Mill Material Balance
12.2.4 Result of Projection Projection
After the simulation of the Brix and Pol degrees on sheet-III completed and have the values shown underneath conform to the limitation, then on sheet-IV can be seen the overall result of calculation in the following pages, which consist of: §
Page 1: The complete mill material balance, for for overall and individuals. individuals.
§
Page 2: The performance performance targets, overall overall and and individually. individually.
§
Page 3: The proposed mills mills setting and the average analysis of juice extracted by each mill, imbibition water, etc.
§
Page 4: The projection of Brix curve.
§
Page 5: The approximate mill power required.
The Computer Program
XII-17
Mill Materia l Balance
M I L L M A T E R I A L B A LA N C E
CA P A CI TY
M I LL TRA I N : 2 CC + 5 M I LLS CA N E Q UA LI LI TY % pol = M a s s kg k g /h r.
M I LL I - J u ic e in
167,860
- F ib e r Tot a l i n
3 2 , 1 40 200,000
% brix
1 5. 9 8
Page : 1
PROJECTION OF PERFORMA NCE
SUGA R F A CTORY E X A M P LE 10.32 Bri x kg /h r.
2 6 , 8 20
:
4, 8 00. 0 TC TCD
M I LLI N G S E A S O N 1 97 7 % brix = 13.41 % fiber = % pol
1 2. 3 0
Po l kg /h r.
Densi ty kg / d m 3
PERIOD Da t e :
:
X
La s t d a t e
16.07 V ol u me d m 3/ h r .
E v a lu a t io n
2 0, 6 40
1. 07138
156,676
M I LL I Dk =
10.02
r=
1 . 3 5 01
1. 60000 1. 13146
2 0, 0 87 176,763
L= n=
21.33 27 0
r' = m=
1 . 3 4 92 0 . 3 3 71
1 3. 4 1
2 6 , 8 20
1 0. 3 2
2 0, 6 40
8 9 , 6 77 7 8 , 1 83 3 2 , 1 40
1 6. 0 2 1 5. 9 9
1 4 , 3 22 1 2 , 4 98
1 2. 9 8 1 1. 5 6
1 1, 6 04 9,036
1. 07181 1. 07088 1. 60000
8 3, 6 68 7 3, 0 08 2 0, 0 87
h= i= Ve d o =
0 . 3 8 05 2.05 6 8, 9 52
y= K= H Ke j =
0.34 2.56 81.02
110,323
1 1. 3 3
1 2 , 4 98
8. 19
9,036
1. 18506
9 3, 0 95
Ve d =
6 8, 9 52
kB =
1.000
- Ju J u ic e in - F ib e r
166,841 3 2 , 1 40
1 0. 4 7
1 7 , 4 63
7. 57
1 2, 6 26
1. 04793 1. 60000
159,210 2 0, 0 87
Dk = L=
10.23 21.33
r= r' =
1 . 3 3 16 1 . 3 3 80
Tot a l i n E x t r a c t e d j u ic e - Ba B a g a s s e j u ic e
198,981 110,323 5 6 , 5 18
8. 78 9. 82 1 1. 7 9
1 7 , 4 63 1 0 , 8 00 6,662
6. 35 7. 65 7. 45
1 2, 6 26 8,414 4,213
1. 10978 1. 04561 1. 05248
179,297 105,510 5 3, 7 00
n= h= i=
27 0 0 . 2 9 95 2.59
m= y= K=
0 . 3 3 52 0.26 3.24
3 2 , 1 40 8 8 , 6 58
7. 51
6,662
4. 75
4,213
1. 60000 1. 20154
2 0, 0 87 7 3, 7 87
Ve d o = Ve d =
5 5, 4 11 5 5, 4 11
H Ke j = kB =
77.90 0.935
M I LL I I I - J u ic e in
134,564
6. 75
9,082
4. 35
5,851
1. 03251
130,327
