pt indocode surya

CHAPTER X

THE COMPUTER PROGRAM

The example of calculation for a complete mill material balance as described above was done
manually with the use of an ordinary calculator. Perhaps it will take too much time to complete,
say sometimes for about 7 (seven) or 8 (eight) hours for a mill tandem, excluding the time to
compose its evaluation, conclusions and the recommendations.
With the computer program made by the writer a complete mill material balance will be
calculated instantly and the user needs only to fill the input data. But it is to be noted that, the
use of a computer program will be nothing if unreliable source of data used to the computer, the
same with the saying that when the garbage in, then will garbage also out.
There were 2 (two) programs made with Lotus-123, one for the tandem of 4 (four) mills and the
other for the tandem of 5 (five) mills. Each program consist of 2 (two) versions of calculation:
The Evaluation Program
The Projection Program
The evaluation program is use to evaluate the performance of the mill tandem respectively, using
its average daily analysis and data obtained from the operation of a week period or two weekly
as well during the milling season.
While the projection program is to be use for the planning of an optimal performance of a
tandem. Whereas the extractions value of Brix in mill #1 and the total, the total sugar, the %pol
and dry matter of the last mill bagasse could be determined based upon the tandems capability
and quality of the cane going to be milled.
Beside the items described above, the complete mill material balance also determining the gaps
between the rollers, i.e. the work opening for each mill. This means that the Projection Program
can also be use as reference of the setting for the next milling season, as well as the re-setting or
adjustment of the mills needed during the season. The program provided with such relevant
calculation including determination for the distances of feeder rollers and the Donnelly chutes.

10.1

THE EVALUATION PROGRAM

The program consisting of 2 (two) sheets:

Sheet-I, for the data inputs.
Sheet-II, the results of material balance and its evaluation.
10.1.1

The Data Sheet (Inputs)

Let us use the same example with the calculation on Chapter IX.
Fill in the data on Sheet-I (Evaluation Data), that are the blue letters or numbers only in the red
lined boxes and follow the instruction providing the sheet.
The ComputerProgram

X- 1

Sugar Factory
Mill Train
Milling Season (year)
Period of 15 milling days, number
Period dates evaluated up to

I. MILL ROLLERS IN USE (dimension in mm)

M I L L N O: --------------->
Outside diameter (Do):
top
feed
delivery
Groove correction (k):
top
feed
delivery
Length of shell
L
Actual roller rotation/hour
rph
Mill settings:
- delivery opening
hd
- feed to delivery ratio hf/hd
i
Top roller lift:
t
- top angle
a

EXAMPLE
2 CC + 5 MILLS
1977
X
Last date

I
1.052,0
1.050,0
1.048,0
25,0
25,0
25,0
2.133
268

II
1.073,0
1.069,0
1.066,8
25,0
25,0
25,0
2.133
244

III
1.051,0
1.048,0
1.040,0
15,0
15,0
15,0
2.133
216

IV
1.050,0
1.048,0
1.040,0
15,0
15,0
15,0
2.133
191

V
1.064,0
1.052,0
1.048,0
15,0
15,0
15,0
2.133
193

41,23
2,20
6,0
78

36,33
2,00
6,0
78

27,79
2,00
6,0
78

26,14
2,00
6,0
78

24,62
2,00
6,0
78

II. M I L L I N G O P E R A T I O N
Cane:
crushed, total
Q
crushing duration
jg
pol
pt
brix
bt
fiber
f
Mixed juice:
gross
Gnm
brix
bnm
correction
knm
Imbibition water, total
Gi
Applied on:
bagasse 1
bagasse 2
bagasse 3
bagasse 4
Average value of fiber density
Brix ratio juice#1 to cane
bn1/bt =

4.351,0
24,00
10,32
13,41
16,07
3.718,7
14,69
1,00308
843,1
0
0
0
100
1,53924
1,30

III. RESULTS OF ANALYSIS (average):

M I L L NO: --------------->
Juice:
brix
bn
pol
pn

I
17,46
14,05

10.1.2

TCD =
hours
%
%
% cane
Tons =
%, pol =

181,29 TCH

154.946
11,40

Purity =

76,96 %

kg/hr =
Purity =

85,47 % cane
77,62 %

Tons =
35.128
ltr/hr =
120,58 % fiber
%
%
%
%
kg/dm3
Last mill bagasse juice to fiber =
111,01%

II
12,48
9,29

III
8,90
6,45

IV
5,75
4,06

V
2,94
2,00

unit
%
%

The Evaluation Sheet

The result of calculation made by the computer is shown on Sheet-II (Evaluation), such as:
The Material Balance, overall and individually (page: 1).
The overall performance of the tandem (page: 2).
The individual performance of each mill (page: 2).
The actual versus the projection of Brix Curves (page: 3).
The result of calculation made by the computer with the use of the same input, the same
example in Chapter IX is presented herein after for the overall as well as for the individual
performance of each mill in the tandem.

pt indocode surya

MATERIAL BALANCE IN THE MILL TRAIN

EVALUATION OF PERFORMANCE
SUGAR FACTORY
EXAMPLE
CAPACITY
4.351,0 TCD
PERIOD
: X
MILL TRAIN
2 CC + 5 MIILS
MILLING SEASON
1977
Date : Last date
CANE
% pol = 10,32 % brix = 13,41 %fiber= 16,07
QUALIT
Mass
kg/hr.

