INPLANT TRAINING REPORT AT THE KAITHAL COOPERATIVE SUGAR MILLS LTD.

KAITHAL
Submission of training report in the partial fulfillment of the requirement for the award of degree of B. Tech

Submitted By:Name: Deepak Sharma Roll no: 1709564 Semester: 5th (Fifth) Session: August 2011 to December 2011

DEPARTMENT OF MECHANICAL ENGINEERING HARYANA COLLEGE OF TECHNOLOGY AND MANAGEMENT, KAITHAL

ACKNOWLEDGEMENT

I am Deepak Sharma pre-final year student of MECHANICAL ENGINEERING in HCTM,KAITHAL completed the training from THE KAITHAL CO-OPERATIVE SUGAR MILLS LTD.KAITHAL (HARYANA). Under the guidance of ER. KRISHAN KUMAR SHARMA. Firstly they help me to complete this training on time and also create better study environment that helps me in increasing my design skills. I am also very thankful to Er. ARVIND KUMAR who solved all my queries and satisfy me a lot. He is contact on following address: BLOCK-B SUGAR MILL COLLONY, KAITHAL (HRY). I again very thankful to the authority of the organization regarding my training.

ABSTRACT

Industrial training is part and parcel of our technical course and give a face or form to all the theoretical knowledge we gain in our classroom. We get to have a virtual experience of the processes methods, objects and phenomenon which used to be just a imaginary picture in our mind. It also give an explosure to the environment of the industry and workshop which are virtual component of our professional life. We too were get this opportunity this summer. K.C.S.M.(Kaithal cooperative sugar mill) offers a wide range of machine, mechanism and devices, in the industry we get face to face with the life of a mechanical engineer. This industry established in 1991, located at 4 k.m. away from the city kaithal. There was a lot of useful machines like boiler, turbines, feed pump, pan, quads, etc. Today sugar mill kaithal is one of the best mill in Haryana. The workers working in this mill is nearly 750 which are giving there best for the future of the company. The production of the mill is 2500 tonn . This mill provides there sugar to different parts or states of india and it is a proud for us that we have got trained from this national working company.

TABLE OF CONTENTS
S. No.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 10.1 10.2 11. 12. 13. 13.1 13.2 13.3 13.4 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Description of contents
Factory profile Plant layout Flow chart Cane unloader Cane carrier Cane leveller Cane cutter Cane fibirizor Mill house Mixed Juice tank Juice tank Juice sulphation tank Callifier Vaccum filter Evaporator and boiling plant 1st evaporator body 2nd evaporator body 3rd evaporator body 4th evaporator body Vapour cell Syrup sulpation tank Pen station Crystallisor Hopper Sugar gradder and bagging Baggase carrier with elevator Mollasses storage tank Boiler Turbine Conclusion

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1 2 3 6 6 7 7 8 9 11 11 11 12 13 13 14 14 15 16 17 17 18 19 19 20 21 22 22 24 25

TABLE OF FIGURES
S. No.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Cane Unloader Cane Carrier Cane Leveller Cane Fibrizor Mill House Calirifier Vaccum Filter Semi Kessioner Evaporator Body Syrup Sulphiter Tank Pen Station Boiler

Description

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1. FACTORY PROFILE
The sugar mill is established in 1991.

Location -4km away the city kaithal Raw material sugar cane Product- sugar Turn over-40 crores(2009-2010) Production-With 2500TCD production of 2500quintal(app) takes place
No. of workers-750(app)

Area-147 acres Recovery -8% per quintal

Selling of sugar is through out the country,but also on the other hand for the selling of

mollasses and baggase tenders are pass out.

