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Reducing sugarcane juice reabsorption in sugar mills using mill rolls with
internal drains: Greater sucrose extraction and lesser moisture in bagasse

Article  in  International Sugar Journal · March 2015

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 REDUCING SUGARCANE JUICE REABSORPTION IN SUGAR MILLS USING
MILL ROLLS WITH INTERNAL DRAINS: GREATER SUCROSE EXTRACTION
AND LESSER MOISTURE IN BAGASSE

By:

SANCHEZ, J.J., CHAVARRO, S.

Fundiciones Universo S.A., Cali - Colombia

jsanchez@fundicionesuniverso.com, schavarro@fundicionesuniverso.com

KEY WORDS: Internal drainage, High extraction, