pt indocode surya

CHAPTER IX

THE CALCULATION OF MILL MATERIAL BALANCE

Besides the analyses of juice extracted by each mill and for the last mill bagasse, another data
also required such as the analysis / quality and the amount of cane crushed, the total crushing
hours, the total mixed juice and the total imbibition water consumed.
Also the technical specification of each roller in use, such as the outside diameter, inside
diameter, the groove correction, average actual roll rotation per hour, the dimension of work
opening when set and the ratio between the feed and delivery work openings as well.
Furthermore, the definitions and the units used have to be agreed consistently. The system use
kg/hour for the weight units, dm3/hour for the volume units and kg/dm3 for the densities.
An example for the use of all the formulas derived and described in previous Chapters for the
calculation based upon the following data is presented below (using the average or totaled data
obtained from the operation):
Sugar Factory
Mill train
Milling season / year
Period of 15 days, number
I. MILL ROLLERS IN USE
MILL
Outside diameter (Do):

Groove correction (k):

Mean diameter (Dk):

Roller/Shell length
Actual roll rotation per hour
Mill settings:
- Delivery work opening
- Ratio of hf/hd
- Top roll lift
- Top angle

EXAMPLE
2 CC + 5 MILLS
1977
X

top
feed
delivery
top
feed
delivery
top
feed
delivery
L
rpj

The Calculation of Mill Material Balance

hd
i
t

(dimension in mm)
I
II
1.052.0 1,073.0
1,066.8 1,066.8
1,066.8 1,066.8
25.0
25.0
25.0
25.0
25.0
25.0
1,002.0 1,023.0
1,016.8 1,016.8
1,016.8 1,016.8
2.133
2.133
268
244
41.23
2.20
6.0
78

36.33
2.00
6.0
78

III
1,051.0
1,066.8
1,066.8
15.0
15.0
15.0
1,021.0
1,036.8
1,036.8
2.133
216

IV
1,050.0
1,066.8
1,066.8
15.0
15.0
15.0
1,020.0
1,036.8
1,036.8
2.133
191

V
1,064.0
1,066.8
1,066.8
15.0
15.0
15.0
1,034.0
1,036.8
1,036.8
2.133
193

27.79
2.00
6.0
78

26.14
2.00
6.0
78

24.62
2.00
6.0
78

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pt indocode surya

II, CRUSHING INFORMATION

Cane:

crushed, total
Q
4,351 TCH = 181,291 kg/hour
crushing hours
jg
24.00 hours
pol
pt
10.32 %
brix
bt
13.41 %
fiber
f
16.07 % cane
Mixed juice:
gross
Gnm
3,718.7 Tons = 154,947 kg/hour
corrtn
knm
1.003076
brix
bnm
14.69 %, pol =
11.40 %
Imbibition water, total:
Gi
843.1 Tons =
35,128 kg/hour
Applied on: bagasse 1
0 %
bagasse 2
0 %
bagasse 3
0 %
bagasse 4
100 %
Fiber density, average = 1.53924 kg/dm3
III, AVERAGE JUICE ANALYSES
MILL
Juice:
brix
bn
pol
pn

I
17.46
14.05

II
12.48
9.29

III
8.90
6.45

IV
5.75
4.06

V
2.94
2.00

First we calculate the value of items based on the main formula of mill material balance:
Cane + imbibition water = mixed juice + bagasse
Whereas:
Cane,

the total cane crushed, constitutes the crushing capacity, the value known from
the result of weighing, in kg/hour,
Imbibition water, the total water used to dilute sugar in the milling process, the amount
known from the weighing or measurement, in kg/hour,
Mixed juice, the total juice extracted by mill#1 and mill#2 and the amount known as the result
of weighing or measurement after deduction of the dirt content, in kg/hour,
Bagasse,
the residual material from the cane milling process after the juice extracted
optimally, in kg/hour,
4,351 x 1000
---------- = 181,291 kg/hour
24
Imbibition water
= 35,128 kg/hour
Mixed juice
= 154,946 kg/hour
Bagasse
= 181,291 + 35,128 - 154,946
= 61,473 kg/hour
The next calculation follows the items grouped to each mill unit in the tandem,
Cane