2. LAY OUT OF SUGAR MILL

3. FLOW CHART
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Cane Cane yard Cane Carrier Leveller Cutter Fibrizor ( Quartary Ammonium Compound + Dia Thio Carbonate Base ) II Mill III Mill iV Mill Boiler Mixed Juice Steam ( Phosphoric Acid ) Turbine Mixed Juice Tank Bagasse Ist Mill

 Juice Heater (Ist heating Raw juice 70c) House Juice Sulphitor Juice Heater ( IInd Heating sulphited juice 102c ) ( Magna Floc LT 27 ) Vaccum filter Mud Clear Juice Clear juice heater (116C) Mixed Juice Tank Semi Kessioner Vapour Cell Ist Body Evaporator Anti Scalent + Caustic Soda + Cmmon salt + Scale
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Exhaust Boiling Lime + So2 gas

Clarifier

Muddy

juice

Filtrate Juice Go to

II Body Evaporator

III Body Evaporator Softner (chemical Boiling .) Iv Body Evaporator Cleaning of evaporator bodies. Syrup Syrup Sulphitor SO2 gas Syrup Tank Seed Slurry +Phosphoric Acid + Hydrosulphite soda + Phosphoric Acid Massecuite Crystallizer Molasses Tank Molasses Centrifugal Machine Moist Sugar Hopper I Hopper II Hopper III
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Pan Station

 Sugar Elevator Grader Bagging

4. CANE UNLOADER

FIG 1(CANE UNLOADER) i. The function of can eunloader is to pick up the cane from the tractor and sterred into the cane carrier chain
ii. Capacity is 5T,long travel speed is 15m/min by means of electric motor

5. CANE CARRIER

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FIG 2(CANE CARRIER)

The function of this chain is to carry the cane which is dropped by the unloader Its horizontal length is 32.119m and width is 1700mm,feeding depth is1600mm Its total length is 51.41m It is driven by electric motor HP50 and rpm 1440

6. CANE LEVELLER

The function of cane leveller is to smooth running of the cane because the cane dropped by the unloader is not in proper manner.

No. of blades used are 32. Motor driven by 250HP and at 589 rpm. Clearance between carrier and blades 180 mm.

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FIG 3(CANE LEVELLER)

7 . CANE CUTTER
Its function is to make small pieces of sugar cane by means of knives which are dragged on the roller

No. of blades is 36 Motor driven 250HP Material of the blade is mild steel

8. CANE FIBRIZOR

It used to make the fibres of all small pieces of canes which are forwarded by cutter.
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It has 64 hammer of stainless steel having cast steel body. They are in the rectangular shape. This is also driven by electric motor.

FIG 4(CANE FIBRIZOR)

9. MILL HOUSE
The function of mill house is to drawn the juice from the fibre of the cane received by the cane carrier chain. There are 4 mill in the plant.
1st mills job is to drawn the juice approx. 70% juice are drawn here with the help of

4 roller. Their name are: Top

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 Feed Discharge Unfeed

These 4 rollers are driven by steam turbine with the help of primary gear, secondary and the transmission gear.

FIG 5(MILL HOUSE)

All the juice driven by the roller is to be collected in the juice tank with the help of pumps. Pitch : 50 mm
Feed : 65mm Grooves : 34mm

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 Depth: 46mm

2nd mill of plant

Here 20% of total juice is to be drawn out and also juice is pumped to the tank. The speed of roller is 13 m/min. RPM 4.57
FEED : 62mm GROOVES : 38mm DEPTH : 46mm

MATERIAL of the roller cast iron and cast steel

3rd mill of plant

Here, hot water of 70* C is to be impinges on the bagasse and here, most of the juice from every cane is drawn out and pumped to tank.

Feed : 33mm Grooves: 56mm Depth 30mm RPM of turbine 3000-4000 Control by Governor In this mill complete juice is drawn out from the cane and residue is called Baggasse, which is carried by Baggasse carrier chain.

4th mill of plant

Horizontal length 61.1 meter.

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Effective width 1500 mm The Electric motor haspower 37 kilowatt at 1470 RPM The RED. GEARBOX ratio is 40:1

10. MIXED JUICE TANK

In this tank,juice from all the tank of mills house Is collected in a big tank is called mixed juice tank through the pumps.Juice is measured & weighted by automatic boulogne type juice weighing scale of 60 tonnes capacity per tips.with recording counter With a 10 tonnes platform steel years weigh Bridge for check weighment.

