EFFICIENT MILLING BEE (ORO eG ENMILL TECHNOLOGIES RON sees een cos eel oso SURAJPUR INDUSTRIAL AREA GREATER NOIDA, (U.P) — 201306Sm (aa zebeo vee =e) ae oo ese 1]Cane Feeding [Manual [Cant Titng Wagons OT Ceane [Truck Tepper 2]Cane Preparation |Cuner Fierizer Shredder In Line Shredder = 3 as io 5 ae ¢ = 7| GRPF al [AC Motor VED 9] jpcs } | 1 Shaft Mowacd lPtanctary Gear Bar! 3 Two Roller Mit with GREEFEATURES REQUIRED FOR EXTRACTION EFFICIENCY Optimum Milling Capacity Robust Machinery Cane Preparation = PL90 and above Mill Setting + Adequate compression Mass Flow Variation + Smallest peak and valley Blanket Slippage + Roller adequately rough Optimum Power Consumption : Less kick and serge Low Friction losses Trash plate setting Floating Top Roller Bladder Pressure of hydraulic Imbibition Efficiency = Compound and hot water Differential Surface Speed : To facilitate cell rupture “Oe wae: All functions monitoredSPECIFIC HYDRAULIC PRESSURE IN THREE ROLLER MILL Figure + Resohton of pestures ne tvee Figure 2 fect fash plate reaction onthe rote it yar load = In three roller mill, about 35 Kg/em2 to 60 Kg/em2 is absorbed by'the trash plate which is equivalent to 20 to 30% of the total hydraulic load (Hugot, 1986). He explained the resolution of pressure and effect of trash plate on hydraulic load in the figures 1 & 2 respectively = The remaining only some 75% hydraulic pressures are available to exert the pressures F1 & F2 at the entry and delivery openings. He defined the specific hydraulic pressure is lower to the extent of 35% of “P” being the applied hydraulic pressureEFFECT OF PERMEABILITY & RE-ABSORP’ Figure 4 Squeezing o Bagasse between tee os 8 main three roller mill configuration, despite the permeability is high due to low specific hydraulic pressure, amount of trapped liquid will obviously be£+FECT OF PERMEABILITY AND RE-ABSORPTI Be igure Sqaagng between Four Fematon ovr. FaguteT Darbutan ot & SSS RSE SAT Epes a) ont = The permeability is very low because of high specific hydraulic pressure and consequently trapped liquid will be forced to flow backward. Thus, re-absorption will take place. see ewww eeMASS BALANCE OF A SUGAR MILL WITH COMPOUND IMBIBIT & NUMERICAL MODEL - PAPER WRITTEN BY : EVON CAMP! Periodical Monitoring Mass Balance evaluation of : Individual Mill with software is modern practice‘MILL CONTROL DATA SOFTWARE BY ENMILL ENTER DATA MARKED RED : GRAPH WILL BE GENERATED AUTOMETICALLY = MLS i z a [aR 7.0 z FEED| — Ww. 73a aE A DscH] 1950 | —a28 437 < coueo | 13.66 Tt uaz Tar DAL an Te aim [Por we] em 7 See 7 FEED] — tose se 1 — a DiscH] 16.38 sa a8 mm i ‘COMO | 16.48 520 aa | o_O ae | aes [ror TON a FEED] —es.e0 [e201 a5 | i Disc | —sa00 | e188 73.86 ca coueo] e381 | ws 20.35 Ta |SAGASSE TOT PODS oa] aa Tse “| BAGASSE FREE POL 633 FR 282 taa_| 1 16 Se MOIST ®. Siar} aa 02 sist | — 30.29 Tir frorac Po. % CANE ars | 135 sa75 315. [ 13.75 . 16 [BRE 5 CANE 1290 [1290 4290 [4280] — 1290 18 [WAGER % CANE, 45.20 45.80. 45.80. 45.80 | 45.80 1 te TA BRK, BOL, PTY. BART PUL “Pic MOB Paa@woRra® “Oven unoren “ wELEX ,BRIX CURVEo Individual Mill Extraction Curve is moderate. oa Intermediate mills have wide fluctuation ma exracron SECONDARY MILL EXTRACTION —_——BAGASSE MOISTURE 0 Variation in intermediate Mill is prominentOPEN CELL PERCENTAGE —— o Cell Rupturing 000 Ce 1 0. Individual Mill Open Cell analysis is showing oe [7 that all mills are having positive Cell Rupturing § “* y tc. cones itePOL EXTRACTION wl 0} =|MASS FLOW VARIATION CONTROL 1 simultaneously as seen in green dots Drocore earn ——a bah n:| 8.6) i 52 iog TBE Kam C82 say OB rye B25 aye COB pn CTS any MIB