Professional Documents
Culture Documents
10.2
As it was mentioned above, that the use of the Projection Program or the Planning Program of a
complete calculation of mill material balance is best to have the projection of an optimal
performance of a milling tandem.
Scientific calculation program was made based upon the existing mill tandem and the quality of
cane crushed, which then obtaining adequate and reasonable values used for the operation
targets of the sugar factory. The targets also normally used for the purpose of budgeting, which
should not be taken as average from the previously milling seasons.
The programs are in one file and consist of 4 (four) sheets, 2 (two) sheets for the Evaluation and
another 2 (two) sheets for the Projection, that are:
Sheet-III, inputs for the Projection, and
Sheet-IV, the result of the Projection.
10.2.1 Projection Data
All the inputs for the Projection must be typed in sheet-III, which is identical with sheet-I for the
Evaluation inputs. Here all the data must also be typed replacing the blue letters in the red lined
boxes only.
The same with the inputs for the Evaluation, the followings shall be filled in:
Name of the sugar factory
The mill train composition
Milling season / year
Period of 15-days, number
:
:
:
:
Then the data of the mill rollers in use, each for diameter, groove correction, etc.; the same with
the example in Chapter IX as shown hereinafter:
(The same data for the Evaluation Program is used here)
Type in the data (blue letters) in the red lined square boxes
Sugar Factory
Mill Train
Milling Season (year)
Period of 15 milling days, number
Period dates evaluated up to
EXAMPLE
2 CC + 5 MILLS
1977
X
End dfate
Length of shell
Mill roller speed
Top roller lift:
- top angle
Program Komputer
top
feed
delivery
top
feed
delivery
L
n
t
a
II
III
IV
1.052,0
1.050,0
1.048,0
25,0
25,0
25,0
2.133
270
6,0
78
1.073,0
1.069,0
1.066,8
25,0
25,0
25,0
2.133
270
6,0
78
1.051,0
1.048,0
1.040,0
15,0
15,0
15,0
2.133
270
6,0
78
1.050,0
1.048,0
1.040,0
15,0
15,0
15,0
2.133
270
6,0
78
1.064,0
1.052,0
1.048,0
15,0
15,0
15,0
2.133
270
6,0
78
X- 1
pt indocode surya
crushed, total
Q
crushing duration
jg
pol
pt
brix
bt
fiber
f
Mixed juice:
gross
Gnm
brix
bnm
dirt corr.
knm
Imbibition water, total
Gi
Applied on:
bagasse
bagasse
bagasse
bagasse
Average value of fiber density
Bx ratio juice#1 to cane
bn1/bt =
Juice:
M I L L NO: --------------->
brix
bn
pol
pn
4.800,0
24,00
10,32
13,41
16,07
4.800,0
12,60
1,00308
1.581,3
0
0
30
70
1,53924
1,19
I
15,90
12,88
TCD =
200,00 TCH
hours
%
%
Purity =
76,96 %
% cane
Tons = 200.000 kg/hr = 100,00 % cane
%, pol =
10,04 Purity =
79,69 %
%
Tons =
65.887 ltr/hr =
205,00 % fiber
32,94 % cane
%
%
%
%
kg/dm3
Last mill bagasse juice to fiber =
105,00 % -----> 100%
II
9,90
7,72
III
5,60
4,05
IV
3,10
2,10
V
1,90
1,18
Unit
%
%
gnhs =
khar =
PSHK
33,22 %
1,03 %
97,51 %
While simulating the value for Brix and Pol degrees of the respective mill juice, observe the
result follows thereunder:
Juice:
purity
HK
81,00
77,98
72,32
67,74
62,11
En
53,62
66,55
66,45
66,81
59,83
Graduall
Best >
kB
0,992
0,935
0,822
0,705
0,602
y
60%
0,9-1,1
0,8-1,0
0,7-0,9
0,6-0,8
decreasi
0,5-0,7 (decreasi
2,48
3,14
2,99
2,92
da
1,1758
1,1911
1,2053
1,2128
1,2138 Graduall
density
1,3091
1,2923
1,2771
1,2691
1,2681 yGraduall
absorp.abi
ditto,
r'
1,3091
1,2982
1,2874
1,2767
ydecreasi
1,2655 Graduall
normal
fiber
kf
29,22
36,76
42,13
45,89
48,78
yincreasin
Graduall
content
fiber
0,45
0,57
0,65
0,71
0,75
decreasi
y
Graduall
index
red.