MILL I
- Juice
- Fiber
Total in

%
brix

Density
kg/dm3

Volume
dm3/hr.

Page : 1

Brix
kg/hr.

%
pol

Pol
kg/hr.

18.709 1,07138 142.020

1,53924 18.926
18.709 1,12641 160.946
9.631 1,07788 63.792
9.078 1,06608 78.228
1,53924 18.926
9.078 1,15826 97.154

MILL I
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =

10,02
21,33
268
0,4123
2,20
74.154
73.107

r=
r' =
u=
h' =
K=
HKnp =
kB =

1,3289
1,3172
0,34
0,4065
2,20
80,47
1,089

Evalu

15,98

24.311

12,30

- Fiber
Total

152.158
29.133
181.291
68.761
83.397
29.133
112.530

13,41
17,46
14,80

24.311
11.969
12.342

10,32
14,05
10,89

10,97

12.342

8,07

MILL II
- Juice
- Fiber

145.368
29.133

12,28

17.858

8,99

13.075 1,05564 137.706

1,53924 18.926

MILL II
Dk =
L=

10,23
21,33

r=
r' =

1,3081
1,3062

174.501
86.185
59.183
29.133
88.316

10,23
12,48
12,06

17.858
10.723
7.135

7,49
9,29
8,61

8,08

7.135

5,77

13.075 1,11408 156.632

7.982 1,05646 81.579
5.093 1,05445 56.127
1,53924 18.926
5.093 1,17672 75.053

n=
h=
i=
Vlbo =
Vlb =

244
0,3633
2,00
60.737
57.376

u=
h' =
K=
HKnp =
kB =

0,34
0,3432
2,73
74,44
1,013

109.253
29.133
138.386
61.971
47.282
29.133
76.415

9,17

10.014

6,52

7,24
8,90
9,51

10.014
5.515
4.498

5,15
6,45
6,62

5,89

4.498

4,09

7.126 1,04258 104.791

1,53924 18.926
7.126 1,11857 123.717
3.997 1,04191 59.478
3.129 1,04345 45.313
1,53924 18.926
3.129 1,18954 64.239

MILL III
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =

10,21
21,33
216
0,2779
2,00
41.048
49.645

r=
r' =
u=
h' =
K=
HKnp =
kB =

1,2940
1,2954
0,35
0,3361
2,49
72,47
0,971

89.272
29.133
118.405
50.070
39.202
29.133
68.335

6,42

5.733

4,45

4,84
5,75
7,28

5.733
2.879
2.854

3,35
4,06
4,94

4,18

2.854

2,83

3.969 1,03119 86.572

1,53924 18.926
3.969 1,12234 105.498
2.033 1,02889 48.664
1.936 1,03414 37.908
1,53924 18.926
1.936 1,20236 56.834

MILL IV
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =

10,20
21,33
191
0,2614
2,00
34.108
44.395

r=
r' =
u=
h' =
K=
HKnp =
kB =

1,2802
1,2846
0,36
0,3402
2,38
70,61
0,895

74.330
29.133
103.463
41.990
32.340
29.133
61.473

3,84

2.854

2,60

2,76
2,94
5,01

2.854
1.235
1.619

1,87
2,00
3,39

2,63

1.619

1,78

1.936 1,01772
1,53924
1.936 1,12506
840 1,01772
1.096 1,01772
1,53924
1.096 1,21241