The Calculation of Mill Material Balance

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pt indocode surya

The input portion:

Cane for mill#1 or bagasse for the following mills, each containing juice and fiber,
The output portion:
Consist of extracted juice and bagasse, where the bagasse itself containing juice and fiber,
The following form is use for the mill material balance:
Description
MILL#1
- Juice
- Fiber
Total input
Extracted juice
- Juice
- Fiber
Total bagasse
MILL#2
- Juice
- Fiber
Total input
Extracted juice
- Juice
- Fiber
Total bagasse
MILL#3
- Juice
- Fiber
Total input
Extracted juice
- Juice
- Fiber
Total bagasse
MILL#4
- Juice
- Fiber
Total input
Extracted juice
- Juice
- Fiber
Total bagasse
MILL#5
,,,,,,,,,, etc, ,,,,,,

Mass
kg/hr

%brix

Brix
kg/hr

%pol

Pol
kg/hr

Density
kg/dm3

Volume
dm3/hr

Miscellaneous
Dk =
L =
n =
h =
i =
Vlbo=
Vlb =

r =
r =
=
h' =
K =
HKnp=
kB =

Dk =
L =
n =
h =
i =
Vlbo=
Vlb =

r =
r =
=
h' =
K =
HKnp=
kB =

Dk =
L =
n =
h =
i =
Vlbo=
Vlb =

r =
r =
=
h' =
K =
HKnp=
kB =

Dk =
L =
n =
h =
i =
Vlbo=
Vlb =

r =
r =
=
h' =
K =
HKnp=
kB =

The result of calculation is directly filled to the form as shown above,

The Calculation of Mill Material Balance

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pt indocode surya

The description and meaning of the abbreviations:

Dk = mean diameter of the top roller, in dm
L
= roller / shell length, in dm
n
= actual rotation of the top roller per hour during the milling of cane
h
= delivery work opening, actually when set
i
= ratio of feed and delivery work openings, actually when set
Vlbo = the escribed volume of the delivery work opening in dm3/hour, the volume escribed by
the actual height (h) of the delivery opening based on the following formula:
Vlbo = . Dk . L . n . h
Vlb = the no-void volume of bagasse passing through the delivery opening, in dm 3/hour (see
formula 15)
Ga
Vlb =
ds
r
= absorption ability factor (see formula 13)
Va
r =
Vlb
r'
= normal absorption ability factor (see formula 18)
ds . Vlb - (ds - dnp) Vs
r'

dnp . Vlb
= coefficient of friction for bagasse and the mill roller (cast iron/steel, see formula 19)
= 0.43 - . Dk . n

60 x 1524
h'
= the average actual work opening
Vlb
h' =
. Dk . L . n
K
= compression ratio / value
Vm
K =
Where Vm = no-void volume of input portion
Vlb
HKnp = purity of the extracted juice
%pol of extracted juice x 100
HKnp =
%brix of extracted juice
kB = Brix distribution coefficient
Bnp . Gnm
kB =
Bnm . Gnp
Where:
Bnp = weight of brix in extracted juice
Bnm = weight of brix in juice of the input portion
Gnm = weight of juice of the input portion
Gnp = weight of the extracted juice
The Calculation of Mill Material Balance

IX- 4

pt indocode surya

We begin from:
MILL#1
The input portion:
- Juice

181,291 - 29,133

- Fiber

0.1607 x 181,291

29,133
1.53924

Total input (cane)

- The no-void volume of fiber

152,158 kg/hour

29,133 kg/hour
------------=
181,291 kg/hour
18,926 dm3/hour

The weight and no-void volume of fiber calculated above each has its same value for the other
mill unit respectively (the value of Gs and Vs),
Further we calculate:
The weight of Brix in cane

