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ABSTRACT
Advanced cane feedrng clevices szrch as toothed roller pressure feeding system (TIlPI;)
and Grooved Roller Presszlre Feeding ,system (GRPF) suffer Jrom varioils drawbcrcks
inclzlding high power conszl~nptlon. heavy wear ancl tear elc. Pressure Cht(teless Toothed
Roller Feeding system (TRF) 1s on zlniyzle introduction to Sugar Industry to increase
throughpzit and e,fficiency of lhe cone ~nilllngsystem. Presszlre chztteless tootlzed roller
feeding systeln cnn he ~nstolleclwith any S I Z E 0.f 1n11I1ngplant and can he of any
configzlratlon viz. single or 1nz11tz peqforclfed toothed roliers. A beauty of the system is
that ~t glves n positive ,feedabillty like TRPF crnd has ~ u i c eremoval cl?aracteristics like
GRPF ~ ~ r con~paratively
th low power consirmplion due to elimination of frictional losses
in crhsence 0.f the presszlre chute. One silch feeding systenz was installed at Upper Doah
Sugar Mrlls, Ltd. Shamll, Inclia in the c r ~ l s h i n g,season 1993-95 on an old existing
lnilling tancle~n of srze 960 x 1981 mm.
INTRODUCTION
The capacity and efficiency of a cane nlilling plant inainly depends upon cane feeding
devices used. Earlier underfeed rollers of 40%) of diameter of tnill rollers were used as
feeding devicesS (Hugot, 1986) and later on use of full size under feed rollers became
the practice. The literature contains a n u n ~ b e r of references on various work done by
different investigators on various designs of feeding devices. The conventional designs of
feeding s ~ 7 s ~ e iare
n heavy duty toothed rollcr pressure feeding devices and heavy duty
grooved roller pressure feeding dcvices. A large number of cane sugar factories are
using one of the above stated Seeding systcins with coiiventiollal three roller mills for
extraction of juice.,
The conventional pressure feeding devices suffer froin various drawbacks including high
power consumption, re-absorption and heavy wear and tear. Apart from these, it was also
observed that most of the installations arc facing problems like stalling of mill or TRPF
drive, jalnining or bursting of pressure c l ~ ~ l t eand
s intermittent breakdown of several
conlponents of the system.
The heavy duty grooved roller pressure feeding device is often more smooth in working
than heavy duty toothed roller pressure feeding systeln due to allowable slippage in
grooved rollers and reinoval of some quantity of juice. However, GRPF system has lesser
feedability and the drawback of higlzer pou7er absorption wit11 respect to TRPF system.
Fig. 1
In short, it is established that operatioil and illaiiltenallce of TRPF or GRPF requires
skilled and esperienced operating personnel.
Pressure chuteless toothed roller feeding system (TRF) is an inaovati\~e desigd v111ich
gives a very high grip on cane / bagasse inat (lesser contact angle4), (Murry, 1967) and
feeds the cane / bagasse inat positively at a high density to the mill, without slippage.
Thus it helps to achieve high crush rate even at a higher rate of iinbibitioli and at a
lower power cons~uinption.Toothed roller feeder (TRF) without pressure chute feeds to \
.the three roller tliill and works as a rotary convergiilg pressure chute. It successively
coinpacts and red~lces the thickness of bagasse inat and a t the same time extracts the
juice in a sequence of low, inediunl and high pressure zones. T h e entraped a i r in
bagasse mat as well as 'juice escapes through pcrfbrations pxov~ded on the surface of
toothed rollcrs. Thus the bagasse blanket becomes drier and conlpact before it is fed to
three roller illill. Subsequently, n ~ i l lrollers take better grip on the drier cane 1 bagasse
blanket' (Maxwell, 1932)l. As the slippage is restricted and bagasse is drier, the mill
speed is reduced and phenome~ioa of juice re-absorption is m ~ n i m i s e d(Trompi,
~ 1936).
This rcsults into lo\\? liquid pressurc \vithin the co~npressioilzone which ultimately leads
to inlprovcd perfornlance and low powcr coi~sui~lption. The comparison between TRF
system TRPFIGRPF systeill has been given in Table-l .
