79th STAI ANNUAL CONVENTION

INNOVATIVE AND SUSTAINABLE OPTIONS FOR IMPROVING

JUICE EXTRACTION EFFICIENCY

By

R A CHANDGUDE
Head, Sugar Engineering Department,
Vasantdada Sugar Institute, Manjari
(Bk),Taluka- Haveli, District-Pune, India
ra.chandgude@vsisugar.org.in/ admin@@vsisugar.org.in
(Contact: 020-26902301/305/100 Fax: 020-26902244)
 Background
 India using the rollers as well as worm gearing technology for juice
extraction from sugar cane by 17th century.

 The some sugar mills are using 60-70 years old technology for juice
extraction as well as its drive like steam turbines with combined mill drive.

 Milling is the most important unit of sugar plant.

 Economy of sugar plant entirely depends upon milling efficiency.

 Milling plant consumes about 50% power of total consumption of sugar

plant and co-generation requires efficient milling operation.
 Objectives of sugar cane milling plant
 To extract sucrose-rich juice from sugarcane

 To prepare good quality bagasse as fuel for boiler

 To minimise power consumption for cane preparation as well as milling and

its utilities.

Maximum Extraction Minimum Extraction Minimum pol % Minimum Low power

of Sugar of Non-sugars Bagasse Moisture % Bagasse consumption for
juice extraction
Sugar cane juice extraction methods

Sugar cane juice extraction methods

Sugar cane Diffuser

milling Technology

Conventional three Bagasse

roller milling Diffuser

Cane
Two roller milling
Diffuser
Factors affecting performance of milling
 Cane quality
 Cane preparation
 Fibre % cane
 Number of mills in the tandem
 Mill roller surface speed
 Imbibition
 Mill sanitation
 Personnel working and automation level at mill station
 Developments in cane handling
 Higher capacity cantilever unloaders with VFD drive, hydraulic de-hooking are
developments which helps to avoid vehicle jamming at cane yard and reduce cane
handling time.

 Centralized operating & controlling for cane handling, preparation and milling which helps
to manage cane handling in minimum time lag with minimum man power.

 Hydraulic truck & tractor tipplers with auxiliary carrier for smooth handling of mechanically
harvested cane.

 For smooth control & power saving of cane handling utilities with planetary gear boxes &
VFD drives.

 Double screening of juice to minimize bagacillo in mixed juice and improve clarification
 Sugarcane preparation

 Different cane varieties have different degree of preparation under the

same preparation treatment.

 The fresh cane improves the preparatory index where as stale cane
lower preparatory index which also increases power consumption.

 Higher the cane trash in cane lower preparatory index as well as lower
the milling efficiency and capacity.
 Developments in sugarcane preparation

Recent developments in sugarcane preparatory devices for improving

cane preparation and energy efficiency.

 Potential to use variable speed drives for cane preparatory equipment.

 The leveler shall be swing type and chopper, leveler knives shall be self-
sharpening with hardness 45 to 48 HRC.

 Fibrizer swing diameter shall be up to ¢2150mm with tip speed 85m/sec

and hammers shall be provided with replaceable carbide tips with hardness
63HRC.

 Whole cane Shredder with 95 m/sec tip speed is better option to achieve PI
 Experiments with variable-speed drive for cane preparatory devices

The study of variable-speed drive for cane preparatory devices was conducted by VSI in
two sugar mills and performance parameters are summarised as below.

Speed r/min Preparatory Primary Fibrizer power Mill power Total power
Index (%) Extraction (%) kWh/ tonne consumption consumption
(kWh/tonne) (kWh/tonne)

Case study I

630 81.93 67.11 3.67 6.92 10.59

680 83.74 69.11 3.82 5.86 9.68
730 86.70 70.25 4.04 4.90 8.94

Case study II
730 87 72.10 4.00 4.90 8.90

Source: Proceedings of the International Society of Sugar Cane Technologists, volume 30, 921–927, 2019
 Variable-speed drive for cane preparatory devices

RPM Vs PI
P.I. P.E. MILL POWER FIBRIZER
RPM Vs PE
100
8
RPM vs Power kWh/tonne
6.92

86.7
83.74
90 81.93 7
5.86
6
80 4.9

70.25
69.17
5

Power kWh/ tonne

67.11

3.82 4.04
70 4 3.67
P.I. & P.E. %

3
60
2
50 1

0
40 630 680 730 RPM
630 680 730 RPM
MILL POWER 6.92 5.86 4.9
P.I. 81.93 83.74 86.7
FIBRIZER 3.67 3.82 4.04
P.E. 67.11 69.17 70.25

Change in the preparatory index and primary extraction Power consumption of the fibrizer, leveler and
with a change in fibrizer speed for a 2500 t/d mill mill in a 2500 t/d mill at two speeds.
 Observations on variable-speed drive for cane preparation

 Preparatory index and primary extraction observed increased.

