,
r =Re-absorption factor.
VB = Volume of the bagasse as it passes under pressure at axial plane.
Ve = Escribed volume generated by the opening and rotations of the rollers.
The ratio increase with degree of compress. If we consider that loose bagasse
at opening of mill except the layer in contact with the rollers is not dragged, forward
bodily at the peripheral velocity slip therefore occurs and re-absorption is less than
one. This will happens at only when pressure is increasing or mill being closed. So re-
absorption ratio is such that to avoid normal slip.
In theoretical curve, it is assumed that re-absorption is absent i.e., all the
bagasse material was moved forward at a peripheral speed of the rollers.

Compression ratio: -
The principle factor, which determines the extraction in a mill, is the degree of
compression. Compression ratio is defined as reduction in volume of the prepared
cane for Ist mill and bagasse for other mills being presented to the mill to the volume of
bagasse at delivery opening. [E.Hugot33]
No void volume of the material entering the mill
C .. ................................................................................................................................................................[E.Hugot33]
Volume generated by the opening between the rollers
The compression ratio is really of interest only for first mill which receives cane
of a density which is well known.
The ratio ranges from 4.5 to 5 at first mill to 1.5/7 for last mill.
Filling ratio (cf): -
Filling ratio to determine volume of fibre per unit escribed volume.1331
Fibre Loading (q): -
“Fibre loading is the weight of fibre per unit described by one of the mill rollers “.
Cxf Cxf
Fibre loading = q = ------------- ------------------ [E.Hugot33]
S 60rrnDL
Where,
q = fibre loading, kg/m2, C = crushing rate, kg/hr,
f = fibre per unit of cane, L =Iength of roller, m,
S = Area described by a generatrix of the top roller in 1 hour, in m2.
D = Diameter of the roller, m, n =Rotational speed of the roller, rpm.
Fibre loading itself is proportional to the thickness of the bagasse layer
because if bagasse coming is equal and roller diameter for different mill is different,

- 39 -
then it is proportional to the roller diameter. Fibre loading itself is proportional to the
thickness of the bagasse layer; it follows that in order to compare the loading of two
mills of two mills of different diameters.
Specific fibre loading:-
q
T = ■ Where, [E.Hugot33]

r = Specific fibre loading, kg/m3/m.

q = fibre loading Kg/m2, D = mean diameter of roller, m

compare two mills by using formulall. q< [EHugot33]

D, Da

Fibre Index: -
Fibre index is defined as the quantity of fibre in bagasse per unit of escribed
volume generated by opening between two rollers (top and discharge).1331
Fiber loading (q)
Fibre Index = 0 =
Escribed volume of the opening (6a)

For improved mill extraction the mills at high fibre index. It increases along the
milling train; it is minimal at first mill and maximum at last mill.
Total hydraulic pressure or load is divided into two main on feed side (Ff or Fs)
and on discharge side (Fe or Fo) and some amount of pressure is absorbed by trash
plate (Rb or Rj) and make angle (0=10s) to vertical axis. Forces on feed and delivery
side are making angle to each other equal to Apex angle (a).
Therefore, F = Fpcosa/2 h-FdCoso/2 +Rt cosO
Apex angle = a = 74s to 76s, angle made by trash plate with vertical towards
discharge side = (D = 10s, Rj= 20 to 305 of F, Rt= 0.25F
And as per Hugot, Ff= 0.2 to 0.5 of FD. Load on discharge side is more than feed side.
Polygon of forces [E.Hugot33]: -
For dissolution of forces by using the following steps is done and drawing of polygon
of forces is as shown in fig. 2.4.2.
■ Draw centre point and vertical axis after that draw o/2 ando/2 angle to both of
vertical axis for forces Fs and Fe.
■ Draw force Rb, =10s from vertical towards discharge side.
■ By taking that the centre of pressure that is the centre of gravity of the area included
between the curve and the circumference of the rollers.
■ For that as high pressure is not in axial plane but at 2° to 3° before ahead of it
(neutral plane).