M I LL I I I Dk =
10.21
r=
1 . 3 1 64
- F ib e r Tot a l i n Ex E x t r a c t e d j u ic e
3 2 , 1 40 166,704 8 8 , 6 58
1. 60000 1. 10830 1. 02848
2 0, 0 87 150,414 8 6, 2 02
L= n= h=
21.33 27 0 0 . 2 6 42
r' = m= y=
1 . 3 2 69 0 . 3 3 53 0.26
E x t r a c t e d j u ic e - Ba B a g a s s e j u ic e - F ib e r To t a l b a g a s s e
M I LL I I
- F ib e r To t a l b a g a s s e
M I LL I I
5. 45 5. 60
9,082 4,965
3. 51 4. 05
5,851 3,591
- Ba B a g a s s e j u ic e - F ib e r
4 5 , 9 06 3 2 , 1 40
8. 97
4,117
4. 92
2,261
1. 04036 1. 60000
4 4, 1 25 2 0, 0 87
i= Ve d o =
2.47 4 8, 7 79
K= H Ke j =
3.08 72.32
To t a l b a g a s s e
7 8 , 0 46
5. 27
4,117
2. 90
2,261
1. 21544
6 4, 2 12
Ve d =
4 8, 7 79
kB =
0.830
M I LL I V - J u ic e in - F ib e r Tot a l i n
M I LL I V 117,832 3 2 , 1 40 149,972
3. 41
5,108
1. 92
Ex E x t r a c t e d j u ic e - Ba B a g a s s e j u ic e
7 8 , 0 46 3 9 , 7 86
3. 10 6. 76
2,419 2,688
2. 10 3. 11
- F ib e r To t a l b a g a s s e
3 2 , 1 40 7 1 , 9 26
3. 74
2,688
M I LL V - J u ic e in - F ib e r
8 5 , 9 06 3 2 , 1 40
3. 13
118,046 5 2 , 1 60
- Ba Ba g a s s e j u ic e - F ib e r To To t a l b a g a s s e
Tot a l i n Ex E x t r a c t e d j u ic e
2,876
1. 02159 1. 60000 1. 10738
115,342 2 0, 0 87 135,429
Dk = L= n=
10.20 21.33 27 0
r= r' = m=
1 . 3 0 81 1 . 3 1 58 0 . 3 3 54
1,639 1,237
1. 01851 1. 02766
7 6, 6 27 3 8, 7 15
h= i=
0 . 2 4 37 2.41
y= K=
0.27 3.01
1. 72
1,237
1. 60000 1. 22319
2 0, 0 87 5 8, 8 02
Ve d o = Ve d =
4 4, 9 54 4 4, 9 54
H Ke j = kB =
67.74 0.715
2,688
1. 44
1,237
1. 01262 1. 60000
8 4, 8 35 2 0, 0 87
M I LL V Dk = L=
10.34 21.33
r= r' =
1 . 2 9 85 1 . 2 9 62
2. 28 1. 90
2,688 99 1
1. 05 1. 18
1,237 61 5
1. 12508 1. 01378
104,922 5 1, 4 51
n= h=
27 0 0 . 2 2 02
m= y=
0 . 3 3 41 0.32
3 3 , 7 47 3 2 , 1 40
5. 03
1,697
1. 84
62 2
1. 01087 1. 60000
3 3, 3 84 2 0, 0 87
i= Ve d o =
2.04 4 1, 1 79
K= H Ke j =
2.55 62.11
6 5 , 8 87
2. 58
1,697
0. 94
62 2
1. 23220
5 3, 4 71
Ve d =
4 1, 1 79
kB =
0.607
The Computer Program
4. 33
5,108
2. 44
2,876
XII-18
Mill Materia l Balance
M I L L M A T E R I A L B A LA N C E SUGA R F A CTORY : E X A M P LE M I LL T RA I N
:
CA P A CITY
2 CC + 5 MILLS
CA N E Q U A L I T Y T H E
:
M I LLING SEASON
% pol =
1 0 .3 2
% br ix =
1 3 .4 1
T A R G E T S D e s c r i p t i o n
C a n e :
M i x e d ju ic e :
2 4 .0 0
La s t d a t e
Qj
200,000
gnt
8 3 .9 3
TCD Hours KCH % cane
- weighed, total
Gi
1 ,5 8 1 .3
Tons
- w e i g h e d p e r h o u r
G ij
6 5 ,8 8 7
kg/hr.