q'
134,89
129,41
129,92
130,17
fiber
pol
pa
8,26
4,76
2,91
1,73
0,94
yincreasin
120-130
q' =
brix
ba
11,41
7,54
5,33
3,79
2,58
increasin
gr/dm2
130-140
q' = 140--
dry
zk
40,63
44,30
47,46
49,68
51,36
normal
gr/dm2
160
q' = 150--
extractio
brix
distr.
Compres no-void
Bagasse:
Normal value
2,43
ng)
ydecreasi
126,67 Graduall
q' =
When the values have matched or lies between the limits, then it means the projection of the mill
material balance shown on the Projection sheet (sheet-IV, pager 1 through page 3) for overall as
well as the individual performance are final and good.
Otherwise, simulation has to be redoing until all the values are relevant to the limits.
10.2.2 The Simulation Steps
To be more clear and speeding up the simulation, the steps below are necessary to be followed
within the data filling:
Program Komputer
X- 2
pt indocode surya
Step NR.
Step descriptions
Remarks
1.
2.
Understood.
3.
4.
5.
6.
7.
Program Komputer
X- 3
pt indocode surya
9.
10.2.3
To simplify and speeding up the Projection of mill material balance, the following limit values
used as guidance for the simulations:
1. The no-void density of mill#1 bagasse
Depends on the existence and use of the foreworker:
1 Crusher
1,15 - 1,16
1 Unigrator
1,15 - 1,17
1 Crusher + 1 Unigrator
1,15 - 1,18
2 Cane Cutter
1,15 - 1,18
1,15 - 1,19
1,15 - 1,20
X- 4
pt indocode surya
If it is possible and advisable when simulating the Brix degree for juice #1, the value of r for
mill#1 shall be made equals to the value of its r.
The value of normal absorption ability factor (r) for any mill (mill #n) is lower than its value
for the ultimate mill (mill#n-1). It has decreasing graduation values up to the last mill.
It is very important to observe, that the value of the normal absorption ability factor r for the
last mill bagasse must be less than the value of its r. It is anticipated in practice that if the
calculated value of r > r, then it is definitely juice will spraying out from the last mills
delivery opening. Decreasing the value of the total mixed juice or the total water imbibition
for such condition will retain the last mills delivery opening from spraying out juice.
3. Juice extraction (En)
The best value of juice extraction (En) in each mill to be > 60 %.
When the extraction value in every mill is less than 60%, then it is definitely caused by a too
small quantity of imbibition water applied. But it is to be noted that the maximum quantity
of imbibition water shall refers to the capacity of the existing evaporator tandem.
4. The ratio of Vlb to Vlbo:
Vlb
Vlbo
5 mill tandem
Mill No.1
0,25
Mill No.2
0,28
Mill No.3
0,32
Mill No.4
0,37
Mill No.5
0,45
0,35
0,40
0,45
0,50
0,35
0,38
0,42
0,47
0,50
0,900
0,900
0,800
0,600
0,500
1,100
1,000
0,900
0,800
0,700
2)
Disarikan dan disesuaikan dari C.R. Murray & J.E. Holt, The Mechanics of Crushing Sugar Cane, 1967
Program Komputer
X- 5
pt indocode surya
7. The ratio between the extracted juice volume from the feed and the delivery openings (y):
y = positive, means juice is extracted by the feed opening.
y = negative, means juice is not extracted by the feed opening.
When projecting the performance of a mill tandem, the value of y should be made positive,
whereas around 0,10 to 0,30.
