Material - Balance - in - Milling - Tandem-2014 (Autosaved 14502016

5 MILL 15 ROLLER TANDEM, Compound Imbibitio
Material Balance in milling tandem

Cane = Juice + Fibre
Cane crushi
1
Added imbib
0.3
Cane crushing -- C = J + f
Fibre in can
0.14 Fibre in Bagasse P REIN
Fibre in Ba Fibre Index kg/m
Fibre in Bag
0.3386
32
560
30
525
34
595
Fibre in Bag
0.3748
40
700
39
682.5
39
682.5
Fibre in Bag
0.4109
45
787.5
43
752.5
45
787.5
Fibre in Bag
0.4471
48
840
46
805
50
875
Fibre in Bag
0.4833
50
875
48
840
Brix from p
21
50
875
Bagasee from
0.413467
Bagasee from
0.373533
Bagasee from
0.340716
Bagasee from
0.313129
Bagasee from
0.289675
Mill input = Mill Output C = b1 + j1
Priamary J 0.586533
Juice in Ca
0.86
Material Balance for 100 Tonnes
Priamary E 0.682015
For Mill No 0.323454
Juice comi 0.35104
Juice comi 0.383857
Juice comi 0.423792
MJ % Cane101.0325
BRIX BALANCE IN 5 MILL TANDEM
1)
2)
3)
4)
5)
6)
7)
8)
9)
Cane cr
Fibre %
Imbibit
Brix %
Fibre in
Fibre in
Fibre in
Fibre in
Fibre in
400
14
30
19
0.3386
0.3748
0.4109
0.4471
0.4833
(i)Calculations of Ideal Brix

For compoound imbibition the ideal brix for individual mill
Brix in n th Mill juice = (1 + s + s + s + - + sm- -/1 + s + s + s+ s)
S = W/ f
2.142857
MILL
IDEAL
FEED
S
4.591837
S
9.83965
S
21.08496
a) For mill no -2 ; n= 4
Br
0.454595
Ideal Bri 8.637313
b) For Mill no - 3, n= 3
Brix % Jui 0.200073
Ideal Brix 3.801392
c)For Mill no - 4 n =2
Brix % Jui 0.081296
Ideal Brix 1.544629
d) For Mill no- 5 n = 1
Brix % Jui 0.025867
Ideal Brix 0.491473
m= 4
I
II
III
IV
V
9.55
4.2
1.71
m=4
m=4
m=4
Brix Balance In Milling Tandem

(a) For Mill no - 1; Brix entering in I st mill = Brix leaving from Ist mill juice & Bagasse
Brix in Cane entering = Brix in PJ + Brix in Bagasse
Brix in Bagasse = Brix in Cane - Brix in PJ
Brix % ab
18.316
Brix in Ca 70.69976
Brix in PJ
11.14412
Q=
58.65328
Bx leaving from mill no -1 = Bx in cane entering mill 1- Bx.in PJ leaving from mill 1
59.55564
fibre in bag
0.3386
Qty of mill 4134.672
Bx % Bagas1.440396
(b) For Mill No -2
Bx in J2 = 3.660425
Bx in J3 = 1.459192
Bx in J4 = 0.542227
Bx in J5 = 0.158969
Bx entering in 2nd. Mill = Bx leaving from 2nd.mill in juice & bagasse
Bx in b1 +
57.3544
Bx % 2nd 153.5459
For Mill no-3
Bx entering in 3rd. Mill = Bx leaving from 3rd.mill in juice & bagasse
Bx in b2 + 56.43744
Bx % 3rd 165.6439
(D) For Mill No- 4

Bx entering in 4th . Mill = Bx leaving from 4 th.mill in juice & bagasse
Bx in b3 + 56.05418
Bx % 4 th 179.013
(E)For Mill No - 5
Bx in b4 + 55.89521
Bx % 4 th 192.9583
(3) Mill Extaction
(a) 1st Mil
15.7626
(b) 2nd Mil 3.113493
(c) 3rd Mil 1.296985
(d) 4th Mil 0.542093
(e) 5 th Mi 0.224851
(4) Mill Ex 20.94003
(5) Contribution in Mill Extraction by Individual Mills in the Tandem
% ExtractioBx Extran
a)Priamar 15.7626
76.15
b)Secondary Mills
(i)
3.113493
14.9
(ii
1.296985
5.7
(iii) 0.542093
2.25
(iv
0.224851
1
c) Overal 20.94003
100
Bx = Pol/Purity
Pol % Cane %
13
f --- Fiber %
15
P --- Pol % %
16
Priamary Jui%
20
Priamary Jui%
80
(1) Total Losses in Indian Sugar industry = 1.6% to 2.6 % ,can be 1.6% to 1.7% by Effective Managem
Extraction = x 100
cane
Extraction = . sucrose or in mixed juice % cane x 100
sucrose or pol % cane
the higher the fibre, the greater the loss of the sugar in the bagasse, since:
Sugar loss in bagasse % cane = sugar % bagasse x bagasse % cane
Lost juice % fibre =