- % f i b e r
g is
205.00
% f ib e r
- % c a n e
g it
3 2 .9 4
% cane
- o n b a g a s s e 1
g ia 1
0
% G ij
- o n b a g a s s e 2 - o n b a g a s s e 3
g ia 2 g ia 3
0 30
% G ij % G ij
- o n b a g a s s e 4
g ia 4
70
% G ij
- weighed, total
Gnm
4 ,8 0 0 .0
Tons
- w e i g h e d p e r h o u r
Gnmj
200,000
- % c a n e
gnmt
100.00
- p o l
pnm
1 0 .0 4
%
- b r i x
bnm
1 2 .6 0
%
HKnm
7 9 .6 8
kg/hr. % cane
%
- total per hour
Gal
6 5 ,8 8 7
- % c a n e
g a lt
3 2 .9 4
% cane
- p o l
pal
0 .9 4
%
- b r i x
bal
2 .5 8
%
- f i b e r c o n t e n t
kf
4 8 .7 8
%
- d r y m a t t e r
zk
5 1 .3 6
%
nss
105.00
- j u i c e l o s s i n b a g a s s e - B r i x m ill # 1
gnhs H P B -I
3 2 .9 7 5 3 .4 0
- B r i x t o t a l - s u g a r
H P B -t HPG
9 3 .6 7 9 6 .9 9
- s u g a r o n 1 2 , 5 % f i b e r - can be expected
kg/hr.
% % f ib e r % % %
H P G 1 2 ,5
9 7 .6 6
%
PSHK
9 7 .4 4
%
kt
9 .0 8
% cane
- i n m ix e d ju ic e
knm
8 .9 9
% cane
- l o s s i n b a g a s s e ( r e la t iv e ly )
khar
1 .0 5
%
I N D I V I D U A L P E R F O R M A N C E M I L L NO: ---- ----------- >
I
II
Extr ac tion:
5 3 .4 2
6 6 .1 2
- J u ic e
En = N o r m a l v a lue =
> 60
> 60
III 6 5 .8 9 > 60
IV 6 6 .2 3 > 60
V 6 0 .7 2
% %
> 60
- Pol
Ep =
5 6 .2 2
6 6 .6 4
6 1 .3 6
5 6 .9 8
4 9 .7 4
%
- B r ix
Eb =
5 3 .4 0
6 1 .8 5
5 4 .6 7
4 7 .3 7
3 6 .8 6
%
2 .5 6
3 .2 4
3 .0 8
3 .0 1
2 .5 5
C o m p r e s s io n r a t io : J u ic e e x t r a c t e d b y f e e d o p e n in g
K
=
N o r m a l v a lue = 2 ,4 , 4 - 3 , 3 2 , 6 - 3 ,5 , 5 2 ,6 , 6 - 3 , 3 2 , 5 - 3 ,2 ,2 2 , 4 - 3 , 0 y = 0 .3 4 0 .2 6 0 .2 6 0 .2 7 0 .3 2 m e a n i ng ng =
R o lle r s h e l l d e f l e c t i o n
l
- absorption ability f actor - ditto, norm a l - % cane
=
m e a n i ng ng = da =
B a g a s s e : - n o - v o id d e n s i t y
F ibe r:
:
U ni t
jg
R a t io o f j u i c e p u r i t y C r y s t a l :
V a lu e
- c r u s h i n g d u r a t i o n
- j u i c e t o f i b e r E x t r a c t i o n ' s :
Symbol
4 ,8 0 0 .0
- p u r i t y La L a s t m ill b a g a s s e :
Date 1 6 .0 7
Q
- c r u s h e d p e r h o u r I m b ib i t i o n w a t e r :
1977 % f i be r =
- c ru sh ed , total
- j u i c e c o n t e n t
P a g e : 2
PROJECTION OF PERFORMA N CE 4 ,8 0 0 .0 T C D PERIOD : X