 If the fibrizer motor speed is maintained around 730 r/min (rather than 630
r/min) and fibrizer tip speed at 84 m/s as PI improves from 81.93% to
86.70%.

 The power consumed in the milling station is reduced from 49.46 kWh/t
fibre to 34.98 kWh/t fibre. Thus, for an increase of 5.8% in PI, the power
consumption of the mill tandem decreases by 2.9%.

 VFD system for the fibrizer enhances the efficiency of cane preparation
with overall less power consumption at the cane preparation and milling
 Developments in sugar cane milling for sucrose-rich juice
extraction & power saving
 Higher preparatory index +87% with high bulk density.
 Donnelly chute height 2.5 - 3meter for increasing feed-ability of mills.
 Lotus rollers for top, discharge and top roller of GRPF for preventing juice flooding over
top roller of mills.
 Differential grooving to increase extraction and reduce reabsorption.
 Speed of each mill shall be controlled through DCS with donnelly chute level and load on
respective mills.
 Instead of chevron grooving for top & discharge rollers arcing of rollers is more efficient
which improves feed-ability, extraction & reduces moisture % bagasse.
 The proper trash plate setting and heel clearance for maximum juice extraction &
drainage.
 Installation of additional higher diameter UFR to TRPF/ GRPF (upto 130% higher than
mill roller PCD) for mills, it increases mill capacity as well as primary & overall extraction,
reduces operating speed of mills.
 Developments in sugar cane milling for sucrose-rich juice
extraction & power saving

 Imbibition should be constant and throughout the blanket of bagasse. it shall be

250% - 350% on fibre as per the evaporator capacity and its temperature shall be
75 to 850C.
 Installation of rope/ rope less coupling for free floating of top roller, mill operates at
the designed setting, optimum hydraulic pressure and adjusts for in misalignment.
 Tramp iron separator eliminated damages of cane preparatory devices and mill
roller teeth.
 In investigation obtained 13% sucrose loss due to chemical inversion, 25% due to
enzymes & 62 % due to microbial growth in mills.
 The sugar loss shall be controlled by effective physical and biocide chemical
cleaning. Automatic shock spray of quaternary ammonium compound and frequent
steaming of mills across the dead pockets is more effective.
 Performance of lotus roller
The performance parameters of sugar mill before and after installation of lotus rollers are
summarised in table.
Sl.No Particulars season 2016-17 season 2017-18
1 Roller type Convetional Multi nozzle lotus
2 Flooding Heavy No flooding
3 RME 95 96
4 Pol % bagasse 2.33 - 2.40% 1.89 - 2.00
5 Moisture % bagasse 49 - 50% 48%
Source: International Sugar Journal 3 Jun 2019

 Pol % bagasse reduced by 0.40 unit and moisture % bagasse by 1 unit.

 RME increased by 1unit with no flooding in mills.
 In case sleeve lotus roller, reduction in reshelling cost by 30%.
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 The study of mills with UFR, TRPF and GRPF
The study of milling plants with UFR, TRPF, GRPF were conducted in ten sugar mills and average
performance parameters are summarised as below.

Sl.
Particulars UFR TRPF GRPF
no.
1 Number mills selected for study 04 03 03
2 Mill Extraction 95.03 95.49 96.13
3 Reduced Mill Extraction 95.49 95.73 96.41
4 Imbibitions % Fibre 197.48 201.81 214.05
5 Pol % bagasse 2.62 2.34 1.96
6 Moisture % bagasse 50.41 49.72 49.34
Power consumption for cane preparation
7 6.85 7.93 8.72
(kWh/tonne)
8 Power consumption for milling (kWh/tonne) 7.64 8.13 8.45
Total power consumption for preparation & milling
13.53 16.06 17.17
kWh/tonne
1 Power consumption for milling kWh/t fibre 58.27 61.69 62.55
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 Average performance of milling with UFR,TRPF & GRPF
Reduced Mill Extraction
kWh/t fibre for milling
96.6
63.00 62.55
96.41
96.4
62.00 61.69
96.2
61.00
96
60.00
95.8 95.73
59.00
95.6
58.27
95.49
58.00
95.4
57.00
95.2
56.00
95 UFR TRPF GRPF
UFR TRPF GRPF
Pol % bagasse & moisture % bagasse for milling with UFR,TRPF & GRPF