Table 1 :Comparison hetween Pressure Chuteless Tootlied Roller Feeding (TRF) System and Toothed
Roller Pressure Feeding (TRPF) I Grooved Roller Pressure Feeding (GRPF) System
At Upper Doab Sugar Mills, Shamli, India, the two roller pressure chuteless toothed
roller feeding system is installed with two conventional three roller cane mills, and 3
mills are equipped with single toothed roller feeders. Thus, mill No.1 & 2 are pressure
chuteless 5-roller mill each and mill No.3,4 & 5 are 4-roller mill each. Mill Nos.1, 2 &
4 are individually driven by 600 BHP steam turbines and mill Nos.3 & 5 are driven by
Flender make 6 3 0 kW hydraulic drives mounted on top roller f o r e a c h mill. T h e
orientation of mill No.1 & 2 which are equipjed with two toothed rollers but without
pressure chute is shown in Fig. 2. The Donnelly chute"Donnelley, 1958) feeding to
each mill is about 2 m high and slopes 85" for mill No. 1 and is preceded by a belt
conveyor which is fed by rake type carrier. The Donnelly chute feeds prepared cane 1
bagasse to pair of toothed rollers having fabricated teeth on drum duly hard faced to
about 300 BHW. The first roller of TRF is driven by long teeth pinion mounted on
pintle end of existing mill top roller. The second roller of TRF i s . driven by chain and
sprockets through intermediate shaft.
mla 240
Pre-Extractor
The TRF feeds the three roller mill and at the same time also works as pre-juice
extractor. The extracted juice is drained through perforations in the toothed rollers.
Mill Settings
The mill settings adopted at M/s. Upper Doab Sugar \ Mills, Shamli with TRF system
were as given in Table - 2.
Particulars Mill No
It was observed during the operation that speed of inills can be reduced further with
TRF system to achieve better extractioil but there was a limitatioil on reducing turbine
speed. ,
Control
The auto cane feed regulating system is provided at the milling tandem with CT sensors
for sensing load on fibrizor, cutter, carrier, Do~lilellychute of mill NO. 1 and chest
pressure of steam turbine of Mill No. 1. Shear pins are also provided on piilioils driving
TRF system to work as fuses, in case, over loading is caused due to excessive feeding.
I
The summary of performance for the last four consecutive seasoils after installiilg the
TRF system is tabulated in Table-3. During the season 1997-98 the average rate of crush
achieved was 225 toiles per hour with 14.59% fibre content in cane. Reduced mill
extraction achieved during the season was 9 5 . 2 7 % with an average pol ill cane of
12.5%. The added water % fibre was kept at 170 due to limitation of evaporator
capacity, resulting in lower Reduced Mill Extraction. However, targeted RME of 96% is
achievable with this system, if added water quantity is maintained between 230-250%
fibre.
Table 3 : Summary of Performttnce After Installation of TRF
System at MIS Uppcr Doah Sugar Mills, Shamli, India
1, Time Account
2. Cane Crushed
Daily crushing
1 3. Cane Quality
I Pol (% 12.50 12.47 11.75 12.13
4. Mill Performance
Mill extraction
RME
Moisture in bagasse
6. Reduced Overall %
' 86.56 86.83 86.61 86.25
Extraction
The various brixes of juices obtained fro111 TRF system are tabulated in Table-4 which
shows that the brix of juice obtained from TRF system was in no way less than brix of
juice as is normally obtained in a G R P F system. T h e b r i x e s o f T R F juice a r e
considerably less than the brix of colllposite juice. which encourages to use it as a
macerating liquid on the sallle l l i i l l Icadilig to higher imbibition efficiency.
Table 1 : Brix of Different Juices Extracted Through TRF System
- - --
It is generally accepted that GRPF absorbs about 30% of the total power absorbed by
the mill whereas it is also clainlcd that toothed pressure feeder absorbs about 21%
power. Actual torquc nleasurei~lents in case of TRF system could not yet be done but it
is estiniated fro111 the chest pressure rcadings of turbine that tile power consumption for
TRF systenl is 10% of the total pojvcr consumed by the mill. Thc lower power installed
for Inill at Upper Doab Sugar Mills. Shamli is also an indication of low power absorbed
by TRF systcal. The existing mills. if wcre equipped with GRPF or TRPF system of size
960 x 1981 nlm ( 3 8 " x 7 8 " ) would liavc bcen difficult to operate with an installed
power of 600 BHP while operating turbine at 7.5%)of rated specd to handle a crush rate
of 225 TCH.