brix of bagasse x 10,000
brix of primary juice X fibre % bagasse
Brix of bagasse
=
Pol % bagasse x 100
purity of last expressed juice
The extraction, or, to be more precise, the efficiency of the mill work, decreases as the
capacity ratio (or, what amounts to the same thing, the specific fibre loading) increases.
India it is estimated that the reduced extraction of a milling plant falls by 0.17 when
i t is operated at 10% above normal For example, if a mill is capable of crushing 100
t.c.h., and if its reduced extraction is 95, this should drop to 94.83 if the rate is increased
to 110 t.c.h.
ibre Index kg/m
ance for 100 Tonnes Sugar Unit
DISCHARGE
y Effective Management& Technical skill.(2) Sugar Recovery = Sugar in Cane - Total Losses (3) Reducing Total lo
(3) Reducing Total loss by 1% means rise in Sugar recovery.
(4) 1% rise in Sugar recovery.means10 Kgm ad
ery.means10 Kgm additional sugar recovered per Ton of Sugar cane Crushed.
(5)(a) Sugar Loss
(5)(a) Sugar Loss in Bagasse ---- 0.50 to 0.60 % of Cane
(b)Sugar Loss in Waste Molasses ---- 0.90 to 1.00 % of Cane
(c)Sugar Loss in Filter Cake ----
ss in Filter Cake ---- 0.05 to 0.07 % of Cane
(d) Sugar Loss as Unkown ---- 0.050 to 0.070 % of Cane
Total Losses = 1.5% to 1.74 % of Cane, Optimum
% of Cane, Optimum Imbibition appears to 250% of fibre, At 14% fibre, it will be 114 X 250/100 = 35% out of wh
100 = 35% out of which final bagasse would get saturated with water at level of 20% & remainning 15% will go
mainning 15% will go in MJ with more sugar.
** Bagasse Pol = 52%to 55% of Pol % Last Expressed Juice
essed Juice
Feed Pump 82.00632

(a) Max. se 75.30632
(b) Pressur
0.5
Line Los
1
(d) Presuur
2
(e) Pressur
2
(f) Static
0.2
in steam drum above BFP Discharge in meters =20 meter
(g) Pressur
1
Drum pressKg/ Cm
(i) At NRV
66
(ii) Pressu
1
(iii) Super
67
(iv) Super
0.05
v) Super he 70.52632
(vi) Pressu
1.148
(vii) Press
0.2
(viii) Pres
1.032
(ix) Pressu
0.7
(x) Drum P
70.08
(xi) Pressu
0.7
(Xi) Pressu 74.60632
(Xi) Pressu 75.30632
Drum Desig 77.30632
FEED PUMP 892.2921
Add Margi 267.6876
Design Pu
1159.98
Boiler Capa
80
Feed Pump
90.36
Margin in
99.396
Two feed pu
49.698
50 M/hr, 1160 m Head - 3 nos
Pump HP = 350.6961
KW require 261.6193
0.00365
STEAM AND POWER CONSUMPTION FOR FIBERISER AND MILL TURB

Column1 Column2 Column3 FIBERISER Column4 Column5 Column6
Date
TCH
FIBRE f% TFH
Kg/tfh
Kw/TFh
Kw/TCH
21.1.2003
190.83
12.42 23.70109
662.01
47.17
5.86
18.12.04
196.66
13.18 25.91979
663.83
47.4
5.24
Avg. 15 d
182.97
12.68
23.2006
624.82
44.63
5.65
Jan07 Av.
160.52
12.08 19.39082
712.07
50.86
6.14
Average
182.745
12.59 23.05307 665.6825
47.515
5.7225
1) Date
21.01.2003
2) Cane c
4580
3) TCH
190.8333
4)Fibre %
12.42
5)Ton of fi
23.7015
6) MJ % ca
95.42
7)Steam G TPH
(a) Boiler
22.775
(b) Boiler
23.22083
(c) Boiler
35.33333
TOTAL = 81.32917
42.6179
8) Steam
(i) Fiberiz
(ii) Mill Tu
(iii)Mill Tu
(iv) Mill T
(v) 3 MW T
(vi) PRD st
(vii) Distil
TOTAL Co
TPH
15.67
5.137917
7.9225
7.710833
37.89
3.14
3.720644
81.19189
TPH
9) Bagas 50.41817
10) Steam/
2.2
11) Bagase 36.9678
12) Bagas 13.45036
(13) Power
58149
(14) KWh/t 12.69629
Vapour 21.12.03
% CANE
8.211354
2.692358
4.151528
4.040611
19.85502
1.645415
1.949682
42.54597
26.42
19.37177
7.048225
2422.875
6.653077
Juice Heating from 68 C to 76C
8 lbs steam @ 100 to 125
1
2
3
4
5
6
7
8
9
10
11
12
13
Cane Crush
4530
Cane Crush 188.75
MJ % Cane 176.6134
At 86 C L
547.6
At 95 C L
542
At 100 C L
538.9
At 120 C L
525.7
Loss due to
0.95
RJ1 Heating 3.584839
RJ2 Heating 9.26114
RJ3 Heating 2.483844
SJ heating 8.911741
CLJ heatin 3.446934
14 For A massc
0.2283
Quantiy
43.09163
In Brix
93.52
Syrup Brix
58
Specific Gr
1.5
Quantity of 24.55006
15 For B masse 0.0996
Quantity
18.7995
Brix of inc
96.1
Bx Of Outle
70
16
For C massecute b 0.0548

Quantity
10.3435
Brix of inc
101.58
Bx Of Outle
70
17 TOTAL Stea 37.03226
(a)
Evaporatio 8.891396
(b)
(d)
(e)
Evaporation from IV th Body = + 3.972

Evaporation from III Body = + 3.97+9.260
Evaporation from II Body = +3.97+9.260
Evaporatio 24.22122
= 5 + 8 81.63888
18 Inlet juice
16.59
19 Total Evapo 126.0959
5 + 83.174 = 126.095
20 Evaporatio 8.891396 0.047107
I
II
III
IV
Exhaust req
Exhaust req
Exhaust req
Total Exha
21 Power Gene
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(ix)
a
b
c
61.25348 32.45217
8.911741 4.721452
3.446934
1.82619
73.61215 38.99982
2251.7
22 Exhaust generated by Steam Turbines in TPH

Fiberizer T 15.49893
Mill Turbin 5.081826
Mill Turbin
7.83601
Mill Turbin 7.626654
3000 KW T 35.21659
23 Total Exha 71.26001 37.75365
Make up St 2.352146
1.24617
Distillery
3.26
Steam at 8
3.775
24 TOTAL STEA 80.64715 42.72697
25 TOTAL STEAM GENERATED IN TPH
Boiler No-1
24.3
Boiler No-2 24.58333
Boiler No-4 35.7625
26 TOTAL STE 84.64583 44.84547
ISER AND MILL TURBINES Manjara

Column7 MT 1
Column8 Column9 MT-2
Column10 Column11 MT-3
Kg/TFH
Kw/TFh
Kw/TCH
Kg/tfh
Kw/TFh
Kw/TCH
Kg/tfh
Kw/TFh
0
0
0
0
0
0
0
0
160.74
9.45
1.25
295.56
17.38
2.24
265.83
15.61
162.58
9.56
1.21
242.58
14.26
1.8
254.35
15.08
180.28
10.6
1.28
288.13
16.94
2.046
299.27
17.6
167.8667
9.87 1.246667 275.4233 16.19333 2.028667
273.15 16.09667
from 38 C to 68 C
From 25 C to 38 C
Column12
Kw/TCH
0
2.05
1.9
2.12
2.023333
Calculations of boilers and Steam Consumptions

(i) Bagas
(ii) Mois
(iii) Gros
(iv) Net
(v)Boiler
(vi)Entha
(vii) Ent
(ix) Steam
(x) HP heat
(xi) Brix %
(xi) Ash %
(iii) Gro
(iv) Net
2
50
2276
1801
69
825
105
2.181167
2.379455
2
1.75
2244.185
1796.32
BOILER CALCULATIONS
(1) Steam Q
90
(2) Steam P
89
(3) Steam t
540
(4)Feed wat
105
(5)Boiler
3
(6)Flue gas
145
(7) Ambient
26.7
(8)Hot air
195
(9) Relativ
60
(10)Site Al sea level
(11)Fuel as bagasse
(12)Excees
35
(13)Steam Pressure drop of 2 Kg/cm and Temperature drop 5 C is considered.
(14)Ultimat
(weight %)
(i) Carbon
24.08
(ii) Hydrog
3.02
(iii) Oxyg
21.55
(iv) Nitrog
0.15
(v) Moistur
50
(vi)Ash
1.2
(vii)Sulfur
0
(viii) Highe
2300
(15) Calculations for unit weight of Fuel

(a)Oxygen n0.695016
(b)Nitroge 2.307453
(c)Therotic 3.002469
(d)Excess A 1.050864
(e)Air (dry 4.053333
At 60% RH, 0.052693
(f) total qu 4.106027
(g) Fuel ap
0.988
(h) Total F 5.094027
(i)Sensible 293.7145
12.7702
1727.74
0.769988
1330.339
165.8506
(j)Total mo 0.822681
(k) Dry flu 4.271345
(l) Moistur 0.769988
(i) Co2 fo 0.881328

(ii) H2O f 0.822681
(iii) N2 wi 0.807064
(iv) N2 wit 2.305896
(v) N2 wit
0.0015
Total N2 = 3.11446
(vi) O2 in
0.2438
(vii) Total
5.06227
(ix) ERROR %
-0.623413
(x) Average 5.078148
FLUE GAS
%
MWt.
17.3553
16.20042
15.89287
45.40821
0.029538
61.33062
4.800972
moles
Mole %
MOLE % Dr
44 0.394439 10.85152 14.42269
18 0.900023
24.7608
0
28 2.190379 60.26016 80.09144

32
0.15003 4.127529 5.485876
3.634872
2.734849
27.51129
** THERMAL EFFICIENCY CALCULATIONS IN DIRECT METHOD PTC - IV CODE

(a) Temper
160
(b) Ambien
26.7
1) Dry gas 5.941256
2)Moist in 21.83753
3) Moist.
4) Total S
5) Radiati
6) Unburne
7) Manufac
8) TOTAL
9) Thermal
10) Fuel Fir
11) Fuel Bu
0.14048
27.91927
0.41
2.7
1.5
32.52927
67.47073
67.47073
69.81973
12) Heat required for Steam Generation