8. The coefficient of friction ()
is the coefficient of friction between cane/bagasse and the roller surface. The value of
depends on the mill roller rotations, normally between 0,32 - 0,38.
9. The Compression (K)
The value of compression or the compression ratio, K is between 3,50 - 2,00
Normally the value of K is gradually decreasing from mill #1 to the ensuing mills. But it is
often that, mill#2 is working harder than mill#1. In such condition the value of K for mill #2 is
higher than for mill#1.
The value of compression ratio (K) is normally pro-rate equals to the value of the fiber index
(c). If the value of the compression ratio (K) is low, then is also the value of (c).
The values of compression ratio (K) and fiber index (c) indicates the grabbing and squeezing
capability of the roller in use, enable the bagasse/cane feeds to the mill constantly. A good
roller material, either made of cast iron or cast steel must be acid resistant and having the
character of forming raw grain surface to the roller.
10.2.4 Projection Result
After finishing the simulation of the Brix and Pol degrees on sheet-III (projection inputs) and
resulting the correct values for the table thereafter, or at least near to the limitations, then the
overall result of projection can be seen on sheet-IV as shown on the following pages, consisting
of:
Page 1: Projection of a complete material balance, for overall and individually.
Page 2: Projection of performance, for overall and individually.
Page 3: Projections of the best mill settings and the average extracted juice analyses, the
imbibition water and so on.
Page 4: The best Brix curve projection.
Program Komputer
X- 6
pt indocode surya
MATERI
SUGAR
ALFACTORY
MILL BA
TRAIN
CANE
LA
QUALITY
NC
MILL I
- Juice
- Fiber
Total in
- Fiber
Total
MILL II
- Juice
- Fiber
Total in
- Fiber
Total
MILL III
- Juice
- Fiber
Total in
- Fiber
Total
MILL IV
- Juice
- Fiber
Total in
- Fiber
Total
MILL V
- Juice
- Fiber
Total in
- Fiber
Total
Page : 1
EXAMPLE
2 CC + 5 MILLS
% pol =
Mass
kg/hr.
%
brix
CAPACITY
MILLING SEASON
10,32
% brix =
13,41
Brix
kg/hr.
%
pol
Pol
kg/hr.
MILL I
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =
10,02
21,33
270
0,3944
2,14
71.464
71.464
r=
r' =
u=
y=
K=
HKnp =
kB =
1,3091
1,3091
0,34
0,13
2,48
81,00
0,992
MILL II
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =
10,23
21,33
270
0,3071
2,70
56.805
56.805
r=
r' =
u=
y=
K=
HKnp =
kB =
1,2923
1,2982
0,34
0,10
3,14
77,98
0,935
MILL III
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =
10,21
21,33
270
0,2684
2,57
49.558
49.558
r=
r' =
u=
y=
K=
HKnp =
kB =
1,2771
1,2874
0,34
0,10
2,99
72,32
0,822
MILL IV
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =
10,20
21,33
270
0,2467
2,51
45.502
45.502
r=
r' =
u=
y=
K=
HKnp =
kB =
1,2691
1,2767
0,34
0,11
2,92
67,74
0,705
MILL V
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =
10,34
21,33
270
0,2289
2,09
42.805
42.805
r=
r' =
u=
y=
K=
HKnp =
kB =
1,2681
1,2655
0,33
0,13
2,43
62,11
0,602
167.860
32.140
200.000
90.000
77.860
32.140
110.000
15,98
26.820
12,30
13,41
15,90
16,12
26.820
14.266
12.554
10,32
12,88
11,67
11,41
12.554
8,26
165.296
32.140
197.436
110.000
55.296
32.140
87.436
10,56
17.450
7,64
8,84
9,90
11,92
17.450
10.857
6.594
6,39
7,72
7,52
7,54
6.594
4,76
131.578
32.140
163.718
87.436
44.142
32.140
76.282
6,81
8.959
4,38
5,47
5,60
9,20
8.959
4.896
4.062
3,52
4,05
5,03
5,33
4.062
2,91
114.180
32.140
146.320
76.282
37.898
32.140
70.038
4,39
5.017
2,46
3,43
3,10
7,00
5.017
2.365
2.653
1,92
2,10
3,20
3,79
2.653
1,73
84.018
32.140
116.158
50.272
33.747
32.140
65.887
3,16
2.653
1,44
2,28
1,90
5,03
2.653
955
1.697
1,04
1,18
1,83
2,58
1.697
0,94
Program Komputer
PROJEC
4.800,0 TCD
PERIOD
: X
TION1977
/
Date : Last date
PERFO
% fiber = 16,07
RMANC
Density Volume
kg/dm3 dm3/hr.