rom G72 arp ~ ‘ JMG be AO, ATG, O19 on) 400sDRIVE OPTIONS: 1 : Foot mounted pla gear with square couplingFoot mounted planetary gea Pr ee TaigDRIVE OPTIONS - SHAFT MOUNTED PLANETARYGROOVED ROLLER PRESSURE FEEDER (GRPF)40”X80” €NMILL_ "22"X84" GRPF Pressure Chute under assembly at shop floor 42X84” GRPF Pressure Chute plate at boring machine for surface machining 42°X84” GRPF Pressure Chute plate Stainless Steel LiningUFR Bearing 'JGRPF Pressuge Ghyte, , Water Cooled F Prespuge Chutes 6 CDor Be: ingHEAVY DUTY SHREDDER AND FIBRIZERTWO ROLLER MILLSPECIFIC HYDRAULIC PRESSURE IN THREE ROLLER MILL VS TWO ROLLER MILL MILL. ———— Figure 3 Resolution of pressures ina two rl mil = From figure 3, in two roller mill configuration, it is self explanatory that no loss of applied hydraulic pressure ‘P’ is taking place and the specific hydraulic pressure will be significantly greater. Hence, 100% of the hydraulic load applied to the top roller is transferred to the bottom roller and used for extracting juice.THigh Crushing Capacity High Extraction Efficiency Lower Maintenance ond spare parts eost High Imbibitions Efficieney Figure To RelerEoml Berston Ml Figure 9 Two eer Eom Exraten Mt Difforentiol Speed of Rollers sin rere fae Hydraulically Loaded Top Roller 1 Re-absorption Control Device ‘Automation Lower Investment Cos nd Higher Retuen ron osc, Gren ede onan ween Implementation of energy . oo ow eetficient drivesFigure 14 Automation Figure 15 Feeding Career Figure 16 Donnelly Chute level Setup Speed Control Control The mill is totally automated to maintain consistent juice extraction and cover up the variation in the blanketMILLING TANDEM Kg | ie HE —_ __ Ki Figure 24 Layout of Two-roller Enmill Extraction Mil Tandem A Five Mills Tandem consisting of Two Roller Enmill Extraction Mill is energy efficient model. The first and last mills will be provided with light duty Grooved Roller Pressure Feeder to optimise results upto 96.5 RME. This tandem can achieve upto 15000 TCD with 45°X90" rolley size, 5 oe ee eeWORKING RESULTS Detail on Power Consumption POWER CONSUMPTION, Mill Size_| Installed Power | Consumed Pawar TOR Sugars Lia a2xea | 31S KW 250 KW 2 Reeerenienceass «Kao! | __soRW 3. Sagar Sugar & Allied Products Lid | a2" Kea" | 375 KW TeoKw FTSGEG PCL Biofuels Lid — Sugaull | 40K ao" | a0 KW BAO RW 5. ISGEG -HPCL Biofuels Lid — Lauriya | 40° 80" woo KW TOR ‘The comparison of working results before and after installation of Two Roller Enmill Extraction Mill in operation is carried out in different sugar to observe and record the performance and behaviour of the mill Note that the absence of trash plate eliminates irictional Joss. result mien eovvcecg506¢4 ig in 30% low powerENM. Working Results There is an enormous increase in cane crushing with reduced percentage of pol and moisture in the bagasse Results of JK Sugars Ltd Parameters Before After First Season of =n Installation Installation TOD 4600 5400 Maximum Crush 5070 5680 Pol % Bagasse 200 185 Moisture % Bag 50.24 49.89Working Results Results of Kesar Enterprises Ltd Parameters Same ‘Aor Fisk Season oF Installation ‘hotaiston = eB) e300 e300 Maximum Crash [sera 7370 barse Bag ai 7°30 Hioreturs Sc Bags se soc} Results of Sagar Sugar & Allied Products Ltd Parameters [sii sslnion | Afr Fret Sesser of sialaion TeD : 3000 ~ 3800 Maximum Crush 3320 : 3870 Pol % Bagasse 1.33 f a4 Moisture % Bagasse 52 (4) 49 C) eo ee ee weesResults of Kesar Enterprises Ltd Bolt Bagasse 217 380. Molsture % Gagasse BO. BoC Results of Sagar Sugar & Allied Products Ltd Before installation | After First Season of installation TeD Maximum Crush Bagasse Cranial