(1) Steam Q
90
(2) Steam P
89
(3) Steam t
825
(4)Feed wat
105
(5)Boiler
3
(6) Enthal
825
(7) Saturate
303.74
(8) Saturate
662.66
(9) Heat re
165
(10)UNIT OF 664.1622
(13) STEAM 2.336518
Kg/hr TPH
(14) Steam59774598
59774.6
(15) Fuel F 38518.86 38.51886
(16) Fuel
37222.94 37.22294
(17) Flue 189614.6 189.6146
(18) Air fo 152838.4 152.8384
*** GRATE AREA CALCULATIONS
Heat Load 2305200
Grate Effective Area = Furnace Width x Furnace Depth
Grate Effe 38.43197
Furnace Width is diamensions parellel to steam drum & decided on no. of SH Tubes
Specific V
0.04773
Specific V
0.02861
Average Sp 0.03817
Total Stea
90000
Volume Flo 0.95425
Super hea
50.8
Super heat
4.05
Super heate
42.7
Steam Flow 0.001434
Recommend
17
No. of para 39.13098
Membrane W
102
Roof Tube
102
Clear Gap
25.8
So SH tubes
204
Super heate
204
Width of fu
7344
Furnace Dep5.233111
No. of Side 51.30501
Considering
48
Furnace Dep
4998
Corrected G 36.70531
Actual Grat 2413639
say 35
7.344
5233.111
say 49
4.998
ok
Furnace Height is based on flue gas residence time & Allowable Furnace volumetric heat absn.
Flue gas te furnace water walls
Selection of configuration is based on the capacity,pressure, temperature & Fuel charcteristick
6300
7400
1 -20.3
2 --13.31
3 -11.81
4 -9.2
5
5.235
6 -Rear Wall header level = Hr = 5235 mm
8 -4.998
9 -2.3
10 -- Furnace Width = Width = 7344 mm
11 -- Slag Screen Tube = mm
12 -- Ape
7.4
13 -- Space between Rear wall & Nose
*** Furnace Effective Projected Radiant Surface (EPRS)

EPRS reqd. for caculate Flue Gas temperature leaving furnace
Projected surface is Front wall,roof water wall,sides water wall,rear water wall heat absorbing
surfaces. For membrane & tangent tube Construction radiant surface correction factor is one
where as for space tube radiant tubes it is less than one.
(1) Appera 54.3456
(2) Front
81.5184
(3) Roof W 16.8912
(4) Rear Wall is addition of st. ht + slope
Straight H
6.075
Slope ={ (4 3.086941
(4.9 - 2.3) 7.279204
(13.310 2.25
9.529204
(5) Rear A 67.28529
(6) Side Area is sum of the two side water wall
2 x {(roof 108.8247
34.6495
7.325
2.698
(7)EPRS = 328.8652
* Furnace Exit Gas Temperature (FEGT) = [(Gas Sens.Heat x (mg )/EPRS]/(0.37 x Gas Sens.Heat x mg
576.5725
[(Gas Se 213.3318
793.8231
Total Heat Realesed absorbed by Furnace tubes by radiations& balance from gases through convectio
Ht = Hr + Hc
ric heat absn.

charcteristick
eat absorbing
factor is one
Gas Sens.Heat x mg )/EPRS + 8.512]
es through convection &
Calculations of boilers and Steam Consumptions

(i) Bagas
2
(ii) Mois
50
(iii) Gros
2276
(iv) Net
1801
(v)Boiler
69
(vi)Entha
807
(vii) Ent
105
(ix) Steam 2.237094
(x) HP heat 2.446168
BOILER CALCULATIONS
(1) Steam Q
80
(2) Steam P
66
(3) Steam t
485
(4)Feed wat
105
(5)Boiler
3
(6)Flue gas
160
(7) Ambient
26.7
(8)Hot air
195
(9) Relativ
60
(10)Site Al sea level
(11)Fuel as bagasse
(12)Excees
35
(13)Steam Pressure drop of 2 Kg/cm and Temperature drop 5 C is considered.
(14)Ultimat
(weight %)
(i) Carbon
24.08
(ii) Hydrog
3.02
(iii) Oxyg
21.55
(iv) Nitrog
0.15
(v) Moistur
50
(vi)Ash
1.2
(vii)Sulfur
0
(viii) Highe
2300
(15) Calculations for unit weight of Fuel

(a)Oxygen n0.695016
(b)Nitroge 2.307453
(c)Therotic 3.002469
(d)Excess A 1.050864
(e)Air (dry 4.053333
At 60% RH, 0.052693
(f) total qu 4.106027
(g) Fuel ap
0.988
(h) Total F 5.094027
(i)Sensible 293.7145
12.7702
1727.74
0.769988
1330.339
165.8506
(j)Total mo 0.822681
(k) Dry flu 4.271345
(l) Moistur 0.769988
(i) Co2 fo 0.881328

(ii) H2O f 0.822681
(iii) N2 wi 0.807064
(iv) N2 wit 2.305896
(v) N2 wit
0.0015
Total N2 = 3.11446
(vi) O2 in
0.2438
(vii) Total
5.06227
(ix) ERROR %
-0.623413
(x) Average 5.078148
FLUE GAS
%
MWt.
17.3553
16.20042
15.89287
45.40821
0.029538
61.33062
4.800972
moles
Mole %
MOLE % Dr
44 0.394439 10.85152 14.42269
18 0.900023
24.7608
0
28 2.190379 60.26016 80.09144

32
0.15003 4.127529 5.485876
3.634872
2.734849
27.51129
** THERMAL EFFICIENCY CALCULATIONS IN DIRECT METHOD PTC - IV CODE

(a) Temper
160
(b) Ambien
26.7
1) Dry gas 5.941256
2)Moist in 21.83753
3) Moist.
0.14048
4) Total S
5) Radiati
6) Unburne
7) Manufac
8) TOTAL
9) Thermal
10) Fuel Fir
11) Fuel Bu
27.91927
0.41
2.7
1.5
32.52927
67.47073
67.47073
69.81973
12) Heat required for Steam Generation