-40 -
■ For that purpose take Fs line before 2° to 3° to opposite side of Ff or feed sideline.
■ Similarly draw first extrude Fe in opposite side and take 2° to 3° ahead as Fs. Draw
Fe with scale.
■ From end point to Fs draw parallel line to Fe with scale.
■ At end point of Fe draw line RB with scale and parallel tort with scale.
■ At end point of Rb join to centre o that will be resultant R of (F).
■ RH and RV horizontal and vertical forces of resultant force.

Some relations of forces133,1

Fs = 0.65 F, Fe = 0.25 F,
Fe + Fs = 0.9 F,
Take Fe = 0.4 F, then the Rh will be
vanishes as shown in fig. 2.4.2
But it is not possible in practice as
the feed & discharge setting ratio
will be less than 1.25.
This Rh can be balanced by shifting
hydraulic ram or using inclined mill
housing at 15° with vertical or
provides wear plate & lubrication on
feed side.

Trash Plate: -
Function[3SI: -
1. It facilitates the horizontal movement of bagasse passing through feed roller to
opening between top and discharge.
2. it also distributes some amount of bagasse applied due to the hydraulic pressure
on the top roller.
Position of trash plate[33): -
The position of point B where toe of trash plate meet the feed roller, distance
AB from the toe of trash plate from top roller diameter dimension EF is from trash
plate centre to in vertical axis to the top roller.
Distance GH is from heel of plate and to the top roller.
The Dimension E from heel of trash plate to delivery roller (5 to 10mm).
The curve BH should be like a logarithm spiral with centre T of top roller and
distance A > B > C as shown in fig. 2.4.1

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 These distances are changes in working and value of T remain unchanged.
Trash turner: - It facilitates horizontal movement and also trash turner provides
angular movement to trash plate.
Setting of trash plate: -
It is a device in mill tandem, which is to be changed every season. The position
of the trash plate has a great influence on smooth operation of the mills .Now the
correct setting of trash plate is a delicate operation. [Data supported to problem,
solution & improvement are discussed in later chapters.]
To define its position it is necessary to know; -
1. Position of the point where the plate meets the feed roller.
2. The distance of the toe point from the top roller.
3. The distance measured in the vertical axial plane from the plate to the roller.
4. The distance from the head of the plate to the top roller.
5. The distance from the bed to the delivery roller.
Problem:
1. Poor juice drainage on top and discharge roller compression pair.
2. Splitting of juice on bagasse side.
3. Poor milling performance.
Solution:
1. Trash plate heel side teeth cut out for mill No. 1,2 & 3.
2. Heel clearance increased to the desired setting.
Improvement:
1. Juice drainage on discharge roller side is improved.
2. Splitting of juice by discharge roller is eliminated.
3. Milling performance is improved to the desired extent.
Calculation of mill setting is done by various methods as follow: -
1. Java method.
2. Behene’s method.
3. FCB method (Fives cail Babcock method).
4. Farrel method.
5. Hugot method.
6. Avadut method.
7. Fibre Index method.

42
- -
2.5 Improvement in efficiency of the mill using Under Feed Roller /
Grooved Roller Pressure Feeder / Toothed Roller Pressure
Feeder & speed of mill roller.
It is experience that there is slippage of bagasse in the mill due to substantial
improvement in the cane preparation Further the mills need to have pressure feeding
as the mills are run at close opening to have extraction.
The ideal requirement of feeding to millI10J: -

1. To run the mill at lower speed for more retention time for juice drainage .It also
controls the re-absorption factor ultimately reducing the power in the mill.
2. To set the mill for low ratio of feed opening to discharge opening which gives
effective control on re-absorption.
3. The hydraulic loading can be reduced as the bagasse blanket thickness gets
reduced, reducing the power consumption in the mill.
4. The mill needs to set close at discharge roller for higher extraction.

The function Expected from pressure feeders: -

1. To compact the bagasse for increasing the bulk density of it. Due to this, it should
extract the juice and drain effectively.
2. To generate the sufficient radial pressure to extract the juice and induce the
required feeding force in the bagasse for entering into mill having tight settings.
3. Height from which bagasse is fed into tight settings of mill so inside portion of
feeder of chute is made such like that there will less frictional loss.
4. To change the orientation of bagasse .It should change the position of bagasse
Particulars in course of bagasse flow. This will help the mill to disintegrate or
Rupture the juice cells which are not broken on preparatory devices. This will help to
increase the extraction in following mills.
There are four types of pressure feeding devices, which mainly used in the sugar
mills:
1. Open gravity chute.
2. Closed gravity chute. (Donnelly Chute).
3. Under Feed roller.
4. Continuous pressure feeder.
a) GRPF.
b) TRPF.

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1. Open gravity chute: -
In this gravity feed one side having plate (on lower side) and other side is
opened if this plate is extended that should passes through centerline of feed roller as
shown in fig. 2.5.1.(a). Clearance between gravity plate and feed roller is 5 to 6 mm
and grooved plate at the end for avoiding cane slippage.1331
The force acting on the shoot plate is:
a) Gravity force.
b) Frictional force, which resist the flow of cane in chute.
c) Pushing force.
Feeding force due to cane carrier slots as shown in figure.
Equation Governing the mill feeding in 3-roller mill: -
We can calculate pressure force or feeding force at the bottom of the chute plate.
F= P [sinp - 0cos(J]/s kg/m2. --------------------- (1).
Where, P = weight of bagasse, Kg, p=Angle of feed plate (Chute plate),
0 = Coefficient of friction between bagasse on the feed plate,
s = Area of cross section consider at bottom chute (m2).
P LEZd Weight of bagasse on feed plate chute
-------- -- ---------------- --- ----------------------------------------------------------- ---------- [E.Hugot33]
s LE Area of bottom of chute
Where,
L= Length of roller (m). e = Height of bagasse (m).
d = bulk density of bagasse (kg/m3). Z = length of chute (m).
P
—- = z.d ---------------------------------------- (2).
z
We get feeding force
/ F= z.d (sinp -O.cosp)------------------------------ (3)
For calculate “d” (bulk density) kg/m3.
D=at first mill =400 kg/m3 but it can vary from 300 to 600 kg/m3.
From first mill to last mill it can be calculated by
d= 100[(1/1-h) + A]. ----------------------- (4).
Where, h=moisture / unit bagasse before imbibition,
A = Imbibition / unit fibre {imbibition % fibre} (200 to 220%) = 2.22
For 1st mill bagasse moisture is 70%, A = 0.
d= 100 [(1/1-0.7) +0] = 333.3 kg/m3.
Ilnd mill bagasse moisture is 53.5%, A = 2.22
d= 100 [(1/1-0.535) +2.22] = 435.05 kg/m3

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Illrd mill, Therefore value of h = 52% = 0.52, A = 0.52.
d= [1/1-0.52 +0.52] 100 = 498.33kg/m3.
For IVth mill, Value of h= 50% =0.5, A = 0.5.
d=100[1/1-0.5 +0.5] = 420kg/m3.
To find out the height of chute of first and last mill the value respectively as per
data available from factory is 780 & 1020 Kg/m2. Coefficient of friction 0.3, angle of
inclination of chute taken 84°, moisture of bagasse at last & first mill 70 % & 51 %
respectively, Imbibition % fibre 220%. Then Z is calculated by using above formula
reference are taken from [E.Hugot33].

d for 1st mill = di

di=100 [1/1-0.7 +2.2] = 553.3 kg/m3,
d for last mill =diast
diast =100[1 /1 -0.51 +2.2] = 424.0 kg/m3.
Therefore,
Feeding force = F=Zxdx [sin p -0 x cos P].
Zis, =f/d (sinp - 0cosp) =780 / (553.3) (sin84 - 0.3cos84) = 1.46m.
Ziast = f/d (sinp-0cosp) = 7020 / (424){sin84- 0.3cos84) = 2.497m.
As we consider mean value of'd ‘ density = 400 kg/m3 and 0 =0.3 then value f- in
kg/m2 of component of gravity feed as a function of chute height ‘Z’ and inclination ‘P’
of the feed plate.
Table Values for ‘Z and ‘P’ feeding force ‘F. [E.Hugot33]
Z(m) p= 50° P=60° P= 70° P=80° P=90c
1 210 260 310 340 370
2 420 520 620 680 740
3 630 780 920 1020 1080
4 840 1040 1200 1360 1460
5 1050 1300 1530 1680 1830

