INTERNSHIP REPORT

1
 PREPARED BY:

Suresh Turkio 14ME38

Bhart Kumar 14ME76
Roshan 14ME24
Abdul Waheed 14ME142

Department of Mechanical
Engineering
Mehran University of Engineering and
Technology, Jamshoro.

2
 Dedication
Dedicated to our parents whose sincere efforts and struggles
helped us to reach at this stage.

3
 ACKNOWLEDGMENT
We feel it is our first and for most duty to pay our heartiest gratitude to the
almighty ALLAH, the most merciful for giving us the average deviation to
complete the internship report on Mirpurkhas Sugar Mills in the field of
mechanical engineering. We wish to express our deep and sincere appreciation and
full gratitude to our internship supervisor, shift engineers in mill section, whose
valuable advice saved us a guide post in the completion of this internship report
and we are also very thankful to Sir Haider Bux Rustmani, the General Manager
of MSM, who gave us the permission and trainee engineers for giving the help and
knowledge about the mills throughout whole internship period.
We are also highly obliged the staff of process house, mill house, mechanical
workshop and whole staff of the Mirpurkhas Sugar Mills ltd Mirpurkhas
Sindh.

Table of Content

Chapter No: 01
Introduction to Mirpurkhas Sugar Mills
1. Introduction
Chapter No: 02

4
 Carrier Section
2.0 Introduction
2.1 Cane Yard or Feeding Yard
2.2 Hydraulic Jack
2.3 Feeding Tables
2.4 Auxiliary Cane Carrier
2.4.1 Arm Type Leveler
2.5 Main Cane Carrier
2.5.1 Drum Type Leveler
2.5.2 Pusher Drum
2.5.3 Fiberizer Shaft
2.5.4 Anvil Bar
2.6 Rubber Belt
2.7 Magnet Box
2.8 Elevator
Chapter No: 03
Mill House
3.0 Introduction
3.1 Terminology
3.1.1 Donnelly Chute
3.1.2 Roller
3.1.3 Trash Plate
3.1.4 Scriber
3.1.5 Inter carrier
3.1.6 Juice Gutter
3.2 Mills
3.3 Bagasse Elevator
3.4 Juice Tank
3.5 DSM Screen
3.6 Turbine
3.6.1 Parts of Turbine

5
 3.6.2 Working Mechanism of Turbine
3.7 Juice Extraction Process Chart in Mills section
Chapter No: 04
Boiler House
4.0 Boiler
4.1 Furnace
4.2 Air Heater
4.3 Economizer
4.4 Steam Drum
4.5 Mud Drum
4.6 Side headers
4.7 Super Heater Coils
4.8 Steam Header
4.9 Steam Distributer
4.10 Water and Steam Circulation Chart
4.11 Air Cycle
4.12 Bagasse Path
Chapter No: 05
Process House
5.0 Introduction
5.1 Juice Flow Chart
5.2 Pan Section Chart
5.3 Themaking process of Sugar from Sugar cane
Chapter No: 06
Power House and Store
6.0 Power House
6.1 Store
Chapter No: 07

6
 Water Treatment Plant
7.0 Introduction
7.1 Filtering and Softening Process
7.2 Feed Pump
Chapter No: 08
Mechanical Workshop
8.0 Introduction
8.1 Shaper Machine
8.2 Planer Machine
8.3 Drill Machine
8.4 Lathe Machine
8.5 Milling Machine
8.6 Hacksaw Machine
8.7 Foundry Shop

Chapter No: 01
Introduction to Mirpurkhas sugar mills
Mirpurkhas Sugar Mills is an Industry for the production of sugar from
sugar cane, located 7 kilometers away from Mirpurkhas city in east side on
umerkot road. It is a completely private unit and was installed in 1964. In the
starting, its crushing rate of sugar cane was 3000 tonne/hr but nowadays, with the
enlargement in mill, it is reached to 7000tonne/hr. MSM’s production of sugar

7
increases every year and it produced 73750 tonne sugar by 2014. It produces 1st,
2nd and 3rd class sugar, it exports 30-40% of its production every year. It provides
sugar to Pharma for production of medicine and also provides sugar for common
use. Its working period is 15 November to 15 march, during these days mill is in
operation for 24x7 hours.
It contains Mill house, Boiler house, Process house, Power house and Water
treatment plant. Also, it contains a Mechanical Workshop in which 80% of
machine parts which are used in mill are made and repaired. It also has a store
where sugar is stored. During the season, MSM generates own electricity for the
operation of whole mill.