e x t r a c t e e x t ra r a c t e e x t ra r a c t e e x t ra r a c t e e x t ra ra c t e d 0 .0 0 0 .0 0 0 .0 0 0 .0 0 0 .0 0 safe 1 .1 8 5 1
safe 1 .2 0 1 5
safe 1 .2 1 5 4
safe 1 .2 2 3 2
safe 1 .2 3 2 2
r
=
1 .3 5 0 1
1 .3 3 1 6
1 .3 1 6 4
1 .3 0 8 1
1 .2 9 8 5
r'
=
1 .3 4 9 2
1 .3 3 8 0
1 .3 2 6 9
1 .3 1 5 8
1 .2 9 6 2
gat =
5 5 .1 6
4 4 .3 3
3 9 .0 2
3 5 .9 6
%
kg/dm3
3 2 .9 4
%
- pol - b r ix
pa ba
= =
8 .1 9 1 1 .3 3
4 .7 5 7 .5 1
2 .9 0 5 .2 7
1 .7 2 3 .7 4
0 .9 4 2 .5 8
% %
5 1 .3 6
%
- dry m a t t e r
zk =
4 0 .4 6
4 3 .7 7
4 6 .4 6
4 8 .4 2
- index
c
=
0 .4 7
0 .5 8
0 .6 6
0 .7 1
- loading
q
=
177.38
173.73
174.07
174.25
171.89
gr/dm2
- r e d u c e d lo a d in g
q' =
134.89
129.41
129.92
130.17
126.67
gr/dm2
- % bagasse
The Computer Program
0 .7 8 k g / d m 3
N o r m a l v a lue = kf =
1 2 0 - 1 3 0 g r / d m 2 e s c r i be be d r o l le le r s u r f a c e 2 9 .1 3 3 6 .2 5 4 1 .1 8 4 4 .6 8 4 8 .7 8
%
N o r m a l v a lue =
25-35
%
28-38
32-42
37-47
45-50
XII-19
Mill Materia l Balance
M I L L M A T E R I A L B A LA N C E SUGA R F A CTORY : E X A M P L E
CA P A C ITY
M I L L T RA I N : 2 CC + 5 M I L L S CA N E Q U A L I T Y % pol =
:
P a g e : 3
P R O P O S E D M I LL SETTING 4 ,8 0 0 .0 T C D PERIOD
M I LL ING SEASON 1977 1 0 .3 2 % b r i x = 1 3 .4 1 % f i b e r =
Date
:
:
X
La s t d a t e
1 6 .0 7
O b t a i n e d f r o m t h e m a t e r i a l b a l a n c e ( p a g e 1 ) : n c q
q'
kf
i
b
M ill # 1 M ill # 2
270 270
0 .4 7 0 .5 8
177.38 173.73
134.89 129.41
2 9 .1 3 3 6 .2 5
2 .0 5 2 .5 9
a
M ill # 3 M ill # 4
270 270
0 .6 6 0 .7 1
174.07 174.25
129.92 130.17
4 1 .1 8 4 4 .6 8
2 .4 7 2 .4 1
M ill # 5
270
0 .7 8
171.89
126.67
4 8 .7 8
2 .0 4
hd
hb
n = c = kf =
Roller Roller speed per hour (rph). F i b e r i n d e x , k g / d m 3 e s c r ib ib e d d e l iv iv e r y o p e n i n g . F ib e r c o n t e n t in b a g a s s e , %
i = q =
Ratio of feed and delivery openings. Fiber loading , gr/dm2 escribed roller surfac e
q' =
F i b e r l oa oa d i n g , r e d u c e d t o s t a n d a r d r o l l e r o f 3 0 "
When :
q' = 120-130 gr/dm2 - normal. q ' = 1 3 0 - 1 4 0 g r / d m 2 - r e q u i re re s D o n n e lly c h u t e . q ' = 1 4 0 - 1 6 0 g r / d m 2 - r e q u i re re s l i g h t p r e s s u r e f e e d e r . q ' = 1 5 0 - 1 7 0 g r / d m 2 - r e q u ir ire s h e a v y d u t y p r e s s u r e f e e d e r .