(1) Steam Q
80
(2) Steam P
66
(3) Steam t
485
(4)Feed wat
105
(5)Boiler
3
(6) Enthal
807
(7) Saturate
303.74
(8) Saturate
662.66
(9) Heat re
105
(10)UNIT OF 707.9622
(13) STEAM 2.191963
Kg/hr TPH
(14) Steam56636976 56636.98
(15) Fuel F 36496.97 36.49697
(16) Fuel
35269.07 35.26907
(17) Flue 179661.6 179.6616
(18) Air fo 144815.7 144.8157
*** GRATE AREA CALCULATIONS
Heat Load 2305200
Grate Effective Area = Furnace Width x Furnace Depth
Grate Effe 36.41464
Furnace Width is diamensions parellel to steam drum & decided on no. of SH Tubes
Specific V
0.04773
Specific V
0.02861
Average Sp 0.03817
Total Stea
80000
Volume Flo 0.848222
Super hea
50.8
Super heat
4.05
Super heate
42.7
Steam Flow 0.001434
Recommend
17
No. of para 34.7831 say 35

Membrane W
102
Roof Tube
102
Clear Gap
25.8
So SH tubes
204
Super heate
204
Width of fu
7344
7.344
Furnace Dep 4.95842
4958.42
No. of Side 48.61196 say 49
Considering
48
Furnace Dep
4998
4.998
Corrected G 36.70531
Actual Grat 2286945 ok
Furnace Height is based on flue gas residence time & Allowable Furnace volumetric heat absn.
Flue gas te furnace water walls
Selection of configuration is based on the capacity,pressure, temperature & Fuel charcteristick
6300
7400
1 -20.3
2 --13.31
3 -11.81
4 -9.2
5
5.235
6 -Rear Wall header level = Hr = 5235 mm
8 -4.998
9 -2.3
10 -- Furnace Width = Width = 7344 mm
11 -- Slag Screen Tube = mm
12 -- Ape
7.4
13 -- Space between Rear wall & Nose
*** Furnace Effective Projected Radiant Surface (EPRS)

EPRS reqd. for caculate Flue Gas temperature leaving furnace
Projected surface is Front wall,roof water wall,sides water wall,rear water wall heat absorbing
surfaces. For membrane & tangent tube Construction radiant surface correction factor is one
where as for space tube radiant tubes it is less than one.
(1) Appera 54.3456
(2) Front
81.5184
(3) Roof W 16.8912
(4) Rear Wall is addition of st. ht + slope
Straight H
6.075
Slope ={ (4 3.086941
(4.9 - 2.3) 7.279204
(13.310 2.25
9.529204
(5) Rear A 67.28529
(6) Side Area is sum of the two side water wall
2 x {(roof 108.8247
34.6495
7.325
2.698
(7)EPRS = 328.8652
* Furnace Exit Gas Temperature (FEGT) = [(Gas Sens.Heat x (mg )/EPRS]/(0.37 x Gas Sens.Heat x mg
546.3077
[(Gas Se 202.1339
793.8231
ric heat absn.

charcteristick
eat absorbing
factor is one
Gas Sens.Heat x mg )/EPRS + 8.512]
5 MILL 15 ROLLER TANDEM, Compound Imbibitio

Material Balance in milling tandem
Cane = Juice + Fibre
Cane crushi
1
Added imbib
0.3
Cane crushing -- C = J + f
Fibre in can
0.14 Fibre in Bagasse P REIN
Fibre in Bag
0.34
32
560
30
525
34
595
Fibre in Bag
0.39
40
700
39
682.5
39
682.5
Fibre in Bag
0.45
45
787.5
43
752.5
45
787.5
Fibre in Bag
0.5
48
840
46
805
50
875
Fibre in Bag
0
50
875
48
840
Brix from p
20
50
875
Bagasee from
0.411765
Bagasee from
0.358974
Bagasee from
0.311111
Bagasee from
0.28
Bagasee from
0
Priamary J 0.588235
Juice in Ca
0.86
Priamary E 0.683995
Juice comi 0.378974
Juice comi 0.431765
Juice comi
0
MJ % Cane
102
1)
2)
3)
4)
5)
6)
7)
8)
9)
Cane cr
Fibre %
Imbibit
Brix %
Fibre in
Fibre in
Fibre in
Fibre in
Fibre in
100
14
30
21
0.34
0.39
0.45
0.5
0

Brix in n th Mill juice = (1 + s + s + s + - - -/1 + s + s + s+ s)
S = W/ f
2.142857
MILL
IDEAL
FEED
S
4.591837
S
9.83965
S
21.08496
Br
0.440113
Ideal Bri 9.242369
Brix % Jui 0.178832
Ideal Brix 3.755474
Brix % Jui 0.056901
Ideal Brix 1.194924
Brix % Jui
0
Ideal Brix
0
m= 4
I
II
III
IV
V
9.55
4.2
1.71
m=4
m=4
m=4

(a) For Mill no - 1; Brix entering in I st mill = Brix leaving from Ist mill juice & Bagasse
Brix % ab
20.244
Brix in Ca 17.40984
Brix in PJ
12.35294
Q=
58.82353
Bx leaving from mill no -1 = Bx in cane entering mill 1- Bx.in PJ leaving from mill 1
5.056899
fibre in bag
34
Bx % Bagas12.28104
(b) For Mill No -2
Bx in J2 =
0
Bx in J3 = 1.621481
Bx in J4 = 0.452845
Bx in J5 =
0
Bx in b1 +
6.67838
Bx % 2nd 18.60406
For Mill no-3
Bx in b2 + 5.509744
Bx % 3rd 17.70989
(D) For Mill No- 4

