Chapter No.

DESIGN AND OPTIMIZATION OF OPERATING

I PARAMETER OF MILL
7.1 Introduction
Sugar mill capacity & efficiency is totally depends upon the mechanical behaviour
& of mill components like no. of mills in tandem, roller diameter with peripheral speed
grooving on rollers, underfeed devices, cane preparation etc. seven operating parameters
like type of cane with fibre index, cane preparation index, purity of juice, imbibition's
water used etc.

The power is a function of the tonnage of fiber treated & the unit is indicated
hoarse power per tonne per hour (i.h.p. / l.f.h) or per tonne
Of cane per hour Q.h.p I t.ch)

Power Requirement Of Mill For 15 to 18 roller

Sr. tandem
Author
No
Ihp/Tch Ihp/Tfh
1 Deer 3.3 - 4.4, average 3.7 26 - 34, average 29
Java Hawaii
2 Maxwell
26-30 30 approx.
3 Tromp 15-51,
average 28
Table 7.1 Power Requirement of Mill For 15 to 18 roller tandem
7.2. Mill capacity depends upon
1. Fibre index
2. Cane preparation
i
3. Number of mills in tandem
4. Grooving adopted
5. Roller surface
6. Use of feeding devices
7. Speed (peripheral)
7.3. FORMULA FOR MILL CAPACITY

A=0.9*C*n*(l-.06nD) L*D*N/F
A=TCH
C=1.13 for fiberizer
n= speed of mill in RPM
-: 180
 N=no of rollers in tandem
D=Diameter of roller in meter
L=Length of roller in meter
F=Fiber % in cane
G=n(l-.06nD)*LD
Gm=(N-l)*Gl+G2+G3+ GN/2*(N-1)

Gl=n(l-.06nlDl)*Ll*Dl 2

=5(1-0.06*5*0.981)* 1.981*1.00002

=6.989
G1=G2=G3=G4=G5=6.989
G mean =6.989
A= 0.9CGm*VN/F=0.9* 1.18*6.989* Vl 5/0.14=205.33
A=205.33 TCH
MILL CAPACITY= A=205.33 TCH
If 24 hrs then A= 4927.92 TCD
7.4 Power Requirement

DATA
1. Roller Size= 981* 1981 *mm
2. Mill Speed =4.53
3. Crushing Rate =200TCH
4. Fiber % cane =14
5. Fo/Do=2.57
6.To/Fo=1.93
7. Reabsorption =1.4
8. P.I= 85
9. Coefficient of friction bearing =0.1
10. Coefficient of friction between trash plate =0.35
Fo=49
Do=19
To=95
Fiber kg/min= TCH*Fiber %cane * 1000/60
=200*0.14*1000/60

=466.67 kg/min
F.I= Fiber kg/min
Surface speed * roller length
-: 181 :-
 F.I=466.67/14*1.981

F.I= 16.826 kg/m3

7.5 Reabsorbtion factor at discharged roller

r =0.65+0.0052*48.95+0.01*48.92

=1.39

r=6r-5/Vr(l+Vr-l)

r=1.74

Specific Opening =VDo/D

7.6 POWER CONSUMPTION OF MILL

1 Compression of bagasse Pl=0.5FnD (6Y-5)/(V(1+VY-1)VEA

The friction between the shaft & bearing &

2 P2=2/l.9*0.4 FnD= 0.4 FnD
rollers

3 Friction between bagasse & trash plate P3= 0.035 FnD

4 Friction between the scrapers P4=LnD

Table 7.2 Power Consumed By Mill Elements

The power consumption depends upon the hydraulic pressure chosen on the speed
at which it is operated & corresponding fibre loading. From above equation of power
consumption the product FnD is to be optimize . 'F' is the hydraulic pressure it is
increased more then it will create more stress & strain on crushing component. Therefore
the product nD is to be controlling factor in the power consumption. In mill setting the
average of three diameter are taken for keeping maximum rate of crushing. Then only
variable is the 'n' i.e. speed of the shaft peripheral speed of the roller. The higher speed of
the shaft will give more crushing rate per hour but extraction of juice is getting affect.
Also speed is directly proportional to wear. Therefore to reduce wear or power
consumption in overcoming friction the speed is to be minimum / optimize. There is very
snkall effect on power consumption (4-5 %) by increasing of the crushing rate by 25%
Therefore it is necessary to work with thickest possible bagasse blanket. The economic
rotational speed & peripheral speed is inversely to the diameter of the roller Nc or Vc &
(1/D)

-: 182:-
7.6.1. Power absorbed for compression of bagasse

PI =0.4*(6r-5)*V£A*n(mill speed)*D*f/(Vr (l+(Vr-l)))

PI =0.4*1.74*4.53*0.981*0.15*340

=158.06HP

7.6.2. Power loss due to friction in mill bearing

P2 =1.9*f*1000*fl*n*dj*n/60*75

Fl =0.1 for gun metal bearing

P2 =1.9*340*981*0.1*3.14*0.460*4.53/60*75

=92.14 HP

7.6.3. Power in dragging bagasse over trash plate

P3 =0.25*1000*f*f2*2*3.14*TR*n*0.75/75*60

F2 coefficient of friction between bagassse and steel=0.35

TR =595 mm

P3 =0.25*981*340*0.35*2*3.14*0.583*4.53/60*75

=107.56 HP (19.65%)