10.1 JUICE TANK

From the mixed juice tank,juice is heated in juice heater by the means of exhaust steam. One stainless steel plate type heat exchanger of 100 sq.m heating surface for clear juice heating having a by pass arrangement.
5 high velocity vertical juice heater of 170 sq.m heating surface each working with

exhaust and vapour.all five heaters are interchangable and are used for raw and sulphiated juice heating.
Temp. of juice is 70c. Stainless-steel tube outer dia. 45mm (OD)X42mm (ID)x4000mm(L) No. of tubes are 320

10.2 JUICE SULPHIATION TANK

After heating the raw juice,it pumped to sulphitation tank. Here juice is mixed with soda-lime and the sulphar gas is passed through the juice.all these things are rotated in a tank with the help of motor at the top of the tank.

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11. CLARIFIER
From the juice heater,juice is pumped to the clarifier,here juice is keep stationary for a sufficent time,so that impurity are setteled down in the bottom. Impurity + some juice is taken out from the tank and pumped to the vacum filter.
Clear juice is pumped again to clear juice heater and here temp. of juice is 116c

FIG 6(CALIRIFIER)

12. VACCUM FILTER

Muddy juice with the help of pump is reached to the vacum filter.in this vacum is created by the pumps.

The mud is stick to the screen and the clear juice is passed through the small pipe and finally mixed in juice tank.

2 rotatry vacum filter Dia. 2.44m Length is 4.88m Filtering area 36 sq.m, stainless-steel screen.

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FIG 7(VACUUM FILTER)

13. EVAPORATORS & BOILING PLANTS SEMI KESNER

After heating the clear juice in heater,juice is pumped to the semi kesner.it is doubleeffect pre-evaporator.

The function of semi kesner is to heat the juice for less than 2 min. It has two chamber Heating surface area is 800 sq.m. Long tube of 45mm (OD) x42mm (ID)x4655mm(L). No. of tubes are 1302.

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FIG 8(SEMI KESSIONER)

13.1 EVAPORATOR BODY 1st Evp. Body

Juice from vapour cell is pumped to 1st evp body, juice is evaporated here.

Length: 4000mm Heating surface : 450sqm Vapour pipe dia: 600mm No. of tubes: 1724 Tube length: 2 meter
ID : 42.5mm

OD: 45mm

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FIG 9(EVAPORATOR BODY)

13.2 2ND EVAPORATOR BODY

Length: 4000mm Heating surface : 450sqm Vapour pipe dia: 600mm No. of tubes: 2248 Tube length: 2 meter
ID : 42.5mm OD: 45mm

13.3 3rd Evaporator Body

Length: 4000mm Heating surface : 600sqm
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 Vapour pipe dia: 550mm No. of tubes: 1138 Tube length: 2 meter
ID : 42.5mm

OD: 45mm

13.4 4th Evaporator Body

Length: 4000mm Heating surface : 300sqm Vapour pipe dia: 750mm No. of tubes: 1138 Tube length: 2 meter ID : 42.5mm OD: 45mm

14. VAPOUR CELL

From the semi kesner, juice is pumped to the vapour cell. Here juice is heated upto 2 minutes. Heating surface 950 sq.m Tube length 2000 mm Diameter 45mm(OD) and 42mm (ID)
No. of tubes are 3580 It is made of stainless steel material.

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FIG 9(VAPOUR CELL)

15. SYRUP SULPHITOR TANK

From all the EVP. Body, the juice is become like syrup. The syrup is treated with sulphurs gas in the tank. one syrup sulphiter tank Working capacity: 50hl ID of shell 2100 mm

FIG10(SYRUP SULPHITOR TANK)

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16. PEN STATION

From storage tank, syrup is pumped to the vacum pan to convert them in solid form. No. of vacum pan: 5 Capacity of vacum pan: 60 tones each Heating surface : 300 sqm Tube length : 900mm No. of tubes : 1094 Syrup change in solid form and it checked time to time by a long checking key provided min tank.