T H E M I L L S E T T I N G ( P R O P O S E D) D) D im e n s i o n i n m m M ill # 1 , top
Do 1 ,0 5 2 .0
k 2 5 .0
Dk 1 ,0 0 2 .0
fe e d d e liv e r y
1 ,0 5 0 .0 1, 1 ,0 4 8 .0
2 5 .0 2 5 .0
1 ,0 0 0 .0 998.0
top fe e d
1 ,0 7 3 .0 1 ,0 6 9 .0
2 5 .0 2 5 .0
1 ,0 2 3 .0 1 ,0 1 9 .0
d e liv e r y top
1 ,0 6 6 .8 1 ,0 5 1 .0
2 5 .0 1 5 .0
1 ,0 1 6 .8 1 ,0 2 1 .0
fe e d
1 ,0 4 8 .0
1 5 .0
d e liv e r y top
1 ,0 4 0 .0 1 ,0 5 0 .0
fe e d d e liv e r y
1 ,0 4 8 .0 1 ,0 4 0 .0
M ill # 2 ,
M ill # 3 ,
M ill # 4 ,
M ill # 5 ,
L 2 ,1 3 3
2 ,1 3 3
t 6 .0
Wo r k
Set
CT C
CT C
O p e n in g
O p e n in g
Wo r k
Set
2 3 .3 8 -16.61
1 ,0 7 9 .0 1 ,0 3 8 .1
4 .7 4 .7
7 8 .0 4 3 8 .0 5
6 .0 4 .7
a
b
1 ,0 7 4 .4 1 ,0 3 3 .4
263
516
258
498
214
409
7 7 .5 4
2 2 .8 7
1 ,0 9 8 .5
1 ,0 9 3 .9
4 .7 6 .0
2 9 .9 5
-24.71
1 ,0 4 9 .9
1 ,0 4 5 .2
1 ,0 1 8 .0
4 .7
6 5 .1 7
3 0 .5 1
1 ,0 8 4 .7
1 ,0 8 0 .0
1 5 .0 1 5 .0
1 ,0 1 0 .0 1 ,0 2 0 .0
4 .7 6 .0
2 6 .4 2
- 8 .2 4
1 ,0 4 1 .9
1 ,0 3 7 .3
1 5 .0 1 5 .0
1 ,0 1 8 .0 1 ,0 1 0 .0
4 .7 4 .7
5 8 .7 4 2 4 .3 7
2 4 .0 7 -10.29
1 ,0 7 7 .7 1 ,0 3 9 .4
1 ,0 7 3 .1 1 ,0 3 4 .7
192
364
146
274
2 ,1 3 3
2 ,1 3 3
top
1 ,0 6 4 .0
1 5 .0
1 ,0 3 4 .0
fe e d
1 ,0 5 2 .0
1 5 .0
1 ,0 2 2 .0
4 .7
4 4 .8 9
1 0 .2 3
1 ,0 7 2 .9
1 ,0 6 8 .2
d e liv e r y
1 ,0 4 8 .0
1 5 .0
1 ,0 1 8 .0
4 .7
2 2 .0 2
-12.64
1 ,0 4 8 .0
1 ,0 4 3 .4
Le g e n d :
Do =
O u tsi d e di a me t er
k= Dk =
Groove correction M e a n d ia m e t e r
L= t =
2 ,1 3 3
6 .0
hf =
Fe ed wo rk o pen ing
hd = CTC =
Le L e n g t h o f s h e ll T op op r ol ol le le r/ r/ hy hy dr dr au au li li c l if if t ( pe pe rm rm i ss ss i bl bl e) e)
D e liv e r y w o r k o p e n in g Center to center distance
a = b=
F e e d in g r o ll d is t a n c e D i st st an a n ce c e / w id i d th th o f D on on ne ne ll l ly c h u te te
E X P E C T A T I O N O F A N A L Y S I S ( a v e r ag ag e ) % pol
Pu r i t y
% zk
% fiber
- Cane - M ix e d jui c e
1 0 .3 2 1 0 .0 4
1 3 .4 1 1 2 .6 0
7 9 .6 8
-
1 6 .0 7 -
- juice # 1 - juice # 2
1 2 .9 8 7 .6 5
1 6 .0 2 9 .8 2
8 1 .0 2 7 7 .9 0
-
-
- juice # 3 - juice # 4
4 .0 5 2 .1 0
5 .6 0 3 .1 0
7 2 .3 2 6 7 .7 4
-
-
- juice # 5 - L a s t m ill b a g a s s e
1 .1 8 0 .9 4
1 .9 0 2 .5 8
6 2 .1 1 3 6 .6 4
5 1 .3 6
4 8 .7 8
I m b ib ib it i t io io n w at at er er : A p p lie d o n :
% br ix
- t ot ot a l
=
6 5 ,8 ,8 8 7 l t r / hr hr . ,
or =
2 05 05 .0 .0 0 % f ib ib e r
- bagasse 1 = - bagasse 2 =
0 % 0 %
or = or =
0 lt r/ hr. 0 l t r/ hr.
- bagasse 3 = - bagasse 4 =
30 % 70 %
or = or =
1 9 ,7 6 6 l t r / h r . 4 6 ,1 2 0 l t r / h r .
The Computer Program
XII-20
Mill Materia l Balance
M I LL M A T E R I A L B A LA N C E SUGA R F A CTORY : E X A M P L E
M I LL TRA I N : 2 C C + 5 M I LLS C A N E Q UA LI LI TY % pol =
CA P A C IT Y
:
EXPECTED BRIX CURVE 4 ,8 0 0 . 0 TC TCD PERIOD
M I LL I N G S E A S O N 1977 1 0 . 3 2 % b rix = 1 3 . 4 1 % f i be r =
Date
:
P a g e : 4 :
X
La s t d a t e
16.07
V a l u e f o r --- - - - - - - - - - - - >
M ill I
M ill I I
M ill I I I
M ill I V
M ill V
% b r i x , e x p e c t e d - - - - - - - - - - - >
16.02
9 .8 2
5 .6 0
3 .1 0
1 .9 0
20 19 18 17 16 15 14 13 > - 12 x 11 i r b 10
% 9 8 <
7 6 5 4 3 2 1 0 Mill I
Mi l l I I
Mill I II
Mill IV
Mill V
Expected Curve
The Computer Program
XII-21
Mill Materia l Balance
M I LL M A T E R I A L B A LA N C E S UGA R F A CT ORY : E X A M P LE
M I L L TR A I N
:
2 C C + 5 M I LL S
C A N E Q U A LI TY
% po l =
P a g e : 5
P O WE R C A L C U L A T I O N
CA P A CITY
:
M I LLING SEA SON 1 0 . 3 2 % br i x =
4 ,8 0 0 . 0 TC TC D
PERIOD
1977
1 3 . 4 1 % fibe r =
Date
:
:
X
La s t d a t e
16.07
P O WE WE R C A L CU CU LA LA T I O N D e s c r i p t i o n M ill h y d r a u lic p r e s s u r e D ia m e t e r o f h y d r a u lic p is t o n M e c h a n ic a l e f f i c i e n c y , t o t a l R o l l e r s h a f t d i a m e t e r , a v e r a g e
U ni t
M ill I
M ill I I
M ill I I I
M ill I V
M ill V
kg/cm2
180
190
200
210
220
mm
330
330
330
330
330
% mm
86
86
86
86
86
420
420
420
420
420
R o l l e r s h a f t l e n g t h
mm
4 ,2 2 0
4 ,2 2 0
4 ,2 2 0
4 ,2 2 0
4 ,2 2 0
To To p r o l l e r m e a n d ia m e t e r
mm
1 ,0 0 2 . 0
1 ,0 2 3 . 0
1 ,0 2 1 . 0
1 ,0 2 0 . 0
1 ,0 3 4 . 0
R o l l e r l e n g t h
mm
2 ,1 3 3
2 ,1 3 3
2 ,1 3 3
2 ,1 3 3
2 ,1 3 3
Ro Ro l l e r r o t a t i o n
r ph
270
270
270
270
270
134.89
129.41
129.92
130.17
126.67
R e d u c e d f ib e r l o a d i n g C r o s s s e c t io n a r e a o f h y d r a u lic p is t o n
gr/dm 2 cm2
854.87
854.87
854.87
854.87
854.87
307, 751
324,849
341, 946
359,043
376, 141
H y d r a u lic f o r c e
kg
To To p r o l l e r w e i g h t
kg
16, 943
17,555
17, 496
17,467
17, 881
T o t a l p r e s s i n g l o a d
kg
324, 694
342,404
359, 442
376,510
394, 022
B a g a s s e c o e f f i c ie ie n t o f f ri ri c t i o n C irc u m f e r e n t ia l f o r c e Po P o w e r r e q u i r e d f o r m i l l i n g, a v e r a g e S p e c ific p o w e r r e q u i r e m e n t
µ
0 .3 3 7 1
0 .3 3 5 2
0 .3 3 5 3
0 .3 3 5 4
0 .3 3 4 1
kg
109, 454
114,757
120, 534
126,293
131, 655
HP
400
429
449
470
497
12.46
13.34
13.98
14.63
15.46
H P / t o n f ib e r
It is to be noted that after the amount of imbibition water increased to 205% fiber, a better mill performance would have been projected in their operation (see and compare with sheet-II / Evaluation). Beside the additional amount of imbibition water, the mill roller rotation has also to be increased and conform to its nominal speed of the mill drive.
12.2.5 The Mill Setting Setting
Basically the mills’ setting is the same with the system usually applied that is the Java Method. The main different is the use of ratio between the feed and delivery openings (i). Usually it was determined by the value from the historical ratio used during previous operations, which # gradually decreasing or increasing from mill 1 to the ensuing mills. With the use of material balance calculation the ratio is determined based upon the compression value occurred in each mill, and that approximately 70%-80% from the value of K of the respective mill. Unlike the determination in practice the distance between feeding roller and the top roller (a) is not by approximation of a certain figure times the delivery work opening or the top roller diameter, but it has to be set based on the formula of continuity for the flow of materials (cane or bagasse) feeds into each mill. Also determination of Donnelly chute width, that is the distance of front and rear plates. Each defined based on the following formulas: The incoming no-void volume of cane / bagass e entering the feeding roller:
The Computer Program
XII-22
Mill Materia l Balance
Vrp =
Wim drp
where drp = Frp = a.L vrp = 0.55 .π.D.n
Vrp = Frp.vrp 1,1.r .Wim dim
=
dim 1.1.r
1.1 .r .Wim dm
hence Vrp = Vrp =
a .L.0.55.π.D.n
a.L.0.55. π.D.n
Therefore the distance between the feeding roller and top roller is: a=
2. r . Wim.h.100 dim.Ved
mm 2
With the same calculation system, but the value of drp = dm : 1.1.r and vrp = 0.38.π.D.n; the distance between the front and rear plates of the Donnelly chute is: b =
2.9. r 2. Wim.h.100 dim.Ved
mm
12.2.6 The Key Key of Success
When a mill material balance completed with the relevant projection and criteria based upon the ability of the mill tandem and quality of the cane to be crushed, the following resume of actions become the key of its operational operational success: 1. Each mill shall be sets actually and conforms conforms to the calculation resulted from the projection of mill material balance (see page 3, projection program). 2. Operate the mill tandem always with reference reference and guidance obtained from the material balance, mainly items related to: The recording of the actual mill rotations from its individual counter and not by calculation based on the gear ratios. The triangle formed by the top, feed and delivery rollers has to be measured daily to define the actual work openings. Pay attention to the results of analysis for the extracted juices, mixed juice, last mill bagasse and the application of imbibition imbibition water, etc. Pay attention to the actual Brix curves (see page 3, evaluation program). 3. Evaluate the mill tandem performance periodically periodically (daily, weekly, bi-weekly and monthly). 4. Do the resetting / adjustment adjustment (if necessary), 3 (three) or 4 (four) (four) weeks after the campaign starts and / or every mill wash, or projected mill stop for periodical maintenance. §
§
§
§
References:
1. Hugot, Emil (1986). Handbook Handbook of Cane Sugar Engineering, Third Third Edition, Elsevier. 2. Sumohandoyo, Toät (1980). (1980). Pemerahan Pada Suatu Gilingan, Majalah Gula Gula Indonesia Indonesia – Volume VI No. 4, Desember 1980. 3. Mead-Chen (1977). Cane Sugar Handbook, Tenth Edition, John Wiley & Sons. 4. Murry, C.R. & Holt, J.E. (1967). The Mechanic of Crushing Sugar Cane, Elsevier. 5. P3GI – Pasuruan. Bulletin No. 4 & Bulletin No. 11.
The Computer Program
XII-23
Mill Materia l Balance
. er c en t wei g ht or Brix d egree
Den sity
er ce n t wei gh t or Bri x deg ree
Density
e r ce n t wei gh t or Br i x degree
D ensity
e rc en t w eig ht or Br i x d egree
Den sity
er c en t wei gh t or Brix d eg ree
Den sity
0.0 0.1 0.2 . . . . 0.7 0.8 .
0.99 640 0.99 678 0.99 717 . . . . 0.99 910 0.99 948 .
5 .0 5 .1 5 .2 . . . . 5 .7 5 .8 .
1.015 92 1.016 32 1.016 71 . . . . 1.018 70 1.019 10 .