MILL V
Dk =
L=
n=
h=
i=
Vlbo =
Vlb =

10,34
21,33
193
0,2462
2,00
32.907
39.937

r=
r' =
u=
h' =
K=
HKnp =
kB =

1,2696
1,2696
0,36
0,2988
2,30
68,03
0,766

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

The ComputerProgram

73.036
18.926
91.962
41.259
31.777
18.926
50.703

X- 2

pt indocode surya

MATERIAL BALANCE IN THE MILL TRAIN

EVALUATION OF PERFORMANCE
SUGAR FACTORY
EXAMPLE
CAPACITY
4.351,0 TCD
PERIOD
: X
MILL TRAIN
2 CC + 5 MILLS
MILLING SEASON
1977
Date : Last date
CANE
% pol = 10,32 % brix =
13,41
% fiber = 16,07
QUALIT
ACTUAL PERFORMANCE
Y
Descr
Symbol
Value
Unit
Target
- crushed, total
Q
iCane:
ption
4.351,0 TCD
4.800,0
- crushing duration
jg
24,00 hours
24,00
- crushed per hour
Qj
181.291 KCH
200.000
- juice content
gnt
83,93 % cane
83,93
- weighed, total
Gi
Imbibition water:
843,1 Tons
1.581,3
- weighed per hour
Gij
35.128 kg/hr.
65.887
- % fiber
gis
120,58 % fiber
205,00
- % cane
git
19,38 % cane
32,94
- on bagasse 1
gia1
0 % Gij
0
- on bagasse 2
gia2
0 % Gij
0
- on bagasse 3
gia3
0 % Gij
30
- on bagasse 4
gia4
100 % Gij
70
- weighed, total
Gnm
Mixed juice:
3.718,7 Tons
4.800,0
- weighed per hour
Gnmj
154.946 kg/hr.
200.000
- % cane
gnmt
85,47 % cane
100,00
- pol
pnm
11,40 %
10,04
- brix
bnm
14,69 %
12,60
- purity
HKnm
77,62 %
79,69
Gal
Last mill bagasse: - total per hour
61.473 kg/hr.
65.887
- % cane
galt
33,91 % cane
32,94
- pol
pal
1,78 %
0,94
- brix
bal
2,63 %
2,58
- fiber content
kf
47,39 %
48,78
- dry matter
zk
50,03 %
51,36
- juice to fiber
nss
111,01 %
105,00
- juice loss in bagasse
gnhs
31,84 % fiber
33,22
- Brix mill #1
HPB-I
Extraction's:
49,23 %
53,19
- Brix total
HPB-t
93,34 %
93,67
- sugar
HPG
94,14 %
97,00
- sugar on 12,5% fiber
HPG12,5
95,44 %
97,67
Ratio of juice purity
PSHK
94,51 %
97,51
- can be expected
kt
Crystal:
9,08 % cane
9,08
- in mixed juice
knm
8,59 % cane
8,99
- loss in bagasse (relatively)
khar
5,38 %
1,03
INDIV
MILL
NO:
Extractio
-------------->

- Juice

En =
Normal

- Pol
- Brix

Compres
Juice
extracted
by
Roller
feed
opening
shell
deflectio - noBagasse
void
- ditto,
density
-%
- pol
- brix
- dry
Fiber:
- index
- loading
-%

The ComputerProgram

Ep =
Eb =
K =
y =

I
II
III
IV
V
45,19
59,29
56,72
56,09
56,49
> 60
> 60
> 60
> 60
> 60
51,48
61,05
56,09
51,22
43,38
49,23
60,05
55,08
50,22
43,26
2,20
2,73
2,49
2,38
2,30
2,4-3,3 2,6-3,5 2,6-3,3 2,5-3,2 2,4-3,0
-0,20
0,59
0,32
0,19
0,11

meaning = no extion

l =
meaning
da =
r =
r' =
gat =
pa =
ba =
zk =
c =
q =
q' =
Normal value =
kf =
Normal

extted

extted

extted

Page : 2

%
%
%
%

extted

-0,03
-0,09
0,27
0,37
0,25
safe
safe
danger danger danger
1,1583 1,1767 1,1895 1,2024 1,2124
1,3289 1,3081 1,2940 1,2802 1,2696
1,3172 1,3062 1,2954 1,2846 1,2696
62,07
48,72
42,15
37,69
33,91
8,07
5,77
4,09
2,83
1,78
10,97
8,08
5,89
4,18
2,63
36,86
41,07
44,01
46,81
50,03
0,40
0,51
0,59
0,66
0,73
161,98 174,26 197,24 223,27 217,97
123,18 129,80 147,20 166,80 160,63
120 130 grams/dm2 escribed surface
25,89
32,99
38,12
42,63
47,39
25-35
28-38
32-42
37-47
45-50

%
kg/dm3

%
%
%
%
kg/dm3
gr/dm2
gr/dm2
%
%

X- 3

pt indocode surya

MATERIAL BALANCE IN THE MILL TRAIN

SUGAR FACTORY :

EXAMPLE

MILL TRAIN

2 CC + 5 MILLS

CANE QUALITY

THE BRIX CURVES

CAPACITY

MILLING SEASON :

% pol =

Va l u e

10,32

% brix =

f o r -------------->

4.351,0 TCD

Page : 3
PERIOD NO.

1977

Date

13,41

% fiber =

16,07

Last date

Mill I

Mill II

Mill III

Mill IV

Mill V

% brix , expected ----------->

15,90

9,90

5,60

3,10

1,90

% brix , actual ---------------->

17,46

12,48

8,90

5,75

2,94

20
19
18
17
16

<---------- % brix ---------->

15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
Mill I

Mill II

Mill III

Expected Curve

The ComputerProgram

Mill IV

Mill V

Actual Curve

X- 4

pt indocode surya

The ComputerProgram

X- 5