Evalu
X- 7
pt indocode surya
MATERI
SUGAR
ALFACTORY
MILL BA
TRAIN
CANE
LA
QUALITY
NC
Page : 2
EXAMPLE
2 CC + 5 MILLS
% pol =
CAPACITY
MILLING SEASON
10,32
% brix =
THE TARGETS
Descr
iCane:
ption
crushed,
- juice
content
Imbibitio
- % fiber
n water:
-%
- on
- on
- on
- on
bagasse
Mixed
juice:
-%
- pol
- brix
- purity
Last mill
-%
bagasse:
- pol
- brix
- fiber
- dry
- juice to
- juice
loss in
bagasse
- Brix
Extractio
- sugar
n's:
- sugar
Ratio of juice purity
Crystal:
- can be
- in
expected
- loss in
Program Komputer
13,41
PROJEC
4.800,0 TCD
TION1977
/
PERFO
% fiber = 16,07
RMANC
PERIOD
: X
Date : Last date
Symbol
Value
Unit
Q
4.800,0
TCD
jg
24,00
Jam
Qj
200.000
KCH
gnt
83,93 % cane
Gi
1.581,3
Tons
Gij
65.887 kg/hr.
gis
205,00 % fiber
git
32,94 % cane
gia1
0 % Gij
gia2
0 % Gij
gia3
30 % Gij
gia4
70 % Gij
Gnm
4.800,0
Tons
Gnmj
200.000 kg/hr.
gnmt
100,00 % cane
pnm
10,04
%
bnm
12,60
%
HKnm
79,69
%
Gal
65.887 kg/hr.
galt
32,94 % cane
pal
0,94
%
bal
2,58
%
kf
48,78
%
zk
51,36
%
nss
105,00
%
gnhs
33,22 % fiber
HPB-I
53,19
%
HPB-t
93,67
%
HPG
97,00
%
HPG12,5
97,67
%
PSHK
97,51
%
kt
9,08 % cane
knm
8,99 % cane
khar
1,03
%
=
=
=
=
I
II
III
IV
V
53,62
66,55
66,45
66,81
59,83
> 60
> 60
> 60
> 60
> 60
55,99
67,05
61,46
56,93
48,95
53,19
62,21
54,66
47,13
36,01
2,48
3,14
2,99
2,92
2,43
2,4-3,3 2,6-3,5 2,6-3,3 2,5-3,2 2,4-3,0
0,13
0,10
0,10
0,11
0,13
y =
meaning = extracted extracted extracted extracted extracted
l =
0,00
0,00
0,00
0,00
0,00
meaning =
safe
safe
safe
safe
safe
da =
1,1758
1,1911 1,2053 1,2128 1,2138
r =
1,3091 1,2923 1,2771 1,2691 1,2681
r' =
1,3091 1,2982 1,2874 1,2767 1,2655
gat =
55,00
43,72
38,14
35,02
32,94
pa =
8,26
4,76
2,91
1,73
0,94
ba =
11,41
7,54
5,33
3,79
2,58
zk =
40,63
44,30
47,46
49,68
51,36
c =
0,45
0,57
0,65
0,71
0,75
q =
177,38 173,73 174,07 174,25 171,89
q' =
134,89 129,41 129,92 130,17 126,67
Normal value =
120 130 grams/dm2 escribed surface
kf =
29,22
36,76
42,13
45,89
48,78
Normal
25-35
28-38
32-42
37-47
45-50
%
%
%
%
%
kg/dm3
%
%
%
%
kg/dm3
gr/dm2
gr/dm2
%
%
X- 8
pt indocode surya
Mill #1
Mill #2
Mill #3
Mill #4
Mill #5
b
a
hd
n =
c =
kf =
i =
q =
q' =