1 0. 0 1 0. 1 1 0. 2 . . . . 1 0. 7 1 0. 8 .
1 .0360 8 1 .0364 9 1 .0369 0 . . . . 1 .0389 6 1 .0393 7 .
15.0 15.1 15.2 . . . . 15.7 15.8 .
1.05 694 1.05 736 1.05 779 . . . . 1.05 991 1.06 034 .
2 0 .0 2 0 .1 2 0 .2 . . . . 2 0 .7 2 0 .8 .
1.078 55 1.078 99 1.079 43 . . . . 1.081 64 1.082 08 .
. . 1.2 1.3 1.4 . . . 1.8 1.9
. . 1.00 103 1.00 142 1.00 180 . . . 1.00 336 1.00 374
. . 6 .2 6 .3 6 .4 . . . 6 .8 6 .9
. . 1.020 70 1.021 10 1.021 50 . . . 1.023 10 1.023 50
. . 1 1. 2 1 1. 3 1 1. 4 . . . 1 1. 8 1 1. 9
. . 1 .0410 2 1 .0414 3 1 .0418 5 . . . 1 .0435 0 1 .0439 2
. . 16.2 16.3 16.4 . . . 16.8 16.9
. . 1.06 205 1.06 248 1.06 291 . . . 1.06 463 1.06 506
. . 2 1 .2 2 1 .3 2 1 .4 . . . 2 1 .8 2 1 .9
. . 1.083 86 1.084 30 1.084 75 . . . 1.086 53 1.086 98
. . . 2.3 2.4 . . . 2.8 2.9
. . . 1.00 530 1.00 569 . . . 1.00 725 1.00 764
. . . 7 .3 7 .4 . . . 7 .8 7 .9
. . . 1.025 11 1.025 51 . . . 1.027 13 1.027 53
. . . 1 2. 3 1 2. 4 . . . 1 2. 8 1 2. 9
. . . 1 .0455 8 1 .0460 0 . . . 1 .0476 7 1 .0480 9
. . . 17.3 17.4 . . . 17.8 17.9
. . . 1.06 678 1.06 721 . . . 1.06 894 1.06 938
. . . 2 2 .3 2 2 .4 . . . 2 2 .8 2 2 .9
. . . 1.088 77 1.089 22 . . . 1.091 01 1.091 46
. . 3.2 . 3.4 3.5 . 3.7 . 3.9
. . 1.00 882 . 1.00 961 1.01 000 . 1.01 078 . 1.01 157
. . 8 .2 . 8 .4 8 .5 . 8 .7 . 8 .9
. . 1.028 75 . 1.029 55 1.029 96 . 1.030 77 . 1.031 59
. . 1 3. 2 . 1 3. 4 1 3. 5 . 1 3. 7 . 1 3. 9
. . 1 .0493 4 . 1 .0501 8 1 .0506 0 . 1 .0514 4 . 1 .0522 8
. . 18.2 . 18.4 18.5 . 18.7 . 18.9
. . 1.07 068 . 1.07 155 1.07 198 . 1.07 285 . 1.07 373
. . 2 3 .2 . 2 3 .4 2 3 .5 . 2 3 .7 . 2 3 .9
. . 1.092 81 . 1.093 72 1.094 17 . 1.095 07 . 1.095 98
4.0 . . . . 4.5 4.6 . 4.8 4.9
1.01 197 . . . . 1.01 394 1.01 433 . 1.01 513 1.01 552
9 .0 . . . . 9 .5 9 .6 . 9 .8 9 .9
1.031 99 . . . . 1.034 03 1.034 44 . 1.035 26 1.035 67
1 4. 0 . . . . 1 4. 5 1 4. 6 . 1 4. 8 1 4. 9
1 .0527 1 . . . . 1 .0548 2 1 .0552 4 . 1 .0560 9 1 .0565 1
19.0 . . . . 19.5 19.6 . 19.8 19.9
1.07 417 . . . . 1.07 635 1.07 679 . 1.07 767 1.07 811
2 4 .0 . . . . 2 4 .5 2 4 .6 . 2 4 .8 2 4 .9
1.096 43 . . . . 1.098 71 1.099 16 . 1.100 07 1.100 53
*) Copied from Bulletin-4 of Indonesian Indonesian Sugar Research Research Institute
The Computer Program
XII-24