Chart Title

60
UFR, 50.41 TRPF, 49.72 GRPF, 49.34
50
Pol % & moisture % bagasse

40

30

20

10
UFR, 2.62 TRPF, 2.34 GRPF, 1.96

0
UFR TRPF GRPF
Pol % bagasse 2.62 2.34 1.96
Moisture % bagasse 50.41 49.72 49.34

Pol % bagasse Moisture % bagasse

 Observations on performance parameters for milling with UFR,TRPF &
GRPF
 Mill with UFR has lower primary extraction as well as power
consumption and overall milling performance is less.

 Mill with TRPF has moderate primary extraction and power

consumption.

 Mill with GRPF has higher primary extraction as well as mill extraction.

 The performance of mills with GRPF observed efficient and cost

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The mills with high, low surface speed & shaft mounted pinion
less drive
Mills conventionally operate at 12 to 26 m/minute surface speed and
Indian mills operate in between 8 to 18m/minute.

Two theory are used for selecting mill operating speed

a) Hawaiian theory – This called as thin blanket theory OR high

speed milling which is very popular in Hawaii and Cuba.

b) Javan theory – This called as thick blanket theory and low speed

milling.
 The study of high speed, low speed and shaft mounted pinion
less drive
The study of high and low speed milling technology were conducted in seven sugar mills and
performance parameters are summarised as below .
# Parameter Unit/ case 1 2 3 4 5 6 7
study
Mill Speed High Speed Low Speed
Mills in tandem 5 6 4 5 4 4 4
1 Preparatory index (PI) % 86 82 85.47 84.91 83.89 84.50 85.25
2 Mill speed m/ min 12.81 14.47 12.81 10.81 10.19 8.39 10.89
3 1st mill extraction % 69.50 68.28 69.28 74.28 69.27 72.22 72.18
4 Pol % bagasse 2.13 2.40 2.22 1.74 2.36 2.0 2.25
5 Moisture % bagasse 50.10 50.50 50.15 48.40 51.10 49.80 50.00
6 Imbibition % fiber 199 209 194 214 215 209 245
7 Mill Extraction (ME) % 94.80 95.32 95.24 96.64 95.07 95.40 95.68
8 Reduced Mill Extraction % 95.10 95.72 95.55 96.82 95.24 95.79 96.04
(RME)
9 kWh/ t 9.79 Turbine Drive 8.78 7.22 6.93 5.33
Tandem power cane
10 consumption kWh/ t 74.37 Turbine Drive 66.84 55.92 51.33 39.48
fibre * Individual shaft
mounted mill drive
Source: Proceedings of the International Society of Sugar Cane Technologists, volume 30, 1014–1023, 2019

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 Performance parameters high, low speed and shaft mounted drives

100 Preparatory index (PI) 1st Mill extraction

Mill Extraction RME

96.82
90 86 85.47 84.91 83.89 84.5 85.25

96.64
82
80 74.28
PI/1st Mill extraction/1st Mill speed

72.22 72.18
69.5 68.28 69.28 69.27

96.04
70

95.79
95.72

95.68
95.55
60

95.32

95.4
95.24

95.24
ME / RME

95.07
50

95.1
94.8
40

30

20 14.13 14.95 13.58

10.36 10.2 9.01 10.9
10

0
1 2 3 4 5 6 7 1 2 3 4 5 6 7
High speed Low speed HIGH SPEED MILLS LOW SPEED MILLS
Case study
Case Study
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 Performance parameters high, low speed and shaft mounted drives

74.37
Mill in tandem s & kWh/t fibre

66.84

55.92
51.33

39.48

5 6 4 5 4 4 4
1 2 3 4 5 6 7
Sugar mills
kWh/ t fibre mills in tandem Linear (kWh/ t fibre )

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 Observations on high, low speed and shaft mounted pinion
less drive

 In low speed milling the average pol % bagasse and moisture %

bagasse were reduced by 0.17 units and 0.42 units respectively as
compared to high speed milling.

 Low speed milling consumed 13.85% less power at 25% lower speed
than high speed mills.

