Bilagi Internship
Bilagi Internship
Bilagi Internship
Undergone at
BILAGI SUGAR MILL LIMITED, BADAGANDI
Submitted by
G. Priyanka
2BA20EE021
Basaveshwar
Engineering
College
Bagalkot-587102, Karnataka
Certificate
This is to certify that the Internship titled “Process of manufacturing sugar and
generating electricity” is carried out by Miss. G Priyanka, (USN: 2BA20EE021),
at Bilagi Sugar Mill Limited, Badagandi. This report satisfies the academic
requirements with reference to Internship work prescribed for VII semester for
the award of Bachelor of Engineering degree in Electrical and Electronics.
I express sincere gratitude to Dr. S. S. Injangeri (Principal) and Dr. D. S. Jangamshetti (Head
of the Department Electrical and Electronics Engineering), Basaveshwar Engineering
College, Bagalkot for his support and encouragement.
I take opportunity to thank BILAGI SUGAR MILL LIMITED, BADAGANDI for providing a
wonderful environment in their industry.
I express sincere gratitude to Mr. Manjunath Meti (Management Co-ordinator) and Co-Gen
Employees of BILAGI SUGAR MILL LIMITED, BADAGANDI for permitting us to make use of
the facilities available in the industry to carry out the industrial training/internship
successfully.
- G. Priyanka
Abstract
sugar is one of the oldest commodities in the world. It can be produced from
sugarcane, sugar beet or other crops having sugar content. Wide applications of sugar make
massive demand in the domestic including international market. An assessment of
environmental impact for sugar processing industry has done in terms of production,
processing, recycling, and utilization. Sugarcane mill has a significant contribution on
government revenue and employment opportunities. It has other goodness like the
development of community system and administrative aspects of the environmental
management plan. sugar mills in India consume their own bagasse to run their mills during
the season and generate steam to run the boilers and turbines; they generate power to run
their plants. Surplus energy can be exported to the grid of the distribution licenses.
Advanced power generation systems have a big potential to be integrated into sugar cane
factories and thus help generate surplus electricity. Usually, sugar mills having mechanical
steam turbines have higher steam consumption due to the poor efficiency of the mechanical
steam turbines. Replacement of these turbines with electric drives will improve the
electrical power generation since steam will be saved.
List of Tables
Sl no Table Caption Page no
1 Company Profile 9
2 Board of Directors 9
3 Internship schedule
4 Details of existing Boilers at BSML 15
List of Figures
Fig no Figure Caption Page no
2 Over View of Industry 11
2.a Cane weighbridge 11
2.b Cane Unloading 12
2.c Conveying cane 12
2.d Over View of Mill section 13
2.2(a) Schematic diagram of Boiler 14
2.2(b) Picture of Bagasse fired Boiler 15
2.2(c) Horizontal View of Stream Drum 16
2.2(d) Super heater Coil 16
2.2(e) Boiler Economizer 17
2.2(f) Chimney 18
2.3(a) Picture of Turbine 20
2.3(b) Steam Turbine 20
2.3(c) Steam Turbine components 21
Summary of Internship
References
Chapter 1
Introduction
Bilagi Sugar mill Limited is promoted with keen and active interest taken by Shri. S.R. Patil,
Chairman, Bilagi Sugar Mill Limited (BSML), Badagandi and who is former minister and MLC
opposition leader in Karnataka Legislative Council and MLC in Karnataka Legislative Council
last 20 years in the government of Karnataka.
The M/s. Bilagi Sugar Mill Limited (BSML), setup at village Badagandi, Tq Bilagi, dist.
Bagalkot, State: Karnataka is an agro based company focused on the production of sugar
and generation of power which is supplied to state grid. BSML is committed to produce
quality sugar by adopting modern techniques and eco-friendly manufacturing practices.
BSML was incorporated on 19th November, 2001 under the companies Act, 1956. The
factory site is at a distance of 30Kms from Bagalkot city and about 4.7 Kms from Bilagi Town.