Bx in b3 + 5.056899
Bx % 4 th 18.06035
(E)For Mill No - 5
Bx in b4 + 5.056899
Bx % 4 th
#DIV/0!
(3) Mill Extaction
(a) 1st Mil 70.95379
(b) 2nd Mil -9.313591
(c) 3rd Mil 6.712502
(d) 4th Mil 2.601089
(e) 5 th Mi
0
(4) Mill Ex 70.95379
% ExtractioBx Extran
a)Priamar 70.95379
76.15
b)Secondary Mills
(i) -9.313591
14.9
(ii
6.712502
5.7
(iii) 2.601089
2.25
(iv
0
1
c) Overal 70.95379
100
Bx = Pol/Purity
Pol % Cane %
13
f --- Fiber %
15
P --- Pol % %
16
Priamary Jui%
20
Priamary Jui%
80
Extraction = x 100
cane

Brix of bagasse
=
Pol % bagasse x 100
to 110 t.c.h.
ibre Index kg/m
DISCHARGE
y Effective Management& Technical skill.(2) Sugar Recovery = Sugar in Cane - Total Losses (3) Reducing Total lo
(3) Reducing Total loss by 1% means rise in Sugar recovery.
(4) 1% rise in Sugar recovery.means10 Kgm ad
ery.means10 Kgm additional sugar recovered per Ton of Sugar cane Crushed.
(5)(a) Sugar Loss
(c)Sugar Loss in Filter Cake ----
ss in Filter Cake ---- 0.05 to 0.07 % of Cane
Total Losses = 1.5% to 1.74 % of Cane, Optimum
% of Cane, Optimum Imbibition appears to 250% of fibre, At 14% fibre, it will be 114 X 250/100 = 35% out of wh
100 = 35% out of which final bagasse would get saturated with water at level of 20% & remainning 15% will go
mainning 15% will go in MJ with more sugar.
essed Juice
5 MILL 15 ROLLER TANDEM, Compound Imbibition Material Balance in milling tandem

Cane = Juice + Fibre MILL
Cane crushi
1
1
34
595
Added imbib
0.3
2
39
682.5
Cane crushing -- C = J
3
45
787.5
Fibre in can
0.14
4
50
875
Fibre in Bag
0.34
1
32
560
Fibre in Bag
0.39
2
40
700
Fibre in Bag
0.45
3
45
787.5
Fibre in Bag
0.5
4
48
840
Fibre in Bag
0
5
50
875
Brix from p
20
1
30
525
Bagasee from
0.411765
2
39
682.5
Bagasee from
0.358974
3
43
752.5
Bagasee from
0.311111
4
46
805
Bagasee from
0.28
5
48
840
Bagasee from
0
6
50
875
Priamary J 0.588235
Juice in Ca
0.86
Priamary E 0.683995
Juice comi 0.378974
Juice comi 0.431765
Juice comi 0.588235
MJ % Cane
102
1)
2)
3)
4)
5)
6)
7)
8)
9)
Cane cr
Fibre %
Imbibit
Brix %
Fibre in
Fibre in
Fibre in
Fibre in
Fibre in
100
14
30
21
0.34
0.39
0.45
0.5
0

Brix in n th Mill juice = (1 + s + s + s + - - -/1 + s + s + s+ s)
S = W/ f
2.142857
S
4.591837
S
9.83965
S
21.08496
Br
0.440113
Ideal Bri 9.242369
Brix % Jui 0.178832
Ideal Brix 3.755474
Brix % Jui 0.056901
Ideal Brix 1.194924
Brix % Jui
0
Ideal Brix
0
m= 4
m=4
m=4
Mill Performance data

Pol % Cane
13.48
Fibre % ca
13.11
Brix % Can
15.6
Brix in PJ
10.4
Added Water
200
Particulars MILL 1
Discharge Juice Analysis
Brix %
17.65
Pol %
15.25
Purity %
0.864023
m=4
Bagasse Analysis
Pol Reading
8.7
Moisture %
60
Moisture F
1.128
(a) For Mill no - 1; Brix entering in I st mill = Brix leaving from Ist Pol % Baga
9.8136
Fibre % Ba 28.64196
Bagasse % 0.45772
Brix % ab
20.244
Pol in Baga 4.491881
Brix in Ca 17.40984
Individual 0.666774
Brix in PJ
12.35294
Unit Pol Ex 0.666774
Q=
58.82353
Cumulative 0.666774
Bx leaving from mill no -1 = Bx in cane entering mill 1- Bx.in PJ lea Brix % Bag 11.35804
5.056899
Individual 0.666667
fibre in bag
34
Unit Brix E 0.666744
Cumulative 0.666744
Bx % Bagas12.28104
Brix in Ba
5.1988
(b) For Mill No -2
Bx in J2 = 5.436688
Bx in J3 = 1.621481
Bx in J4 = 0.452845
Bx in J5 =
0
Bx in b1 + 1.241693
Bx % 2nd 3.459001
For Mill no-3
Bx in b2 + 0.073057
Bx % 3rd 0.234825
(D) For Mill No- 4

