Written Equipment Design Report for Roller Mill

INTRODUCTION

Mechanical separation is a technique used for the separation of heterogeneous

mixtures. This technique can be applied for separation of solids from solids, solids from liquids
and solids from gases. It is based on physical differences in phase density, in phase fluidity, and
in such mechanical properties of particles-as size, shape, and density; and on such particle
characteristics as wettability, surface charge and magnetic susceptibility. There are many types
of methods for mechanical separation. One of the methods is the size reduction.

Size reduction is the application of energy to the material to convert it to desired size or
shape. It is also called Comminution. Comminution is done to increase surface area, achieve
intimate mixing, break the material into smaller particles in order to separate the desired
product, dispose waste properly and to improve handling characteristics. There are four
commonly used methods of size reduction, and these are compression, impact, shear/cutting
and attrition. Based on these methods, there are different types of size reduction equipment.

Roller mills are milling equipment that uses cylindrical rollers to flattens, pulverizes or
change the shape and area of the feed by passing between them. It is also known as reduction
mills. Roller mills are under the compression method of size reduction. With the help of pressure
applied between the rollers, these mills are used to cut the large sized particles into smaller
sized particles. It composed of two or more cylindrical rollers positioned horizontally that made
up of stone or metal.

The basic parts in the roller mill are feed hopper, grinding or crushing mechanism
applied by the rollers and the discharge chute where the reduced material out. The feed hopper
delivers the feed into the mill.

Based on the arrangement and number of the rolls, roller mills can be classified into two
high rolling mills, three high rolling mills, four high rolling mill, tandem and cluster rolling mills.
Two high rolling mills can be further classified as reversing mill and non-reversing mill. Two high
revising rolling mills are used in pluming and slabing mills and for roughing work. The rolls in
this type rotate in one direction and then vice-versa, to pass back and forth the rolled metal in
rolls several times. This is more expensive that non reversing rolling mills because of the
reversible drive needed. While in non-reversing mill, the rolls are continuously rotate in same
direction. It used smaller power. However, the material is needed to put back over the top of the
mill to pass through again.
Figure 1.Two high reversing mills Figure 2.Two high non reversing mills

Three high rolling mills consists of three parallel rolls one above the other in a roll stand.
The rolls rotates in opposite direction, so that the material may be passed between the top and
the middle roll in one direction and the bottom and middle rolls in opposite direction. The
material first forwardly passes through the middle and bottom rolls then return in top and middle
rolls. Every time the material passed through in the rollers, the thickness is reduced. In this type,
more less power is required than revising mills.

Figure 3.Three high rolling mill Figure 4.Four high rolling mills

Four high rolling mills consist of two back up rolls and two work rolls that are parallel one
above the other. The first two rollers in the top rotate in opposite direction same as the two
bottom rollers. Back up rolls is to provide the necessary rigidity to the work rolls. It is used for
the hot rolling armor and cold rolling of plates, sheets and strips.

Tandem rolling mills have a set of two or three stands of roll set aligned in parallel. In
cluster rolling mills, the work rolls are back up by two or more larger back up rolls.
 F

Figure 5.Cluster rolling mills Figure 6.Tandemr rolling mills

The two types of roller mills; one is RMS roller that used in particle reduction, and
ease maintenance. The other type is Monster Mill MM3 3-Roller Mill which was fabricated with
base, hopper, and corded electric drill. Roller mills can also use in pharmaceutical purposes,
food industry, flour and semolina mills, etc.

OBJECTIVE

The main goal of this design is to extract the juice from the sugar cane and separate the
bagasse from the juice using 5 rollers mills.

FEEDSTOCK

Figure 7.Sugar Canes

One of the largest agricultural products here in the Philippines is sugar.