Now BSML is expanding its plant crushing capacity from present 3500 TCD to 12,500 TCD
and CO-Generation capacity from 8 MW to additional 30 MW (8 MW+30 MW=38 MW) and
plans are for further expansion to 60 MW in near future.
After expansion combined sugar and Co-generation plant will help to improve the overall
working of the company, which will enable them to make higher payment towards cane
price to farmers who supply cane to factory.
Also, from October onwards till May end state faces power shortage and factory can make
its contribution by giving power from their cogeneration unit to state grid. Government of
India and Govt of Karnataka has also recognized for cogeneration units. The biomass power
generation also helps in reduction of CO2 emission for cleaner environment.
Bilagi Sugar Mill LTD, Badagandi is a highly ambitious multipurpose company. The company
is producing plantation white sugar as a main product and molasses/press mud as by-
products along with co-generation of power
INDUSTRY PROFILE
Bilagi Sugar Mill Limited (BSML) is a Public Limited Company registered in the State of
Karnataka under the Companies Act, 1956 bearing Certificate of Incorporation Number (CIN)
U15429KA2001PLCO29788 dated 19-11-2001, with site located at Girisagar Road, Village
Badagandi, Taluk – Bilagi, Dist. Bagalkot, Karnataka.
1.2 About the Organisation
1.2.1 Company Profile:
Table. 1 Company Profile
Cane weighment
The vehicles carrying cane are weighed on the electronic weigh bridges. These weights are
printed on the weighment slips which also carry’s farmer’s details and net weight etc.
Cane unloading
The cane from the vehicles which are in bundles are unloaded with the help of cane
unloader on the feeder table. Feeder table cane is fed to cane carrier in required quantity.
Conveying cane
The cane from the feeder table is then dumped to the main cane carrier, which conveys the
cane to the cane preparatory devices. The speed of the cane carrier will be controlled by
electronic devices depending on the cane crushing rate and level in the cane carrier, etc.
Milling
The prepared cane then passes through the milling tandem having three roller 3 to 5 mills
with necessary pressure feeding devices. The mills run at 3 to 5 RPM, driven through D.C.
/A.C motors, steam turbines or hydraulic drives. The hydraulic pressure is applied on top
roller to extract juice. The extracted juice is filtered in rotary juice screen and sent to boiling
house for further processing. The fibrous residue after juice extraction known as bagasse
from the last mill is conveyed through drag type steel conveyers to Boiler as a fuel.
Crushing of Sugarcane:
Sugarcane is harvested in the fields, dressed in small bundles, stacked in lorries, tractor
trailers or bullock carts, brought to factory, weighed and crushed in a set of mills. Crushing
takes place mainly in two stages. Firstly, the preparation and then the milling. Milling takes
place after prepared the cane in leveller, cutter and fibrizer. The prepared cane is then
crushed by passing through four sets of mills. After crushing, the bagasse is separated and
used as fuel for boiler and the juice is sent for further processing.
Juice clarification:
The weighed quantity of juice is primarily heated to 70-75oC in juice heaters and then
treated with lime solution. The juice is heated again to 100-115 oC in another set of juice
heaters. The hot juice is then sent to clarifier. Clarified juice is the decanted out and sent for
evaporation through the Multiple Effect Evaporator bodies (MEE). The juice at 15% is
concentrated in the evaporators into syrup from 15% to 60% concentration.
Fig.2.2(b) Juice Clarifier
Crystallization:
The syrup is then sent to plant floor for further concentration in vacuum pans. The syrup
collected in supply tanks is taken to pans for boiling where the syrup concentrates and
attains super saturation stage. In such a condition, sugar grains are formed in the syrup. The
syrup mass with sugar particles is called massecuite. The massecuite is dropped in
crystallizers and cooled to complete the crystallization process.
Centrifuge:
The massecuite is then taken into the centrifugal machine. Sugar crystals are separated from
mother liquor in high-speed centrifuge. Sugar thus separated is sent to driers. Non
crystallisable matter from the syrup, called the molasses is drained out from the centrifuge.