Chapter No: 02
Carrier Section
2.0 Introduction
Carrier section is responsible for feeding of sugar cane in the mills by
converting it into powdered shape. It contains feeding yard, hydraulic jacks,
feeding plates, auxiliary and main cane carriers, fiberizer, rubber belt cane carrier,
magnet box and prepared cane elevator which are defined below.
8
2.1 Cane Yard
It is the area where trucks and trolleys loaded with sugar cane come from
different areas for feeding.
2.2 Hydraulic Jack
It is used to lift the loaded trucks at maximum inclination of 50 0 by the
hydraulic pressure system for the unloading sugar cane to the feeding tables. There
are three feeding tables in this mill, one is rectangular having dimensions 12x20 ft 2
and other two are rounded of diameter 20 ft. The rounded jacks cane be rotated at
3600.
2.3 Feeding Table
It is used to carry unloaded sugar cane to the auxiliary cane carrier. It
contains 14 parallel chains connected with head and tail shaft by the chain and
sprocket connection, the head shaft is connected with the reduction gear by chain
and sprocket connection. Further, the reduction gear is connected with electric
motor by the coupling, hence, the driving unit of head shaft is electric motor. Here,
the reduction gear is used to decrease and increase the RPM and torque of electric
motor respectively.
2.4 Auxiliary Cane
It is used to carry the sugar cane from feeding tables to the main cane
carrier. It contains a conveyer belt which is made up of metallic slides bolted on
three parallel chains, these chains are connected with the head and the tail shaft by
the chain and sprocket connection. It is 5.35 wide and 175 (approximate) long. Its
driving unit is same as of the feeding tables. Auxiliary cane carrier also contain a
leveler which is given below.
2.4.1 Arm type leveler
It is used to level the sugar cane in the auxiliary cane carrier. It is made up of
14 arms fixed on a shaft which is driven by an electric motor in the same way as in
auxiliary cane carrier. The rotation of arm type leveler is in the opposite direction
to the motion of sugar cane in the auxiliary cane carrier. It rotates with the 6-10
RPM.
2.5 Main Cane Carrier

9
 It is used to carry sugar cane from auxiliary cane carrier to the rubber belt
prepared cane carrier. It contains a conveyer belt which is same as in auxiliary cane
carrier and connected to the head and tail shaft by the chain and sprocket
connection. It is driven by an electric motor in the same way as in auxiliary cane
carrier. It is 5.83ft wide and 120ft long. Following parts are inserted in between the
main cane carrier.
2.5.1 Drum type leveler
It is used to level the sugar cane in the main cane carrier. In this, small
triangular arms are fixed on a drum which rotates in the opposite direction to the
motion of sugar cane to level it before it goes to the pusher drum. Its speed is 6-10
RPM and driving unit is same as of auxiliary cane carrier.
2.5.2 Pusher Drum
It is used to push the leveled cane. When it pushes, the cane on the other side
will rise up and so fiberizer shaft will easily convert it to the powdered shape. Its
speed is 5-8 RPM and driving unit is same as of auxiliary cane carrier.
2.5.3 Fiberizer Shaft
It is used to convert the sugar cane to the powder shape which is called as
prepared cane. It is a shaft on which hammers are connected with the help of six
other shafts. Every shaft contains 18 hammers, hence, 108 hammers are connected
to the fiberizer shaft and mass of each hammer is 20kg. Fiberizer shaft is directly
coupled with a turbine of 1.5MW and 900RPM. So when fiberizer shaft, hence,
hammers rotating with such speed strike with the sugar cane, the sugar cane will be
converted into powdered shape.