7.6.4. Friction in Screeping and bagasse power required

P4 =2*L*n*D

=2* 1.981*4.53*.981
P4 =17.6HP

Total Power required at square end of roller

=P1+P2+P3+P4
=158.06+92.14+107.56+17.6
=375.36HP

-: 183 :-
7.6.5. Power absorbed in gearing arrangement
Considering 18% loss of power in the gearing arrangement at square end roller
P5 = 375.36 HP *0.18
= 67.56 HP (Thus the total power requirement =442.92 HP
TFH=TCH*Fiber %cane=200*0.14
TFH=28
HP/ TFH = 442.92/28
HP/TFH=15.81
HP/TCH=442.92/200
=2.21HP/TCH
7.6.6 Summary of total power & power consumed at different components of milling
with percentage.

1) Total HP required =442.92 HP (100 %)

2) For one ton crushing /HP =2.21 HP

3)HPATFH =15.81 HP

4) Power of compression baggase =158.06HP (35.68%)

5) Power of overcome friction in mill bearing =92.14HP (20.8%)

6) Power in dragging baggase over trash Plate = 107.5 6HP (24.2%)

7) Power for overcome friction of scrapper =17.6HP (3.97%)

8)iPower loss in gearing =67.56HP (15.25%)

Discussion:-From the above calculations it is seen that power consumed for one tonne of
crushing per HP comes to 2.21 against 3.7 derived by author Deerr. Also the IHP per
tonne of fibre per hour is 15.81 against the average given by authors Deerr; Maxwell &
Tromp are 29, 28-30 & 28 respectively. It proves that the mill speed taken for above
calculations gives minimum / optimum values of minimum power consumption &
maximum extraction.

Data of turbine & mill test conducted from First Mill of Padmashree Vitthalrao
Vikhe Sahakari Sakhar Karkhana Limited, Pravaranagar.

-: 184:-
 STEAM
BHP RPM TORQUE
CONSUMPTION
1650 0
2000 55
2500 70
3000 120
3500 180
4000 200
4500 240
5000 280
5500 330 3540 450
6000 375 3600 445
6500 420 3700 440
7000 465 3800 435
7500 510 3900 430
8000 550 4000 425
8500 595 4100 422
9000 640 4200 416
9500 680 4300 412
10000 725 4400 408
10250 750 4450 406
10500 750 4500 404

PERFORMANCE OF MILL TURBINE OF 750 BHP

TORQUE AT GEAR OUTPUT SHAFT(KG/M)

400 410 4 £ 0 £ 3 0 4 4 0 4 5 Q , „ ,
11000 ——•—• • *™ • 14600
•4500
4400

s
z
o
o

100 200 300 400 50?P 600 700 750

OUTPUT(B.H.P.)

-: 185 :-
 Fig. 7.1 Performance characteristic of 750 bhp turbine

7.6.7 Statement of the Problem

To optimize the operating parameters of sugar mill speed is the variable all the
setting & all other parameters depends on speed as seen from calculations for mill settings.

From the graph of steam consumption Vs output BHP it is seen that graph is linear
so it's equation can be written in the form Fl(y) = m x + c >=0 as

y = 493.68x+1057.9 or

y=493.68x=1057.9 (1)

Subject to the constraints x>=0 & y>=0

Also, y>=1650 andx>=0

<=10500andx<=750

For the graph of Torque Vs Turbine speed the nature of curve can be considered as
two degree polynomial in the form of F2(x) = ax2 + b x + c > =0 as

y = -2.0979x2+118.81x + 3470 or

y+2.0979x2- 118.81x=3470 (2)

Subject to the constraints x>=0 & y>=0

Also, y<=4500 and x >= 404

y>=3540andx <=450

As there are only two governing equations with constant, only the intersection
point is the feasible solution. So the corresponding values are[50]
i Steam Consumption 7770 kg/hr

Turbine Speed 3950 R.P.M

Brake Horse Power 530 B.H.P

Torque 425 KG-M

Discussion: - The steam consumption, turbine speed, brake horse power

& torque obtained from the trial & from the graphical method of linear
programming problem are valid for the performance parameters of mill
turbine.

-: 186:-
 Mill Settings
7.7 Introduction
It consists of selecting the most favorable positions to be given to the three rollers
and the trash plate in order to obtain the best conditions for the feeding the cane and to
obtain maximum extraction the relative position with the mill empty determine those when
operating, when the top roller lift against the hydraulic pressure under the thrust of the
baggase.