When:
hb
c
0,45
0,57
0,65
0,71
0,75
Page : 3
q
177,38
173,73
174,07
174,25
171,89
q'
134,89
129,41
129,92
130,17
126,67
kf
29,22
36,76
42,13
45,89
48,78
i
2,14
2,70
2,57
2,51
2,09
CTC
Work
CTC
Set
Roller
Fiber
Fiber
Ratio of
Fiber
Fiber
q' =
q' =
q' =
q' =
THE
Dimensio
Mill #1,
Mill #2,
Mill #3,
Mill #4,
Mill #5,
top
feed
delivery
top
feed
delivery
top
feed
delivery
top
feed
delivery
top
feed
delivery
Do
1.052,0
1.050,0
1.048,0
1.073,0
1.069,0
1.066,8
1.051,0
1.048,0
1.040,0
1.050,0
1.048,0
1.040,0
1.064,0
1.052,0
1.048,0
Legend:
Do =
k=
Dk =
L=
t =
k
25,0
25,0
25,0
25,0
25,0
25,0
15,0
15,0
15,0
15,0
15,0
15,0
15,0
15,0
15,0
Dk
1.002,0
1.000,0
998,0
1.023,0
1.019,0
1.016,8
1.021,0
1.018,0
1.010,0
1.020,0
1.018,0
1.010,0
1.034,0
1.022,0
1.018,0
L
2.133
2.133
2.133
2.133
2.133
Work
Set
Opening Opening
t
6,0
4,7
4,7
6,0
4,7
4,7
6,0
4,7
4,7
6,0
4,7
4,7
6,0
4,7
4,7
Outside
Groove
Mean
Length
Top
84,27
39,44
29,61
-15,22
1.085,3
1.039,4
1.080,6
1.034,8
257
487
83,01
30,71
28,35
-23,96
1.104,0
1.050,6
1.099,3
1.045,9
249
467
69,08
26,84
34,41
-7,82
1.088,6
1.042,3
1.083,9
1.037,7
205
380
61,84
24,67
27,18
-9,99
1.080,8
1.039,7
1.076,2
1.035,0
183
336
47,77
22,89
13,11
-11,77
1.075,8
1.048,9
1.071,1
1.044,2
141
259
hf =
hd =
CTC =
a=
b=
Feed
Delivery
Center
Feeding
% zk
% fiber
Imbibition water :
Applied on :
- total =
- bagasse 1 =
bagassebagasse-
Program Komputer
10,32
10,04
12,88
7,72
4,05
2,10
1,18
0,94
65.887
0
0
30
70
% brix
13,41
12,60
15,90
9,90
5,60
3,10
1,90
2,58
ltr/hr.,
%
%
%
%
Purity
79,69
81,00
77,98
72,32
67,74
62,11
36,44
or
or
or
or
or
=
=
=
=
=
51,36
205,00
0
0
19.766
46.120
16,07
48,78
% fiber
ltr/hr.
ltr/hr.
ltr/hr.
ltr/hr.
X- 9
pt indocode surya
EXAMPLE
MILL TRAIN
2 CC + 5 MILLS
CANE QUALITY
4.800,0 TCD
MILLING SEASON :
% pol =
V a l u e
10,32
% brix =
f o r ------------->
1977
13,41 % fi ber =
Page : 4
PERIOD
Date
Last date
16,07
Mill I
Mi ll II
Mil l III
Mill IV
Mi ll V
15,90
9,90
5,60
3,10
1,90
20
19
18
17
16
<-------
% bri x
------->
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
Mill I
Mill II
Mill III
Mill IV
Mill V
Expected Curve
Program Komputer
X- 10