2.5.4 Anvil Bar

It helps to convert sugar cane into the prepared sugar cane by giving support
to hammers of fiberizer shaft. As fiberizer shaft move across anvil bar, the distance
between anvil bar and hammers decreases continuously. Initially, it is 12 mm and
at the end it is reduced to 4 mm.
2.6 Cane Rubber Belt

10
 It is used to carry prepared cane from main cane carrier to the elevator.
2.7 Magnet Box
It is used to remove metallic pieces from prepared sugar cane. It can remove
metallic pieces of mass upto 20kg.
2.8 Elevator
It is used to carry prepared sugar cane from cane rubber belt and drop it into
Donnelly chute with the help of wooden planks which are fixed in two parallel
chains. These chains are driven by electric motor in the same way as in feeding
tables. The elevator is inclined at 600.

Chapter No: 03
Mill House
3.0 Introduction

11
 In this house juice is extracted from prepared sugar cane with the help of
mills and send to the process house. There are six mills installed in this
house and these mills are driven by turbines individually.
3.1 Terminology
There are some parts which are used in the every mill. These parts are
defined bellow.
3.1.1 Donnelly Chute
This is used to catch prepared sugar cane which is dropped by
elevator/inter carriers and feed it into feeder roller in the proper
way.
3.1.2 Roller
It is cylindrical shaped component which contains teethes and
grooves on its rounded surface. Its diameter and longitudinal
length is 38 and 78 inches respectively.
 Feed Roller
It is used to feed prepared sugar cane for compression.
 Top Roller
It is used to crush prepared sugar cane by compressing it. It is
driven by a turbine with the maximum speed of 7 RPM. And
Top Roller drives feed and discharge rollers.
 Discharge Roller
Its function is to discharge remaining bagasse to the inter
carrier after the juice is extracted from prepared sugar cane.
The compression for the extraction of the juice takes place
between top and discharge roller.

3.1.3 Trash Plate

It is inserted in between the feeder and discharge roller and its
function is to keep motion of prepared sugar cane from feeder
to discharge roller. It also prevents the bagasse from falling
12
 down in the juice gutter. Here, the trash plate is installed in all
the mills except 1st mill.
3.1.4 Scriber
It is used to remove bagasse from grooves of roller.
3.1.5 Inter carrier
It is used to carry bagasse from one mill to another.
3.1.6 Juice Gutter
The extracted juice falls down in the juice gutter from where it
goes to the juice tank.
3.2 Mills
The function of all the mills is to extract juice from prepared sugar
cane/bagasse with the help of rollers. The 1st mill contains 3 rollers, 2nd
contains 4 rollers and the remaining all mills contain 6 rollers in each. The
top roller of each mill is connected to the turbine. The reduction gear and
crown gear are used in between the roller and turbines to decrease RPM and
increase torque produced by turbines. The maximum speed of turbines is
6700 RPM but after the own reduction gear of turbine, main reduction gear
and crown gear it becomes 945, 21 and 7 RPM respectively. So maximum
speed of top roller is 7 RPM.
3.3 Bagasse Elevator
It carries bagasse from 6th (last) mill to boiler house.
3.4 Juice Tank
The juice extracted from mills is stored in juice tank from where it goes to
the DSM screen.
3.5 DSM Screen
Here, the juice which comes from juice tank is filtered and send to the
process house.

3.6 Turbine
It is a mechanical device which converts the heat energy of steam into mechanical
energy.

13
3.6.1 Parts of Turbine
 Rotor
It is a circular shaped component on the circumference of which a series of
blades are fixed. When the live steam strikes with these blades, it will cause
the rotor to move. The blades are so designed that steam should apply
maximum force on them.
 Blades
There are two types of blades, namely, moving and fixed blades. Further,
moving blades are high pressure and low pressure side moving blades.
Moving blades are fixed in rotor and fixed blades are attached in casing.
Here in the turbines of this mill, high pressure side and low pressure side
moving blades are 182 and 242 respectively. Also, there are 89 fixed blades.

 Governor
Its function is to maintain speed of turbine by operating the throttle valve as
per situation demand.