2. Closed gravity chute (Donnelly Chute): -

With feed plate angle ’p’ is greater than 55s in open gravity chute than falling of
bagasse on the top roller, it becomes rolled and forms on the top roller. Hence front
plate or front plate is provided to avoid this falling which is called Donnelly chute or
closed gravity chute as shown in fig. 2.5.1.(a). In such chute generally ‘P’ angle of
slope is in between 85s to 87s. Point p of AB plate meet at feed roller at a = 30s before
the vertical axial plane. This angle is called angle of contact.1331

45
- -
 Fig. 2.5.1 (a) Open chute and Donnelly Chute [E.Hugot33]

The plane of front plate CD meets at point E to top roller when it extended. Van
Hongel gives this thickness of bagasse ‘E’ of Donnelly chute varies slightly with angle
of inclination (3 from 55 to 90 value of E.
E for 1st mill = 11 to 12 times of 6a.
E for last mill =8-9 times of 6a-
Where,
6a = operating on work opening of respective discharge roller. If 8 is less than
60s then a =90-p and best angle for p =80s to 85s.
Distance between D of the front plate =0.3m and p’ = (p-1)s.
The coefficient of friction of front plate is more than the coefficient of friction on the
bottom plate (0’ > 0).

3. Under Feed Roller: -

If Donnelly chute arrangement, when there is high crushing then this
arrangement is not sufficient. Therefore, for this situation one roller of cast iron
grooved having 75% to 85% diameter of mill roller. Its prescribed speed is about 10%
higher than that the last mill roller. Due to this U.F.R. known juice is extracted but
sufficient force is generated.1331

Donnelly chute is to meet at U.F.R. at point F and upper plate of donnelly chute act as
a point E to top roller as shown in fig. 2.5.1 (b).
a =cos'1 [1/2(1+a/D)].

Cosa = [1/2(1+a/D)]

46
- -
 Fig. 2.5.1 (b) Under Feed Roller [EHugot33]
Where,
o= Space between feed and top roller.
D= diameter of top roller.
a= 135s - (p+ e)
Where,
e =angle OO’G with horizontal O’G.
p’=p-1= angle of inclination (55ato 90s).
Function of U.F.R: -
Due to higher U.F.R. setting very light radial pressure is developed to extract
the juice and generate the sufficient force.
Drawbacks of U.F.R: -
As there is no juice drainage arrangement it forms the juice pool in front of top
roller by which roller surface get mode resulting in reducing the coefficient of friction.
Little increase in rate of crushing and heavy imbibition, bagasse gets slipped.
Mills cannot be set closed due to insufficient feeding force. Due to this there will not
change in orientation of bagasse. Hence, this arrangement of U.F.R is being replaced
by positive pressure feeding like T.R.P.F and G.R.P.F.
4. Continuous pressure feeder: -
It consists of a pair of rollers a head of the mill, with on enclosed chute,
diverging slightly, which gives the bagasse a positive movement from these rollers to
the feed opening of the mill. It improves the crushing capacity and extraction 25 to
30% is increased. Also decreasing moisture % of bagasse occurs. The action of the
feed roller is continuous and uniform.

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Modification: Pressure feeder replaced U.F.R. of Is1 & Last mill standard design
MERU make. TRPF & IInd & IIIrd are standard design Kill make C.l. heavy duty U.F.R.
& Donnelly chute to all mills.
Two types of Continuous pressure feeders: -
a) Grooved Roller Pressure Feeder (GRPF).
b) Toothed Roller Pressure Feeder (TRPF).