Bx in b3 + -0.379789
Bx % 4 th -1.356389
(E)For Mill No - 5
Bx in b4 +
0
Bx % 4 th
#DIV/0!
(3) Mill Extaction
(a) 1st Mil 70.95379
(b) 2nd Mil 21.91408
(c) 3rd Mil 6.712502
(d) 4th Mil 2.601089
(e) 5 th Mi
0
102.1815
(4) Mill Ex
100
% Extraction
a)Priamar 70.95379
b)Secondary Mills
(i)
21.91408
(ii
6.712502
(iii) 2.601089
(iv
102.1815
c) Overal
100
Bx Extran
76.15
14.9
5.7
2.25
1
100
Bx = Pol/Purity
Pol % Cane %
13
f --- Fiber %
15
P --- Pol % %
16
Priamary Jui%
20
Priamary Jui%
80
Extraction = x 100
cane


Brix of bagasse
=
Pol % bagasse x 100
to 110 t.c.h.
MILL
I
II
III
IV
V
IDEAL
17.41
8.59
3.83
2.51
MILL
I
II
III
IV
Actual
18.69
10.38
6.43
3.93
ng tandem
MILL 2
MILL 3
MILL 4
ice Analysis
10.05
7.25
3.52
8.22
5.79
2.5
0.81791 0.798621 0.710227
5.3
53
1.118
5.9254
39.75544
0.329766
1.953997
0.564994
0.18827
0.855045
7.244558
0.540469
0.180115
0.846858
2.38901
3.4
50
1.112
3.7808
45.26584
0.289622
1.095004
0.439608
0.063723
0.918768
4.734162
0.426072
0.065249
0.912108
1.371119
2
48
1.108
2.216 0.629545
48.87987
0.268209
0.59435
0.457217
0.037141
0.955909
3.120128
0.389663
0.034248
0.946356
0.836845
y Effective Management& Technical skill
(2) Sugar Recovery = Sugar in Cane - Total Losses
FEED
DISCHARGE
19.16
17.65
8.21
10.05
3.83
7.25
2.55
3.52
IDEAL
18.69
8.72
2.74
2.49
Losses
(3) Reducing
(3) Reducing Total loss by 1% means rise in Sugar recover (4) 1% rise in Sugar recovery.means10 Kgm
overy.means10 Kgm additional sugar recovered per Ton of Sugar cane Crushed.
(5)(a) Sugar Lo
ne
(c)Sugar Loss in Filter Cake --
Loss in Filter Cake ---- 0.05 to 0.07 % of Cane
Total Losses = 1.5% to 1.74 % of Cane, Optimu
4 % of Cane, Optimum Imbibition appears to 250% of fibre, At 14% fibre, it will be 114 X 250/100 = 35% out of
50/100 = 35% out of which final bagasse would get saturated with water at level of 20% & remainning 15% will
remainning 15% will go in MJ with more sugar.
st Expressed Juice
Mill setting by Material balance Method

Cane Parameters
TCH
400 Imbibtion % Cane
0.3
Fibre % Cane
0.14 Imbibtion % Fibre
2.142857
Bagasse % Cane Mill1
0.4135
Cane Quality
1
Pol % cane
0.135 Last Mll Bagasse
Purity in Mix Juice
0.83 Moisture %
0.49
Drop in PJ to MJ
0.018 Pol%
0.02
Priamary Juice Brix
0.19 Priamary Juice % cane
0.5865
Priamary Extraction %
0.7 Brix % Bagasse
0.026738
Purity of Priamary Juice
0.848 Purity of last Mill Juice
0.748
Ind. Mill Extraction
0.385 Fibre % Bagasse
0.483262
Total Mill Extraction
95.71 Bagasse % cane
0.289698
MJ % Cane
1.0103021 Sec. Juice % Cane
0.423802
Pol in MJ
Sugar in Extracted Juice % Cane
Purity of Mill 2 Juice j2
0.823 In PJ % Cane
0.0945
0.8146667 In mill 2 % Cane
0.015593
0.798 In Mill 3 % Cane
0.009589
0.748 In Mill 4 % Cane
0.005897
In Mill 5 % Cane
0.003627
Bagasse % cane
Pol % Bagasse
Mill 1 bagasse% cane
0.4135 Mill 1
0.097944
0.373587 Mill 2
0.066671
0.3407009 Mill 3
0.044961
0.3131362 Mill 4
0.030085
Mill 5bagasse% cane
0.2896979 Mill 5
0.019999
Moisture
Moisture
Moisture
Moisture
Moisture
Moisture
%
%
%
%
%
%
Bagasse
Bagasse
Bagasse
Bagasse
Bagasse
Bagasse
M1
M2
M3
M4
M5
0.5459264
0.5442446
0.5737643
0.5152099
0.4900012
Approx. Discharge work Opening mm

Mill 1
57.245652
Mill 2
46.379898
Mill 3
41.184088
Mill 4
36.544669
Mill 5
31.802334
Approximate Fibre Index kg/m

1
609.4317
2
693.2789
3
780.7434
4
871.8251
5
966.5241
Apperent Opening Volume
Mill 1
Mill 2
Mill 3
Mill 4
Mill 5
1740.002
1741.607
1741.607
1757.659
1821.866
Fibre
Fibre
Fibre
Fibre
Fibre
%
%
%
%
%
Bagasse
Bagasse
Bagasse
Bagasse
Bagasse
Mill
Mill
Mill
Mill
Mill
0.018
0.483262
0.338573
0.374745
0.410918
0.44709
Sugar in Bagasse % Cane