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 Observations on individual shaft mounted pinion-less
drive
 Less space required for installation about 50 to 60% and less civil cost.
 Higher extraction efficiency due to free float of top roller RME observed
96+ and due to low surface speed less number of mills required in
tandem.
 Each roller operate at different speed through DCS control system as
per mill load & donnely chute height.
 Less power consumption only 1.0 to 1.3 kWh/tonne of cane for each
mill.
 Reduction in Lubricant consumption by 40 to 45%.
 Less chances of mill jamming.
 Less wear and tear of mill components.
The study of two roller milling technology
The study of two roller milling was conducted in two sugar mills for different manufacturers and
performance parameters are summarised in table.
Sl.
Particulars Unit -I Unit-II
no.
1 Actual crushing rate (TCD) 4920 2200
2 Capacity Utilization (%) 117.14 176
3 Fibre % cane 13.15 12.08
4 Preparatory index 85.30 80.12
5 Imbibitions % cane 40.20 24.88
6 Imbibitions % fibre 305.70 205.96
7 Primary extraction (%) 77.50 71.30
8 Mill extraction (%) 95.90 95.93
9 Reduced mill extraction % 96.14 95.76
10 Pol % bagasse 2.1 2.25
11 Moisture % bagasse 50.10 47.50
Power
kWh/tonne 5.53 3.55
consumed
12
mill
kWh/t fibre 42.10 29.45
tandem
Observations on two roller milling technology

 The primary extraction observed in the range of 71.30

to 77.50% and reduced mill extraction in the range of
95.93 to 96.14%.

 Power consumption for milling observed in the range of

29.45 to 41.10 kWh/ t fibre.

 The two roller mill with shaft mounted pinion less drive
and antifriction bearing helps to achieve lower power
consumption and less moisture % bagasse.
 The Study of diffuser technology for juice extraction
The study of Diffuser technology for juice extraction conducted in four sugar mills and performance parameters are
summarised as below.
Sl. No Particular Unit Unit –I Unit –II Unit –III Unit –IV
1 Diffuser type Fixed screen Retractable Moving screen Moving screen
moving screen
2 Installed capacity MT 4000 3500 2500 exp. 5000TCD 2500 exp. 5000TCD
3 Preparatory Index % 87-88 88 80.48 85-86.5
4 Reduced Diffuser extraction % 97.13 96.17 96.84 96.35
5 Diffuser extraction % 92.55 90.83 92.83 91.16
6 Dewatering mill extraction % 4.58 3.23 3.94 3.21
7 Added water % fibre % 280.55 298.3 251.95 228.5
8 Mixed juice % cane % 108.01 111.7 105.64 101.0
9 Pol% bagasse % 1.23 1.7 1.46 1.84
10 Diffuser moisture % bagasse % 76.50 71.5 71 75
11 Final moisture % bagasse % 54.50 50.67 51 51
12 Final molasses % cane % 4.97 5.02 4.73 Common for mill &
diffuser
13 Steam % cane % 44.82 44.5 53.50 47-48
14 Power consumption for diffuser kWh/tonne 2.98 2.38 1.54 2.72
15 Power consumption for dewatering mills kWh/tonne 3.82( 2 mills) 4.16( 2 mills) 2.17( 1 mill) 1.75( 1 mill)
16 Total power consumption (diffuser + kWh/tonne 6.8 6.54 3.71 4.47
dewatering mill)
17 Total power consumption (diffuser + kWh/t fibre 51.51 41.52 27.38 33.66
dewatering mill)
 Performance of diffuser technology
PI and RDE PC (Di f f u ser + Mi l l )kW h /t f i b re

51.51
120

100 97.13 96.17 96.84 96.35

41.52
88 88 86.5
80.48

33.66
80

27.38
60

40

20

0
Unit-I Unit –II Unit –III Unit –IV
Unit-I Unit –II Unit –III Unit –IV
PI RDE
kWh/t fibre 51.51 41.52 27.38 33.66
Performance of diffuser technology
Moi st u re % bagas s e POL% BAGASSE

54.5

1.84
1.7

1.46
1.23
50.67

51

51

UNIT-I UNIT –II UNIT –III UNIT –IV UN IT - I UN IT – II UN IT – III UN IT – IV

 Observations on cane diffuser technology

The Reduced diffuser extraction is observed in the range of

96.17 to 97.13%.

Pol % bagasse observed in the range of 1.23 to 1.84%.