The molasses is weighed and sent to storage tanks.
Fig.2.2(e) Centrifuge
Drying, Grading, and Bagging:
Sugar thus obtained is dried in the vibrating hopper and graded by passing through standard
sieves. The graded sugar is then bagged, weighed for 50Kg net, stitched, numbered and
stacked in the sugar go down.
The steam is the main energy source, used in the process of cane sugar production.
Steam is generated by burning bagasse.
The advantage of using steam is, it is distributed and controlled easily. Another
special feature of steam production in sugar factories is the availability of renewable
bio-mass fuel-bagasse, a byproduct of cane after juice extraction.
Modern boiler has one or two steam drums inter connected with water and steam tubes.
The bagasse is burnt in the furnace. Thus, the heat produced is passed through the
passage of boiler tubes which gives its heat energy to water inside to convert in to
steam.
The final gases which after giving maximum heat energy for producing steam are
called flue gases which are let out through Chimney to atmosphere. Chimney outlet
gasses prior to their entry are passed through flue gas cleaning apparatus so that gases
let to atmosphere should not affect surrounding nature or human habitat.
In a Sugar factory co-generation boiler pressure varies from 67 Kg/cm 2 to 110 Kg/cm2
and temp. of steam from 480°C to 540°C.
Steam Turbine
Steam turbine is a device which converts pressure energy of the superheated steam into
useful work.
The nozzles are stationary and the rotor blades are dynamic. When the high-pressure steam
through the nozzle hits the surface of the blades, it creates a rotating motion due to the
change in the momentum of the blade. The resultant force on the blade results in the
difference in the momentum of entering and exiting of the different blades. The blades are
attached to the rotor shaft and convert change in momentum into rotating force.
Fig.2.4(b)Steam Turbine
Because of the high pressures used in the steam circuits and the materials used, steam
turbines and their casings have high thermal inertia. When warming up a steam turbine for
use, the main steam stops valves (after the boiler) have a bypass line to allow superheated
steam to slowly bypass the valve and proceed to heat up the lines in the system along with
the steam turbine. Also, a turning gear is engaged when there is no steam to slowly rotate
the turbine to ensure even heating to prevent uneven expansion. After first rotating the
turbine by the turning gear, allowing time for the rotor to assume a straight plane (no
bowing), then the turning gear is disengaged and steam is admitted to the turbine, first to
the astern blades then to the ahead blades slowly rotating the turbine at 10–15 RPM (0.17–
0.25 Hz) to slowly warm the turbine. The warm-up procedure for large steam turbines may
exceed ten hours.
1. Rotor
Steam turbines are fixed on a casing and a rotor attached with moving blades. The rotor is
fitted inside the casing which consists of rows of moving blades penetrating between the
rows of fixed blades. The high pressure steam flowing through the turbine passes through
the fixed and moving blades alternatively. The mechanism is such that the fixed blade
directs the steam at a right angle for entry into the moving blades. The utmost care has to
be taken so that the rotor and its casing withstands thermal stress and the moving blades
fitted with the rotor must securely withstand the high centrifugal forces.
2. Casing
Casing is required to protect the steam turbine from steam leakage. The ends of the casing
where the shaft of the rotor passes a seal is required to prevent steam leakages. Leakages
are not fully eliminated but can be controlled to a minimal amount.
3. Speed regulator
The speed regulator regulates the overall turbine speed. The speed turbines are designed to
operate at a rated speed called synchronous speed and the turbine operating above the
synchronous speed can damage the machine. At synchronous speed the efficiency of the
turbine is maximum.