% There is an optimum ratio between the two openings for a given set of conditions.
It\s the question of determining this ratio. This problem does not allow of a mathematical
solution, the adjustment is in reality an art, based on empirical considerations . Still it
consist of some calculations if logical and optimal solution is to be obtained. It is always
the delivery opening that is calculated first, the feed opening is next calculated according
to the values found. The opening is expressed as those between the mean diameters of the
rollers considered. The opening is represented by the distance between any two points on
the surface of the two rollers, situated in their common axial plane & in the same plane
perpendicular to the two axes
7.1 Different methods are adopted for mill settings are:
7.1.1 JAVA METHOD
1. Choice of the mill speed.
2. Calculation of the delivery opening.
3. Calculation of the feed opening.
The Java method is totally depends upon the thickness of baggase blanket in each
type of tandem, from first to last mill. Grams of fibre per square decimeter area described
by a generatrix of the roller. The thickness of baggase is proportional to diameter. The mill
speed should be taken which would give a baggase layer corresponding to that is given in
experimental table. The Java method is equally applicable to the mills operating at higher
speeds with fibre index rather than the fibre loading .For optimal values it is recommended
that the best figures for fiber in baggase & hence the best individual mill extraction were
obtained the mills which delivery opening when operating was designed for the ratio
grams of fibre per decimeter cube divided by fibre per unit of baggase for the mill
considered is equal to 1.75 kg/dm .

-: 187:-
7.1.2 Hugot method
The speed of mill is fixed by crushing to attain a given tonnage. The speed may be made
constant throughout the tandem decreasing from the first to last mill or better, slightly
increasing. In the setting calculation the reabsorption factor, fiber index, volume of
baggase passing through the delivery opening, density of bagasse etc. are taken into
acpount.

7.2 Mill Setting Calculation: -

DATA:

TCD =4800 ,Fiber =14%, Fiber loading=466.67kg/min

Mill Top
Turbine
Mill no Surface speed Roller
(rpm) (rpm)
Lift(mm)
1 14.5 4.53 10 4200
2 13.78 4.57 10 3700
3 13.40 4.57 8 3700
4 14.92 4.63 7 3400
5 14.32 4.5 7 3600
Table 7.2 Data ofP.D. V. V.P.S.S.K. Ltd. For mill setting

Fiber loading in kg/min(X)

X=Fiber (kg/min)/Surface speed(m/s) *roller length (m)

Discharge work opening in mm.

1. Xl*1.75
2. X2*1.53
3. X3*1.31
4. X4*1.09
5. X5*0.87

Xl=466.67/14.5 * 1.981=16.24
X2=466.67/13.78*1.981=17.09
X3=466.67/13.40*1.981=17.58
X4=466.67/14.92* 1.981=15.78
X5=466.67/14.32* 1.981=16.45
Discharge work opening = (Fibre loading escribed volume factor)-Lift
Dl=16.24*1.75=28.42-10=19
D2=17.09*1.53=26.14-10=16
-: 188:-
D3=17.58*1.31=23.03-8=15
D4=15.78*1.09=17.20-7=10.5
D5=l 6.45*0.87=14.37-7=7.5
Feed work opening =(Discharge work opening*Feed to Discharge Ratio)- Lift
of roller
F 1=28.42*2.00=56.84-10=47
F2=26.14* 1.95=50.97-10=41
F3=23.03* 1.9=23.75-8=36
F4= 17.20* 1.85=31.82-7=25
F5=14.31*1.8=25.75-7=19

Mill Setting are

Mill 1=47/16

Mill 2=41/16

Mill 3=36/15

Mill 4=25/10.5

Mill 5=19/7.5

Geometry ot Mills

Fig. 7.2 Illustrate the different mill setting

-: 1 8 9 : -
 METHOD Sanjivani PSSK JAVA HUGOT SUGARTECH
MILL D. F.O D. F.O D. F.O D. F.O D.O
F.O O O O O
NO.
Milll 53 23 47 16 59 21 60 16.5 61 26
Mill 2 43 18 41 16 39 16 36 9.6 44 18
Mill 3 38 16 36 15 34 14 30 7.7 33 12
Mill 4 32 13 25 10.5 29 13 24 6 25 8
MillS 28 11 19 7.5 30 13.5 23 5 21 6
Table 7.3 Results of different mill settings

Fig. 7.3 Graphs of Feed & Discharge Openings Vs Mill No.

GRAPH OT DISCHARGE OPENING

GRAPH OF FEED OPENING

s^N.

u
» PSSK
1

f:
PSSK iV.A
.IAVA HUGOT
HUGOT . SUGARTECH
-SUGARTECH

i*
8
^ ^ = ^ ~ I

7.6.7 Discussions:-
I. The feed & discharge openings of sugartech shows continuous drop in openings.
II. The Sanjivani shows the feed opening linear & discharge opening disturbed.
III. The JAVA shows non linearity in feed & discharge opening i.e. the slope of graph is
constant.
IV. PSSK shows uniformity in slope with little variation.
V. HUGOT shows non linearity i.e. slope is almost constant for feed & discharge opening.
7.6.8 Conclusion:-

In PSSK-1 feed setting is ok but discharge is not linear because of the discharge roller
diameter.
In PSSK-2 the feed & discharge openings slopes are almost same i.e. the compression of
bagasse at every mill for extraction is same. The extraction achieved by those settings is
96% The setting is based on fibre loading method.

-: 190:-