The power consumption of juice extraction (Diffuser

+Dewatering mill) is observed in the range of 27.38 to 33.66
kWh/t fibre with one dewatering mill and 41.52 to 51.51 for two
dewatering mills.
 Developments to minimise power consumption for cane
preparation, milling and its utilities
 Proper capacity utilization of mechanical & electrical equipment.
 Unloader, feeder tables, carriers, pumping shall be with planetary & AC VFD. To avoid
frictional losses Teflon runners to carriers with proper selection of bearings.
 Cane preparatory devices shall be with variable speed.
 Mills shall have properly selected planetary/ helical gear boxes and VFD for smooth
operation. Individual shaft mounted pinion less drive is energy efficient for mills.
 Antifriction roller bearings instead of bronze/ Ph Bronze journal bearing.
 Rope/ rope less coupling to avoid transmission losses.
 Selection of energy efficient pumps and electrical motors.
 Centralized lubrication system for effective lubrication.
 Cane preparatory devices and milling should be monitored as well controlled as per load
through DCS system.
 Comparative of juice extraction plants

Following are comparative of case studies

Shaft
Low
Sl. No Particular UFR TRPF GRPF mounted Two roller Diffuser
speed
pinion less
1 Reduced mill/ diffuser 95.49 95.73 96.41 95.95 96.04 95.95 96.63
Extraction
2 Pol% bagasse 2.62 2.34 1.96 2.08 2.25 2.18 1.56

3 Moisture % bagasse 50.41 49.72 49.34 49.75 50.00 48.80 51.79

4 kWh/ t fibre of 58.28 61.68 62.55 58.03 39.48 35.76 38.52

extraction plant
 Comparative of juice extraction plants

RME & Moisture % bagasse Pol% bagasse

120 3
RME Moisture % bagasse
2.62
100 95.45 95.73 96.41 95.95 96.04 95.95 96.63 2.5 2.34
2.25 2.18
2.08
1.96
RME & Moisture % bagasse

2
80
1.56
1.5
60
50.41 49.72 49.34 49.75 50 51.79
48.8
1
40

0.5
20

0
0
UFR TRPF GRPF Low pinion Two Diffuser
UFR TRPF GRPF Low speed pinion less Two roller Diffuser speed less roller
Case study
Comparative of juice extraction plants

Power consumption for juice extraction plants kWh/ t fibre

70
61.68 62.55
58.28 58.03
Power consumption kWh/ t fibre

60

50

39.48 38.52
40 35.76

30

20

10

0
UFR TRPF GRPF Low speed pinion less Two roller Diffuser
Case study
 Additional revenue generation by latest developments in milling (Rs. /tonne
of cane)
Shaft
Low
Sl. No Particular UFR TRPF GRPF mounted Two roller Diffuser
speed
pinion less
1 Revenue generation 0 25 58 48 33 39 94
due to improved
efficiency RME/ pol %
bagasse ( Rs./tonne)
2 Revenue generation 0 -2.18 -2.74 0.16 12.00 14.44 12.67
due to power saving (
Rs./tonne)
3 Revenue generation 0 7 11 8 -5.0 16 -11
due to improved boiler
efficiency
(Rs./tonne)
4 Total additional 0.00 29.82 66.26 56.16 40.00 69.44 95.67
Revenue generation in
• Assumptions: Electricity - Rs. 4.75/ unit, Steam % cane- 40%, Sugar Price- Rs. 31/kg,
each case (Rs./tonne) bagasse sale price- Rs. 2/kg. All calculations based on case studies and compared with
UFR
 Additional revenue generation (Rs. /tonne of cane)

120 Total additional revenue generation in each case based on UFR (Rs./tonne)
• Assumptions: tariff - Rs. 4.75/ unit, Steam % cane- 40%, Sugar Price- Rs. 31/kg,
bagasse sale price- Rs. 2/kg. All calculations based on case studies and compared with
100 UFR 95.67

80
69.44
66.26
60 56.16

40
40
29.82

20

0
0
UFR TRPF GRPF Low speed pinion less Two roller Diffuser
 Conclusions
Variable frequency drive for cane preparatory devices improve preparatory index with less power
consumption for preparation and milling.

Thick blanket milling at lower working speed & with shaft mounted pinion less drive improve
sucrose extraction, less power for milling. This is the best combination for efficient milling and is
cost effective.

The two roller mills are suitable as first mill for improving primary extraction and last mill for
reduction in moisture % bagasse.

The diffuser technology is most viable due to higher sucrose extraction in minimum power
consumption and less capital expenditure, It is most suitable and viable for green filed sugar as
well as upcoming juice ethanol projects.
 The author is thankful to Director General Shri
Thank You. Shivajirao Deshmukh for encouraging the study
on “Latest developments in sugarcane milling”.