Chapter 4
Week -3 Activity Report
4.1 Co-generation plant
Cogeneration is a process that simultaneously produces two or more forms of useful energy,
such as electric power and steam. It harnesses the thermal and electrical energy that is
released as part of the production process in various industries. When a fuel is burnt to
generate heat, and that heat is exploited in a thermo dynamic cycle to produce electricity, a
great deal of energy is wasted. This wasted energy (which can be up to two-thirds of the
energy content of the fuel) emerges as heat. If that heat can be utilized for space heating,
for making hot water or in a manufacturing process, it could reduce the amount of
additional energy needed for those purposes. This makes the economics of cogeneration
extremely favourable.
Technologies of Cogeneration:
Cogeneration can be implemented in many ways. Small diesel engines, gas turbine plants with waste
heat boilers, combined cycle cogeneration stations, biomass-based plants can be used to provide
heat as well as generate electricity. There are two types of cogeneration plants. Topping cycle:
Primary fuel is used to produce electricity, and thermal energy which is the byproduct is then used
for process heating. Bottoming cycle: Primary fuel is used to produce heat which is required for the
process at high temperatures and hence, power is generated through a suitable waste heat recovery
system.
An electrical control panel is an enclosure, typically a metal box or plastic moulding which
contains important electrical components that control and monitor a number of mechanical
processes. They are energised systems that require maintenance, with planned preventative
maintenance and condition-based monitoring being the most effective methods. Electrical
personnel will need to gain access within control panels for fault finding, adjustments, and
electrical safety testing. Operators will interact with the controls of the panel to operate and
control the plant and process.
Different types of control panel used in BILAGI SUGAR MILL LIMITED, BADAGANDI are as
given below
Transformer Panels
Metering Panels
Electro-Static Precipitator (ESP)
Generator Relay Panels
Turbine Relay Panels
KPTCL Interface Panel
Boiler Control Panels
Synchronisation Panel
PCC panel
MCC Panels
LAVT panel
These are used as power distribution board to control the power supply to HT Motors, MCC
Panels and Transformers. Manufacture of these centres is under supervision of the expert
professionals using a superior grade of materials and components. The power control centre
is available in different customised specifications as per the requirements of the industrial
customers.
Features:
1. HT PANEL(PCC/01)
2. LT PANEL (PCC/02)
Motor Control Centre (MCC):
Panels switch govern (take control) of motors is called motor control centre. MCC used for
controlling the process equipments hence, PCC will be acting as an incomer end for MCC.
A. APFC panel
B. DRAW OUT panel
Chapter 5
Week -4 Activity Report
It is possible either to decrease or increase the voltage and currents by the use of
transformer in AC circuits based on the requirements of the electrical equipment or device
or load. Various applications use wide variety of transformers including power,
instrumentation and pulse transformers.
In a broad, transformers are categorized into two types, namely, electronic transformers
and power transformers. Electronic transformers operating voltages are very low and are
rated at low power levels. These are used in consumer electronic equipment like televisions,
personal computers, CD/DVD players, and other devices.
The term power transformer is referred to the transformers with high power and voltage
ratings. These are extensively used in power generation, transmission, distribution and
utility systems to increase or decrease the voltage levels. However, the operation involved
in these two types of transformers is same.
2.2.1 Brief Description of the Transformer
Transformers used in Sugar Industry are
Current Transformer
Potential Transformer
Power Transformer
Distribution Transformer
Converter transformer
NGT transformer
Current Transformer
Specification of Current Transformer:
Make: MEHRU
Ratio:500/11A
Reg no: IS 270S/1892
Type: Outdoor Oil Cooled
Standards:IEC60076-1,IEC60076-2,IEC60076-3,ANSI,IEEE,AS
Highest System Voltage:145KV
Insulation Level:275/650KV
Accuracy Class:1-0.2
Potential Transformer
Specification of Potential Transformer:
Make: MEHRU
Ratio:110/1.73KV
Reg no: IS 270S/1892
Type: Outdoor Oil Cooled
Standards:IEC60076-1,IEC60076-2,IEC60076-3,ANSI,IEEE,AS
Highest System Voltage:123KV
Insulation Level:230/550KV
Chapter 6
Internship Attendance Report
Chapter 7
Outcomes of the Internship
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