Philippines was the 9th largest sugar producer last 2005 in the world. Sugar cane is the raw
material used in making sugars. Sugar canes are a stout tall perennial grass (Saccharum
officinarum). It grows in subtropical and tropical areas. There is an abundance of plantation of
sugar cane here in the Philippines. The half of the country’s total production was from Negros
Island. In the process of sugar, the sugar canes were first harvested. After harvesting, these
sugar canes were transported in the factory for processing. First, sugar canes are feed in the
roller mills for crushing and to extract juice.

OPERATING CONDITIONS
 The roller mill will work under high pressure so that the sugar cane will crush. The
crushing will be done on a batch process. The rollers are set in a fixed speed.

Assumptions:

 Fiber Percent cane = 15%

 Mill Hydraulic pressure = 10MPa
 Thickness of Sugar cane feed, t1 = 50.8 mm
 Height of Sugar Cane, H = 1500mm
 Bagasse Thickness, t2 = 2.8 mm
 Roller speed = 80 rev/min

Constraint:

 Diameter to length ratio, L= 2D

MATERIAL OF CONSTRUCTION

The roller mill are made up of Stainless Steel 304.

RATIONALE FOR EQUIPMENT SELECTION

The designed equipment is for the extraction of sugar juice and separation of bagasse
from sugar cane. The process has also an addition of water in order to increase the efficiency.
This equipment has seven-roller shafts to be able squeeze more the sugar cane. The more
rollers used is the much better for sugar cane.

MATERIAL BALANCE

BAGASSE

SUGAR CANE ROLLER MILL

SUGAR JUICE

EQUIPMENT DESIGN THEORETICAL CALCULATION

Groove Dimensions:

Assumptions:

TP = 38mm

TA = 50°

TF = 5 mm

Tooth Depth
𝑇𝑃−𝑇𝐹 38−5
𝑇𝐷 = 2tan⁡(𝑇𝐴/2) = 2tan⁡(50/2) = 35.38 𝑚𝑚

Length of the rollers

D=500mm

𝐿 = 2𝐷 = 2(500) = 1000𝑚𝑚

Number of Grooves
2𝜋𝐷 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑟𝑜𝑙𝑙𝑒𝑟
𝑇𝑜𝑡𝑎𝑙 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐺𝑟𝑜𝑜𝑣𝑒𝑠 = 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑔𝑟𝑜𝑜𝑣𝑒 x 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑔𝑟𝑜𝑜𝑣𝑒

2𝜋(500 𝑚𝑚) 1000 𝑚𝑚

= 𝑥
38 𝑚𝑚 38𝑚𝑚

= 2176 𝑔𝑟𝑜𝑜𝑣𝑒𝑠

Capacity of the miller

𝜌𝑏 = 400.5𝑘𝑔/𝑚3

𝜔 = 80 𝑟𝑒𝑣 /𝑚𝑖𝑛

𝑄 = 𝜋60𝐷𝐿𝜔𝑑𝜌𝑏

𝑄 = 𝜋 × 60 × 0.5 × 1 × 0.038 × 80 × 0.4005

𝑄 = 114.75𝑡𝑜𝑛/ℎ𝑟

Power Requirement

𝑃 = 0.15 𝐹𝑛𝐷
𝑡𝑜𝑛 𝑟𝑒𝑣
= (0.15) (114.75 ℎ𝑟
) (80 𝑚𝑖𝑛) (0.5 𝑚)

= 688.5 ℎ. 𝑝

𝑃 = 513.62 𝑘𝑊
Torque required by the miller:
𝑃
𝑇 = 2𝜋𝑁

𝑘𝑊 1ℎ𝑟
513.62 ×
ℎ𝑟 60 𝑚𝑖𝑛
= 𝑟𝑒𝑣
2𝜋(90 )
𝑚𝑖𝑛

= 0.015134 𝑘𝑊

𝑇 = 15.134 𝑊

Force required by the miller:

𝑇
𝐹=
𝑟

15.134 𝑁∙𝑚
=
0.5𝑚

𝐹 = 30.27 𝑁

HEURISTICS

 The roller length to roller diameter ratio is 2.