 Throttle valve.
The live steam inters into the turbine through throttle valve.

 Diaphragm
In this component a series of 15 nozzles is fitted through which live steam
strikes the blades with the high speed. Among these nozzles, 8 are in
continuous action and other 7 are operated if the situation requires. Here the
nozzles are used to increase the velocity of live steam. Also, the nozzles are
fixed in such a way that the live steam strikes blades in proper direction.
 Lubrication oil system
This system provides oil to bearings and gears to lubricate and cool them.
 Cooling system
This system cools the oil which is circulating in the parts of turbine, in turn,
oil cools the parts of turbine.

14
  Carbon seal
This seal helps to keep steam only in the rotor section and prevents steam
from interring into bearings and other parts.
 Thrust bearing
These bearings are used to damp the shock in the turbine.
3.7.1 Working Mechanism of Turbine
The pressurized steam comes from boiler and pass through the throttle valve,
after then it goes to the diaphragm where the nozzles are fitted. When the
steam passes through these nozzles, its speed is increased and it will strikes
to the moving blades of rotor with high speed so it will apply high force and
torque on the rotor and will cause the rotor to move with high speed.Initially,
the steam will strike to high pressure side moving blades and then it will
pass through fixed blades which provides the proper direction to it. Further,
it strikes to the low pressure side moving blades after then it is exhausted
through exhaust valve. Here, pressure and temperature of steam are
decreased and mechanical work is done. In this way the heat energy of steam
is converted to the mechanical energy.

3.8 Juice Extraction Process Chart in Mills section

1st Mill Prepared Cane

15
 2nd Mill Juice Tank

3rd Mill
Juice
Bagasse
Ashes

4th Mill

5th Mill
Imbibition
Water

6th Mill
Boiler Furnace Ashes

Chapter No: 04
BOILER HOUSE
4.0 Boiler
A close vessel which is used to convert water into steam by heating is
called Boiler. We can also call a boiler as a steam generator because it generates

16
steam from water by the combustion of fuel in the furnace at high temperature and
pressure.
There are two types of boiler:
1. Water tube boiler
2. Fire tube boiler

1. Water Tube Boiler:-

In this type of boiler water is filled inside the tubes and heat is supplied around
the tubes to convert it in to steam. The steam generated in this type of boiler has
high pressure and temperature, so this type of boiler is commonly used.
2. Fire Tube Boiler:-
In this type of boiler fire blows inside the tubes and water is filled around the
tubes in chamber to convert it into steam.The steam generated in this type of boiler
has low pressure and temperature so, this type of boiler is rarely used.
In this sugar mill, three water tube boilers are installed which have the capacity
for the generation of steam upto 30 tonne/hr, 35 tonne/hr and 80 tonne/hr
respectively. The pressure and temperature of the generated steam are 25 kg/cm2
and 3500C respectively.

4.1 Furnace:-
It is a part of boiler in which burning of fuel takes place. Here we use
bagasse as a fuel and when this fuel burns, it rises the temperature inside the
furnace which convert water inside tubes into steam.

17
4.2 Air Heater:-
It is a part of boiler which is used to preheat the air before admitted to the
furnace so that the burning process will be more efficient and consumes less fuel.
In this, heating process is that the flue gases flow inside tubes and fresh air flows
around tubes inside the chamber with the help of F.D fan.
4.3 Economizer:-
It is a part of boiler which is used to increase the temperature of water before
it is converted to the steam. Here, temperature rises from 750C to 950C before
admitted to steam drum and the source of heat is flue gases. In this, the water flows
inside tubes and flue gases flow around the tubes in the chamber, so, the heat flows
from flue gases to the water. We preheat the water in the economizer so that it
consume less fuel for the conversion into steam.
4.4 Steam Drum:-
Its function is to take hot water from economizer and give it to the furnace
for the generation of steam, this generated steam comes again to the steam drum
where it is filtered and then send to the super heater coils. Half of it is filled up
with water, this water flows to mud drum through circulation tubes which are
connected to the bottom of the steam drum. The generated wet steam comes to
steam drum through generation tubes which are connected above the water level
inside steam drum, further it flows to super heater through super heater coils which
are connected at top of steam drum. Totally, there are 57 tubes.
4.5 Mud Drum:-