Fig. 2.5.2 Schematic diagram of Grooved Roller Pressure Feeder system

a) Grooved Roller Pressure Feeder: -

The surface of rollers may be smooth, but preferably grooved. The pair of grooved
cast iron rollers having equal diameter and 80% of roller diameter of mill [E.Hugot33].
Where, (jo0i= Work opening of GRPF or TRPF (m).
di = Width of pressure chute at entry (m).
(jo02= Work opening (or) feed setting (m).

d2=Width of pressure chute at delivery (m).

0i<259 =199 to 209 normally. 02<459=389 to 409 normally.
The axial plane of two rollers is generally at 459 to the horizontal. The centre
line of the enclosed feed chute between pressure feeder and mill rollers as closely as
possible normal to the axial plane of these rollers so that of the upper the feed rollers
of the mill.
Pitch of grooving on GRPF 45 to 50mm (max. 60mm) angle of grooving =309 to 359.
Opening between GRPF is, ep =GRPF setting =1.5 ef (ef of feed roller).
If length of chute between GRPF and roller opening of mill is more than there will
friction will more, for that purpose inside chute sheet of stainless steel lining is
provided.

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A under feed roller is provided to feed these pair of roller and pressure developed in
this chute is 0.07 to 0.1 kg/cm2. The deviation angle of pressure chute = 3 to 3.5 and
this angle is required to accommodate the bagasse blankets expansion after release
from compression zone of GRPF.
Speed of GRPF= 1.1 to 1.3.
V=Surface speed of the mill roller.
With proper setting of rollers of GRPF, sufficient radial pressure is developed to
extract high proportion of thin free juice in the bagasse thus reducing the excess
moisture of bagasse and with having feeding pressure.
Table 2.2: Compressed Bagasse Bulk Density at Pressure Chute5331: -
At Entry in At delivery in
Mill
kg/m3 kg/m3
I 104 96
II 112 104
ill 120 112
IV 128 120
V 136 128

Drawback p,): -
1. The setting of GRPF is critical and requires experience hand.
2. GRPF or TRPF require more power than other pressure feeding devices
(0.6 to 0.7 Kw/TCH)
3. It will require separate arrangement to revolve pair of roller.
4. It will require lot of space to install. Hence, it is not possible to install where
distance between mills so small.
5. These are so expansive.
b) Toothed roller pressure feeder:
TRPF is developed to overcome the problems experienced in the operation of
GRPF. It consists of a roller having equi-spaced bands or spokes of typical shape
Teeth are widely on the outer surface of drum or roller. The teeth of rollers intermesh
with each other having space to grip the loose bagasse compact it and push it into the
close pressure chute provided between TRPF a mill roller opening [21].
The Donnelly chute before TRPF act like buffer storage of bagasse not as feeding
device (1.5m height) .The diameter of TRPF are generally, tail bar arrangement is
provided for this TRPF.
The TRPF provides positive displacement action on bagasse like gear pump.
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Power for TRPF = 1/6 of power requirement to 1st mill = 1/12 of power requirement
to last mill or (0.20 to 0.30 Kw / TCH).
Function[21J:

It allows using low ratio of feed opening to discharge opening as low as 1.6,
which is ideal requirement of the mill for efficient juice extraction increasing crushing
rate.
Due to teeth on roller it compresses and generate radial pressure maximum
according to power installed to improve bulk density of bagasse, due to this mills can
runs at lower speed and can be set for higher fibre index.
It also reduced the requirement of hydraulic load up to 70% of the load used in
conventional arrangement.
The power required in mill is also reduced to 70% of that having conventional
arrangement including GRPF.
It is insensitive to coarse heterogeneous cane preparations and heavy hot imbibition
water rate.
Drawbacks1211:

1. As rollers are made of mild steel, there is lot of corrosion and wear on the roller.
2. It requires more space ahead of the mill.
Improvement121

1. Increases the density of bagasse entering into mill improve the feedabilifty of

mill to increase rate to higher side.