FIG 11(PEN STATION)

17. CRYSTALLISOR
From the pan, the crystal formed goes to the crystallizer.
3 u-shaped air cooled cryst. Of tonnes capacity each for a m/c 3 v shaped betch type water cooled cryst. ( moving coil) of 65 tones capacity for m/c 2 v shaped air cooled coil cryst. Of 65 tones capacity each for c m/c 25

18. HOPPER
FROM THE CENTRIFUGAL m/c, moist sugar goes to the hopper or sugar drier. There are three gram hopper are single tray and two multi tray gram hoppers. Sugar hoppers no. 2 and 3 with drgint arrangement hot and cold air by blower. Width 1 Width 2 Width 3 Length 1 Length 2 Length 31.5mm (single tray) 1.5mm ( multi tray) 1.5mm ( multi tray) 12m (single tray) 12m (multi tray) 12m (multi tray)

FIG 12(HOPPER)

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19. SUGAR GRADOR

After elevating the sugar, it goes to the sugar grader, here grade is given to the sugar such as small, medium and large grains. 2 no. or sugar graders Capacity : 12 tones/hr Vibrating type sugar grader of three decks. Each deck is capable to sieve minimum 7 tones of sugar driven by electric motor and magnetic iron separator are provided.

20. BAGGASE ELEVATOR

The function of this elevator is to lift the bagase from the bagase chain with the help of electric motor.

Rake type of bagase elevator Length horizontal- 12 meter Inclined length 20 meter Effective width 1500 mm Electric motor drives at 30kw and RPM 1470 Its speed is 25meters/minute

BAGGASE CARRIER
The function of this carrier is to carry the bagasse from the 4th mill

Horizontal length 61.1 meter Effective width 1500mm

Effective motor 37 kw and 1470 RPM Gear box ratio of motor is 40:1

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RETURN BAGGASE CARRIER

Sometimes we require the more bagasse , for the burning in each case, bagasse is to be taken from outside the plant with the help of return bagasse chain.

Horizontal length 8.550 meter Inclined length 26.728 meter Effective width- 1500mm Motor runs at 30 kw and 1465 RPM Reduction Gear Ratio of motor is 40:1 Linear speed- 25m/minute

21. MOLLASES STORAGE TANK

The function of this tank is to store the molasses. No. of tank 8 Shape of tank rectangular Material of tank mild steel Capacity of tank 200 HL each

22. BOILER
The function of boiler is to give the heat to water and then converted into steam. Two no. of bent type bagasse fixed boiler water tube boiler. Working pressure 32kg/sq.cm Heating surface 1170sq.cm Each boiler steam generating capacity 32 tones per hour Efficiency of boiler - 80-85%

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FIG 13(BOILER)

Super heater
The function of this is to heat the feed water by the means of flue gares. Efficiency is improved up to 2% Gilled tube type heating surface 180sq.meter , feed water heating by exhaust steam

Economizer
The function of this is to heat the feed water by the means of flue gares. Efficiency is improved up to 2% Gilled tube type heating surface 180sq.meter , feed water heating by exhaust steam

Other auxiliary boiler components safety valve

Spring loaded safety valve, spring loaded pop type valve Its function is to maintain the steam pressure in the boiler and steam drum FAN ID FAN 300 HP FD FAN 80 HP S FAN 60 HP
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23. STEAM TURBINE

The function of turbine is to convert the energy of steam in mechanical energy One no. 2500 kw rating multi-stage turbine. Steam inlet pressure-32 kg/sq.cm Steam exhaust pressure-1 kg/sq.cm Reduction gear speed- 8325/1500 rpm current used VOLTAGE OUTPUT A.C. 415 VOLTS 2500kw

Purpose for which used for light Power factor No. of phase 0.8 3

Frequency cycle - 50 cycle Maximum demand in season 2500kw Maximum demand in off season 800kw

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CONCLUSION
Training is really important for an engineer. It enhances our confidence. During the training we see the implementation of knowledge that we have gained. It gives us a good exposure to the functioning of organizations. My topic for the training was on production of sugar. I also studied the resources necessary to start any organization. Our mentor Er. Krishan Kumar Sharma stressed on improving communication skills as it plays a very vital role in the corporate world. Three things contribute to communication skills are as under:Body Language Eye Contact Verbal Skill An exposure in the form of summer training is vital before entering into the actual professional career. Thus this training has given me an insight into the industrial world in mechanical field which will prove very helpful in my future professional life.

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