0.0405
Mill 2 bagasse% cane 0.024908
Mill 5bagasse% cane 0.005794
Brix % Bagasse
Mill 1
0.1155
Mill 2
0.08101
Mill 3
0.055189
Mill 4
0.0377
Mill 5
0.026737
Fibre Loading kg/m
Mill 1
Mill 2
Mill 3
Mill 4
Mill 5
Re absorption Factor
Mill 1
Mill 2
Mill 3
Mill 4
Mill 5
34.88731
32.15421
32.15421
31.86056
30.73772
Mill No
1
2
Roller PCD
1.084
1.085
Roller Leng
2.13
2.13
RPM
4
4
Speed m/m 13.61504
13.6276
No void De
1.19
1.189
Fibre % Ba 0.338573 0.374745
Fibre Inde 609.4317 693.2789
Discharge 57.24565
46.3799
Feed / Disc
1.88
1.89
Fwo
107.6218 87.65801
Tro
188.3382 153.4015
Ind. Mill Ex
0.7
0.385
Ind. Mill Extraction Unit
3
4
1.085
1.095
2.13
2.13
4
4
13.6276
13.7532
1.193
1.201
0.410918
0.44709
780.7434 871.8251
41.18409 36.54467
1.895
1.9
78.04385 69.43487
136.5767
121.511
0.385
0.385
Mill no 1 Mass T/hr % Brix

Total Cane
400 0.159198
Juice Extra
234.6
0.19
Bagasse
165.4
0.1155
Fibre
56
Juice in Ba
109.4 0.174637
Brix T/hr Den. t/m

63.67925
1.12
44.574
1.0782
19.10377
1.191
1.52
19.10525
1.0716
Mill no 2
Total Cane in
Juice Extracted
Bagasse
Fibre
Juice in Bagasse
Mill no 3
Total Cane in
Juice Extracted
Bagasse
Fibre
Juice in Bagasse
Mill no 4
Total Cane in
Juice Extracted
Bagasse
Fibre
Juice in Bagasse
Mill no 5
Total Cane in
Juice Extracted
Bagasse
115.8792 0.026737 3.098232
Fibre
56
Juice in Bagasse
5
1.135
2.13
4
14.2556
1.213
0.483262
966.5241
31.80233
1.911
60.77426
106.355
0.385
Vol. m/hr
357.1429
217.5849
138.8749
36.84211
102.0903

Material - Balance - in - Milling - Tandem-2014 (Autosaved 14502016

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5 MILL 15 ROLLER TANDEM, Compound Imbibitio

Material Balance in milling tandem

(i)Calculations of Ideal Brix

Brix Balance In Milling Tandem

(D) For Mill No- 4

Lost juice % fibre =

ibre Index kg/m

ance for 100 Tonnes Sugar Unit

(3) Reducing Total loss by 1% means rise in Sugar recovery.

(4) 1% rise in Sugar recovery.means10 Kgm ad

(5)(a) Sugar Loss

(5)(a) Sugar Loss in Bagasse ---- 0.50 to 0.60 % of Cane

(b)Sugar Loss in Waste Molasses ---- 0.90 to 1.00 % of Cane

(c)Sugar Loss in Filter Cake ----

ss in Filter Cake ---- 0.05 to 0.07 % of Cane

(d) Sugar Loss as Unkown ---- 0.050 to 0.070 % of Cane

Total Losses = 1.5% to 1.74 % of Cane, Optimum

mainning 15% will go in MJ with more sugar.

** Bagasse Pol = 52%to 55% of Pol % Last Expressed Juice

Feed Pump 82.00632

STEAM AND POWER CONSUMPTION FOR FIBERISER AND MILL TURB

Juice Heating from 68 C to 76C

8 lbs steam @ 100 to 125

For C massecute b 0.0548

Evaporation from IV th Body = + 3.972

22 Exhaust generated by Steam Turbines in TPH

ISER AND MILL TURBINES Manjara

Calculations of boilers and Steam Consumptions

(15) Calculations for unit weight of Fuel

(i) Co2 fo 0.881328

28 2.190379 60.26016 80.09144

** THERMAL EFFICIENCY CALCULATIONS IN DIRECT METHOD PTC - IV CODE

12) Heat required for Steam Generation

*** Furnace Effective Projected Radiant Surface (EPRS)

ric heat absn.

Gas Sens.Heat x mg )/EPRS + 8.512]

es through convection &

Calculations of boilers and Steam Consumptions

(15) Calculations for unit weight of Fuel

(i) Co2 fo 0.881328

28 2.190379 60.26016 80.09144

** THERMAL EFFICIENCY CALCULATIONS IN DIRECT METHOD PTC - IV CODE

12) Heat required for Steam Generation

No. of para 34.7831 say 35

*** Furnace Effective Projected Radiant Surface (EPRS)

ric heat absn.

Gas Sens.Heat x mg )/EPRS + 8.512]

5 MILL 15 ROLLER TANDEM, Compound Imbibitio

(i)Calculations of Ideal Brix

Brix Balance In Milling Tandem

(D) For Mill No- 4

Lost juice % fibre =

ibre Index kg/m

ance for 100 Tonnes Sugar Unit

(3) Reducing Total loss by 1% means rise in Sugar recovery.

(4) 1% rise in Sugar recovery.means10 Kgm ad

(5)(a) Sugar Loss

(5)(a) Sugar Loss in Bagasse ---- 0.50 to 0.60 % of Cane

(b)Sugar Loss in Waste Molasses ---- 0.90 to 1.00 % of Cane

(c)Sugar Loss in Filter Cake ----

ss in Filter Cake ---- 0.05 to 0.07 % of Cane

(d) Sugar Loss as Unkown ---- 0.050 to 0.070 % of Cane

Total Losses = 1.5% to 1.74 % of Cane, Optimum