2. Feed to discharge operating, opening ratio reduces to 1.7 to 1.8 depending
upon cane preparation, fibre quality, mill condition and position. So reduced
feed opening than previous one gives more juice drainage at feed side.
3. Reduced feed discharge operating opening ratio reduces feed difference in
value of reaction at feed and discharge to enable fluent lifting of top roller which
allows using more hydraulic pressure on top roller depending upon the mill
conditions and power available.
4. Due to positive grip on bagasse mat mill slippage is much reduced to run at
lower R.P.M. which help to increase juice drainage. Power wasted in slippage,
friction is saved.
5. Higher quantity of water + 250% on fibre can be used 85% deg. C temperature
which help to extract more sugar efficiently by dissolving from bagasse,
6. Being the roller is still constructed it can be reconditioned at factory site by
welding only at low cost to get more and more increased life to the roller.

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-
 7. There is no repeated expenditure for re-shelling like C.l. roller.
8. This roller is much lighter than C.l. Roller dead weight. Mainly toothed
constructed surface is giving high grip to this light weight roller having more
bearing area reduces lubrication cost as well as increased bearing life.
9. It is stuff and strong in construction and forming as a fourth roller integral part of
mill having heavy less part compared with G.R.P.F. and T.R.P.F, parts
including closed pressure chute TRPF roller requires very less maintenance.
10.TRPF system can be easily installed on any type or make of mill with minimum
modification in short time.
11.TRPF system reduces required power so it can be installed even on old mills
with existing driving with minimum modification to get extra crushing rate with
efficiency.
12. Existing GRPF & TRPF system capacity can be increased more than 10% and
reduction in power by modifying the system along with addition of one TRPF
series roller on mill No. 1. & 4 mill
2.6 Modification in the compound imbibition system & temperature
of the imbibition water.
Imbibition'331: -
It is the process of addition of hot water at the last mill so that to extract
maximum amount of juice from cell. The hot water of about 80SC is added at the fast
mill only the water is first weighed by a weight scale (Maxwell Boulonge Weighing
Scale). In this factory compound imbibition scheme is adopted.
The purpose of Imbibition is to extract the sugar left in the bagasse after
primary mill crushing. Imbibition means spraying hot water on the previous mill
bagasse. Imbibition water dilutes the juice in bagasse and reduces its Methods of
imbibition: -
1. ) Simple imbibition.
2. ) Compound imbibition.
1. Simple Imbibition: -
The simplest procedure of imbibition consists of addition of the water at one
point only, between the last two mills then it is called as ‘Single simple Imbibition and
so on.
2. Compound Imbibition: -
This system required less water, which is to be evaporated in evaporation
process. When imbibition on last mill, the juice extracted contains more quantity of
-51 -
water, this juice has been taken and sent back before preceding mill. Imbibition
Scheme followed in B.C.S.S.K. Ltd... [**Data supported to problem, solution &
improvement are discussed in later chapters.]
Compound imbibition scheme adopted. Hot water is used. By using, measuring tanks.
Chockless pump size -“4, capacity- 40cubic meter /hr,
Chockless pump size -5”, capacity-1 OOCubic meter/hr.
Problem:
1. Milling capacity and efficiency affected due to changed due to cane variety.
2. Mill started over flowing as cane was difficult for milling.
Solution:
1. Imbibition water quantity divided and applied before mill No. 4 and 5.
2. Remaceration juice of mill No. 5 and mill No 3, 4 is completely re-circulate.
3. Mill No. 1 & 2 juices sent to boiling house through rotary juice screening.
4. Double compound simple imbibition method achieved please refer to following
fig. with various imbibition system and their effect on mill extraction.
Improvement:
1. Milling capacity and efficiency is improved.
2. Mills over flowing eliminated.
3. Overall milling performance is improved.

EXTRACTION VS IMBIBITION
SCHEME Mill
Extraction
1 f 90.0

j
r *A ‘A T 81.8

% '4k
.—j—
........
86,7

4, *4, ‘4. ' , . i 88.3

1 ? ^ 87.7
___

Fig 2.6.1 Compound Imbibition with Mill extraction **

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