0.1341 x 181,291

24,311 kg/hour

The weight of Pol in cane

0.1032 x 181,291

18,709 kg/hour

- %brix of juice in cane

24,311 x 100
152,158

- The density value obtained from the table x 1.01

15.98

1.07138 kg/dm3

- Volume of juice in cane

152,158
1.07138

142,020 dm3/hour

- Total volume

142,020 + 18,926

160,946 dm3/hour

- %pol juice in cane

18,709 x 100
152,158

- The cane density

181,291
160,946

1.12641 kg/dm3

68,761 kg/hour

12.30

The output portion consist of:

a, Extracted juice:
- the amount

154,947 x

14.69 - 12.48
17.46 - 12.48

- %brix known from the analysis

- The density value obtained from the table x 1,01

The Calculation of Mill Material Balance

17.46
1.07788 kg/dm3
IX- 5

pt indocode surya

- The volume

68,761
1.07788

63,792 dm3/hour

- Weight of Brix

0.1746 x 68,761
1.003076

11,969 kg/hour

- Weight of Pol

0,1405 x 68,761
1,003076

9,631 kg/hour

- Juice content

152,158 - 68,761

83,397

kg/hour

- Juice volume

142,020 - 63,792

78,228

dm3/hour

- Juice density

83,397
78,228

1,06608

kg/dm3

- Bagasse weight
- Bagasse no-void volume

=
=

83,397 + 29,133
78,228 + 18,926

=
=

112,530
97,154

kg/hour
dm3/hour

- Bagasse density

112,530
97,154

1,15826

kg/dm3

- Brix in bagasse juice

24,311 - 11,969

12,342

kg/hour

- %brix of bagasse juice

12,342 x 100
83,397

- Pol in bagasse juice

18,709 - 9,631

- %pol of bagasse juice

9,078 x 100
83,397

- Brix in bagasse

Brix in bagasse juice

- %brix of bagasse

12,342 x 100
112,530

- Pol in bagasse

Pol in bagasse juice

- %pol of bagasse

9,078 x 100
112,530

b, Bagasse:

14,80
9,078

kg/hour

10,89
12,342

kg/hour

10,97
9,078

kg/hour

8,07

Further well find:

Vlbo = 3,14 x 10,02 x 21,33 x 268 x 0,4123

- No-void volume of bagasse passing through the delivery opening:

112,530
Vlb =
=
1,53924
The Calculation of Mill Material Balance

74,154 dm3/hour

73,108

dm3/hour
IX- 6

pt indocode surya

- The absorption ability factor:

1,53924
1,15826

r =

- The normal absorption ability factor:

r' = 1,53924 x 73,108 - (1,53924 - 1,07788) x 18,926
1,07788 x 73,108
- Calculated coefficient of friction:
=

0,43 - x 10,02 x 268

60 x 1524

1,3289

1,3172

0,34

- Average of actual delivery work opening:

h'

73,108
3,14 x 10,02 x 21,33 x 268

0,4065 dm

- The compression ratio:

160,946
73,108

14,05 x 100
17,46

80,47 %

11,969 x 152,158
24,311 x 68,761

1,089

K =

2,20

- The extracted juice purity:

HKnp =
- The Brix distribution value:
kB =

MILL#2
If in mill#1 the calculation begins with the input portion, then it is not for mill #2 and the other
mills, Here, the calculation starts from the back side (the output portion), first with:
a, Bagasse:
- its weight,

Ga2 = 1,53924 (1,53924 - 1,05646) x 18,926 =

1,53924 - 1,3172 x log 9,81 x 1,05646

- its juice
b, The extracted juice:
- its weight
- the Brix

88,316 kg/hour

88,316 - 29,133

154,946 - 68,761

86,185

kg/hour

0,1248 x 86,185
1,003076

10,723

kg/hour

1,05646

kg/dm3

- the density obtained from the table x 1,01

59,183 kg/hour

- its volume

86,185
1,05646

81,579

- the Pol

0,0929 x 86,185
1,003076

7,982

The Calculation of Mill Material Balance

dm3/hour
kg/hour

IX- 7

pt indocode surya

c, The input portion:

- the juice weight

59,183 + 86,185

145,368 kg/hour

- total input

145,368 + 29,133

174,501 kg/hour

The juice in the input portion of mill #2 consisting of bagasse juice of mill #1 plus the juice
extracted by mill#3 (the imbibition juice), and so:
- The juice extracted by mill#3

145,368 - 83,397

- %brix obtained from the analysis

- the density obtained from the table x 1,01

61,971 kg/hour
8,90
1,04191 kg/dm3

- the volume

61,971
1,04191

59,478 dm3/hour

- the Brix

0,089 x 61,971

5,515 kg/hour

- the Pol

0,0645 x 61,971

3,997 kg/hour

Lets go back to the juice in the input portion of mill#2:

- its volume

78,228 + 59,478

137,706 dm3/hour

- the Brix

12,342 + 5,515

17,858 kg/hour

- its %brix

- the Pol

- its %pol

13,075 x 100
145,368

- the density

145,368
137,706

1,05564 kg/dm3

- its volume

137,706 + 18,926

156,632 dm3/hour

- its %brix

17,858 x 100
174,501

10,23

- its %pol

13,075 x 100
174,501

7,49

- its density

174,501
156,632

17,858 x 100
145,368
9,078 + 3,997

=
=

12,28
13,075 kg/hour
8,99

And also back to the total input:

The Calculation of Mill Material Balance

1,11408 kg/dm3

IX- 8

pt indocode surya

At the bagasse portion:

- the volume of bagasse juice

137,706 - 81,579

56,127 dm3/hour

- density of bagasse juice

59,183
56,127

1,05445 kg/dm3

- the Brix in bagasse juice

17,858 - 10,723

7,135 kg/hour

- %brix of bagasse juice

7,135 x 100
59,183

12,06

- the Pol of bagasse juice

13,075 - 7,982

5,093 kg/hour

- %pol of bagasse juice

5,093 x 100
59,183

- the volume of bagasse

56,127 + 18,926

75,053 dm3/hour

- the Brix of bagasse

the Brix of bagasse juice

7,135 kg/hour

- %brix of bagasse

7,135 x 100
88,316

- the Pol of bagasse

the Pol of bagasse juice

- %pol of bagasse

5,093 x 100
88,316

- the density of bagasse

88,316
75,053

8,61

8,08
5,093 kg/hour
5,77
1,17672 kg/dm3

Further well find:

- the escribed volume of the delivery work opening:
Vlbo = 3,14 x 10,23 x 21,33 x 244 x 0,3633 =
- the volume of bagasse passing through the delivery opening:
88,316
Vlb =
1,53924

60,737 dm3/hour

57,376 dm3/hour

75,053
57,376

1,3081

1,3172 x log 9,81

1,3062

0,43 - x 10,23 x 244

60 x 1524

0,34

- The absorption ability factor:

r =
- The normal absorption ability factor:
r' =
- The calculated coefficient of friction:
=
The Calculation of Mill Material Balance

IX- 9

pt indocode surya

- The average actual delivery work opening:

h' =

57,376
3,14 x 10,23 x 21,33 x 244

0,3432 dm

- The compression ratio:

156,632
57,376

9,29 x 100
12,48

74,44 %

10,723 x 145,368
17,858 x 86,185

1,013

K =

2,73

- The extracted juice purity:

HKnp =
- The Brix distribution value:
kB =

The sequence and method of calculation for the next mill is the same as for mill #2, But not for
the last mill, where the weight of bagasse should not be calculated as for the amount of bagasse
in mill#2 and the ensuing mill, because the weight of the last mill bagasse is already calculated
before hand at the start of this calculation,
Further, we have to pay attention for the last mill calculation, that the total juice in the input
portion is the sum of bagasse juice contained in the ultimate mill plus the amount of imbibition
water applied to the corresponding bagasse,
If imbibition water applied not only on bagasse before the last mill, then the total juice incoming
to the respective mill also the sum of juice containing the bagasse from the ultimate mill and the
imbibition water applied to the respective bagasse,

The Calculation of Mill Material Balance

IX-10