 Usually the nip angle is between 20° and 30° but in some large roll crushers it is up to
40°.
 The normal speed of operation of commercial light duty rolls is 130- 300 rpm compared
to heavy duty rolls whose operating speeds are in the region of 80 – 100 rpm.
 The angle of the grooves is about 35 – 55 °, often 45 °. The pitch, which here means the
distance from one tooth to the next, varies from 38 to 100 mm. The most frequent values
are 50 – 75 mm.

EQUIPMENT SPECIFICATIONS

Equipment Specification Sheet

Equipment Type Mechanical Separation
Equipment Design Roller Mill
Roller Diameter 500 mm
Roller Length 1000 mm
Distance between roller 1 & 3 38 mm
Distance between roller 1 & 4 26.8 mm
Distance between roller 2 & 4 14.8 m m
Distance between roller 2 & 5 2.8 mm
Speed of rollers 80 rev/min
Feed Capacity 114.75 ton/hr
Power Requirement 513.62 kW
 Torque of the miller 15.134 W
Force of the miller 13.27 N
Tooth Depth 35.38 mm
Tooth Angle 50°
Tooth Pitch 38 mm
Tooth Flat 5 mm
Total No. of Grooves 2176 grooves

INNOVATION

Batch recycle of filtered sugar cane.

 There is a screen under the rollers that will filter the falling sugar cane/bagasse. When
the 1st batch is done, the screen with filtered sugar cane will be removed and fed again
into the rollers.

Front View:

ROLLERS

SCREEN JUICE CANAL

3D DIAGRAMS

Front View
Isometric View
 Grooves of the rollers

CONCLUSIONS

The design was able to extract sugar juice from the sugar cane. The feed capacity of the
miller was computed which is 114.75 ton/hr. The power needed of the equipment was also
calculated, 513.62 kW. The torque and force needed for the miller is 15.13W and 13.27N
respectively.

REFERENCES

Adam, C., & J, L. (2004). The Effect of Blanket Thickness on Extraction Energy in Sugarcane
Rolling Mills: a Finite Element Investigation. ELSEVIER.

Adam, C., & Loughran, J. (2007). Optimising the Design of Sugarcane Rolling Mills using Finite
Element. International Sugar Journal .

Callister, W. (2007). Materials Science and Engineering: An Itroduction.

Hassan. (2010). Types of Rolling mills. Retrieved October 31, 2016, from mechanical
engineering: http://engineeringhut.blogspot.com/2010/10/types-of-rolling-mills.html

Hatt, R. J., Wilson, D., & Batstone, D. (2000). Apparatus and method for crushing sugar cane.
Grant.

James, W. (n.d.). Mill Capacity Calculations. Retrieved November 1, 2016, from The Sugar
Engineers: http://www.sugartech.co.za/extraction/millcapacity/

Kent, G. (2011). The Effect of Added Water Temperature on Milling Train Operation and
Performance. Sugar Tech.

Mena, A. (1984). THE UTILIZATION OF SUGAR CANE BY-PRODUCTS AS SUBSTITUTES

FOR CEREAL IN ANIMAL FEED.
Miller, S. A. (2014). Mechanical Separation Technques. Retrieved October 31, 2016, from
Access Science: https://www.accessscience.com/content/mechanical-separation-
techniques/412100

Payne, J. H. (n.d.). Unit Operations in Sugar Cane Production.

Sabiha-Hanim, S. (2012). Physical properties of hemicellulose films from sugarcane bagasse.

ELSEVIER.

Saraswathi.B. (2016). Roller mill. Retrieved October 31, 2016, from Pharmainfo.net:
http://www.pharmainfo.net/book/pharmaceutical-machines/roller-mill

Sugar Knowledge International. (2016, October 10). Welcome to the World of Sugar
Technology. Retrieved October 31, 2016, from SKIL: http://www.sucrose.com/home.html

Yamane, T. (2016, April 22). Sugar Cane. Retrieved October 31, 2016, from Encylopaedia
Britannica: https://www.britannica.com/plant/sugarcane