In case of TRF System. power absorbed by the mill is reduced because of both less
slippage and saving in frictional losses due to absence of closed stationary pressure
chute. The rcduction in the amount of material passing through the mills due to pre-
extraction of juice at TRF also leads to lower power consumption.
The experience at Upper Doab Sugar Mills, shows the following advantages of TRF
system.
a A power saving of about 50% colnyared to TRPF
a Substantial rcduction in maintenance cost
Easy and trouble free operation
e No highly skilled manpower rcquircd.
e TRF offers high grip on cane / bagasse Inat and feeds the mill positively with
high density of cane / bagasse mat at reduced feed / discharge operating opening
The experience of installation and performance of TRF systems at Upper Doab Sugar
Mills has indicated that system is very simple and easy to operate. The power absorbed
is reduced by 50% as compared to TRPF I GRPF. The success of TRF system has led
to improvement in reduced mill extractior, and ultimately in rise of recovery and better
rate of crush. The TP.F system offers better extraction efficiency as compared to TRPFI
GRPF and can be considered as a good feeding device.
ACKNOWLEDGEMENT
The authors are thankful to the Management and Technical Officers of MIS. Upper Doab
Sugar Mills, Shamli, for the trial of TRF System in their sugar mill. We also express our
gratitude to the Secretary, Deptt. of Science and Technology, Government of India for his
encouragement.
/
REFERENCES
Tromp, L.A. (1936) Machinery and Equipment of Sugacane Factory Norman Rodger,
London
Murry, C.R. & Halt J.E. The Mechanics o f Crushing Sugarcane, (1967) Elzener
Pzlblishing Co.
RESUMEN
Dispositivos avanzados de alimentacion de caiia talcs como el sistema de alimentacion por presion
de rodillo dentado (APRD) y el sistema de alimentacion por presion de rodillo ranurado (APRR)
sufren de varios inconvenientes, incluso gran consumo de energia, desgaste fuerte y rohira, etc. El
sistema de alimentacion por presion de rodillo dentado sin embudo (ARD) es una introduccion
unica a la industria azucarera para aurilentar la produccion y eficiencia del sisteina de molienda
de caiza. E l sistema de alimentacion por presion de rodillo dentado sin embudo puede ser
instalado en uula plailta de lnolienda de cualquier taillaizo y puede ser de cualqu~iercoilfiguracion,
ya sea simple o ini~ltiplesrodiIlos dentados perforados. La belleza de este sistema es que da mla
alimentabilidad positiva como el APRD y tiene caracteristicas de remover el jugo como el APRR,
con conlparativallleilte, bajo consumo de energia debido a la eliminacion de perdidas friccionales
en ausencia del embudo de presion. Un sisteilla de alimentacion colno Bste fue illstalado en el
ingenio Upper Doab en Shamli, India en la zafra de 1994-1995 en ana bateria de n~olinos
existentes viejos de taillaiio 960 X 1961 milimctros.
Canne avancee qui nourrit des appareils que la pressioll de roulean dentee qui nourrit le systkme
(TRPF) et la Pression RAYE du rouleau qui nourrit le systeme(GRPF) souffre de plusieurs
i i ~ c o n ~ ~ ~ n i qui
e n t sincluent la haute consonlnlation du pouvoir, usure lourde e.t.c. Contraignez
pression sans cllulte de rouleau dente qui nourrit le systkme(TRF) est line presentation unique de
L'industrie sucriere augnlenter debit qui nourrit le systemc peut 6tre installe avec toute dilnension
de plantc du mdtier de meuulier et peut 6tre de tout viz de la configuration seul ou lnulti perfore
le rouleau dente. Une beaut6 du systeine est qu'il donne un feedability positive conlme TRPF et
les characterstics du de~neaagement du jus c o ~ l ~ n lGRPF e avcc consonlrnation de pouvoir
comparativement basse dii a elimination de pertes a friction dans I'absence de la chute de la
pression. Un systeme de l'alimeatation tel a ete intalle a Doab Sucre Moulins SupCrieurs, Ltd.,
Shamli, Inde, dans le temps 1994-95 ecrasant sur 1111 vieux tandem du metier de meutnier esistant
de dinlension 960 x 1981 nun.
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