18
 In this drum water comes from steam drum where mud, silicates, dissolved
salts and other impurities settled down which are harmful for tubes and then, the
purified water goes to the side header for its journey.
4.6 Side Headers:-
Side headers are fitted in each side ofSteam
theDrum
furnace at the top and bottom
Water tubes
positions. Water tube inside the furnace are connected to these side headers. Water
Super heated
inside
bottom side headers and goes through Ciols
comes from mud drum tofurnace water tubes to the
furnace where it is converted to the wet steam, this wet steam goes to the top side
headers from where it further goes to the steam drum through generation tubes.
4.7 F.D Fan:- Steam
Side Headers
Distributer
It sucks fresh air from atmosphere and send it to air heater.
4.8 I.D Fan:-
It sucks flue gases from economizer and send it to chimney.
4.9 Secondary Fan:-
Mud Drum Trubines
It sucks heated fresh air from air heater chamber and send it to furnace.
4.10 Chimney:-
It is the path through which flue gases are exhausted to the atmosphere.
4.11 Super Heater Coils:-
Process
Steamare
These Drum
coils which further increase the temperature of wet steam which
House
0
comes from steam drum up to 350 C to make super-heated steam by heating and
the source of heating is flue gases.
4.12 Steam Distributor:-
Economizer Condenser
It distributes the super-heated steam to the turbines of the mill house, power
house and turbine of fiberizer. Feed Drum

4.13 Water and steam circulation

200-2200C

19
 220-2500

320-3500C

Steam

Water

1900C

90- 950C

70-750C

20
4.14 Air Cycle

Atomsphere

Chimney F.D Fan

Air Heater
I.D Fan (outside
pipes)

Secondary
Economizer
Fan

Air Heater Boiler

(inside pipes) Furnace

21
4.15 Bagasse Path

Sugar Prepared Boiler

Carriers Fibrizer Mills Ash
Cane Cane Furnace

22
 Chapter No: 05
Process House
5.0 Introduction
In this house, the Sugar is prepared from juice which is coming from mill
house. Here, so many chemical processes takes place such as carbonation,
sulphonation, crystallization etc.
Initially, the juice comes from mill house is stored in Raw juice tank
and then send to the primary heater where its temperature is increased. There
are five primary heaters in the process house. Then, it is send to the
Defecation tank where milk lime is added for the cleaning purpose, after
then, cleaned juice is send to the secondary heaters where its temperature
further increased. There are six secondary heaters. The juice again is send to
the flash tank or retention tank from where it goes to the SRI clarifier where
mud is removed from Juice and clear juice is obtained. There are two SRI
clarifier in this house which contain spiral paths which are called as
Launders. When the juice passes through these paths, the mud is settled
down and the pure juice is obtained. The mud obtained is send to the mud
tank where bagasse is added to it, then it is send to the vacuum filter where
the remaining juice is filtered. This filtered juice then send to the primary
heaters for further process. The clear juice obtained from SRI Clarifier is
send to the clear juice tank through rotary screen. Further, this juice is send
to the evaporator where the evaporation takes place, by the evaporation
water vapors are removed and syrup is obtained and send to the syrup tank.
Further, it is send to the pan section from where the final product i.e.
SUGAR is obtained.

23
5.1 Juice Flow Chart

Raw Juice Tank

Primary Heaters

Milk Lime Defecation Tank

Secondary Heaters

Flash Tank

SRI Clarifier

Clear Juice Tank Mud Tank

Vacuum Filter Mud

Evaporator

Syrup Tank Juice

Pan Section

24
5.2 Pan Section Chart

Pan A

A-Centrifugal

A Heavy Mother Liquor

Pan B 1st Carbonation

B Centrifugal 1st Pressure Filter

B Heavy B seed 2nd Carbonation

C Pan 2nd Pressure Filter

C Centrifugal Sulphination

C Light C seed 1st Crystallizer

Liquor R1 seed or A-Class Sugar

2nd Crystallizer

Liquor R2 Seed or B Class Sugar

3rd Crystallizer

R3 Seed or C-Class Sugar A-Heavy

25
5.3 The making process of Sugar from Sugar cane

Feeding Tables Sugar Cane

Auxiliary cane carrier Prepared

(powdered) cane

Main cane carrier Juice

Fiberizer Bagasse

Rubber belt prepared cane carrier

Elevator

Mills

Storage Tank

Boiler furnace

DSM Screen

Ashes

Process House Sugar (Final Product)

26
 Chapter No: 06
Power House and Store
6.0 Power House
Mirpurkhas sugar mills have own power house in which electricity is
produced by the turbines during the season for the operation of whole industry.
6.1 Store
Mirpurkhas sugar mills contain a store in which all the new machine parts
are available in spare. It is divided into three sections; first contains office of the
store keeper, second section contains bearings, belts and other new parts;
centrifugal pumps, sprockets, nut and bolts, split pin, rotter of turbines etc. are
stored in the third section.

27
 Chapter No: 07
Water Treatment Plant
7.0 Introduction
Natural water contains solid, liquid and gases impurities so, this water
cannot be used for the generation of steam in the boiler. This requires that
the impurities present in the raw water should be removed before it can be
used in the boiler.
The various impurities present in the natural water may be in the following
form:
 Dissolved salt such as carbonate sulphate and chloride of calcium, sodium
and magnesium. Sometimes some iron, aluminum, silica salts are also
present.
 Dissolved gases such as carbon dioxide, oxygen and sulpher dioxide.
 Mineral acids.
 Suspended matters such as aluminum and silica may be present as mud and
salts in the water intended for steam boilers. All the impurities are harmful
especially if present in considerable quantities, the scale so found is not
desired as it hampers the process of heat transfer. Presence of mineral acids
in water is always undesired as they may result in the chemical reaction
within the boiler.
7.1 Filtering and Softening Process
The filtering and softening process is used to remove hardness of water and
to purify the raw water which is feed to the boiler by the help of feed pump.
The water from the canal is pumped to softening plant where it enters into
the lime tanks, at the top of lime tanks, two other tanks are provided in
which one is filled with lime stone and water and other tank with aluminum
and sodium phosphate. This is first purification stage which reduces the
hardness of water upto the zero. Then a sat tank is provided to wash the
softener. The pH value of this water is measured by pH meter which is
approx. Equals to the 7, then the purified water is suitable for boilers.

28
7.2 Feed Pumps
A pump is generally may be defined as a machine which when driven from
external source lifts water and some other liquids from a lower level to a
higher level.
After filtering and softening process, the purified water is pumped to the
boiler with the help of feed pumps.

29
 Chapter No: 08
MECHANICAL WORKSHOP
8.0 Introduction
Mirpurkhas sugar mills where types of machines are available which are used for
making various types of machine parts such as shafts, impellers etc. and so many
operations such as shaping, rounding, sharping, grinding, planning etc.
Name and functions of the various machines are available in workshop:
1) Shaper Machine
2) Planer Machine
3) Drill Machine
4) Lathe Machine
5) Milling Machine
6) Hacksaw Machine
8.1 Shaper Machine:-
Shaper Machine is used for shaping the parts and also used for planning the
different parts of the machine as per required extent.

8.2 Planer Machine:-

Planer Machine is used for planning the rough or irregular surface of any
part of machine.

8.3 Drill Machine:-

Drill Machine is used for drilling or making the holes of different diameters
as per required sheets, or any part of the machines.

8.4 Lathe Machine:-

Lathe Machine is used for making the valves, spindles, shafts, caps, nut and
bolt etc.

8.5 Milling Machine:-

Milling Machine is used for making the teeth of gears.
30
8.6 Hacksaw Machine:-
Hacksaw Machine is used for cutting the rods, shafts or pipes into desired
pieces.
8.7 Foundry Shop:-
Mirpurkhas sugar mills also has a foundry shop in which different parts are
making with casting process, which are not present in the store or market or are
available at very expensive rate in market.

31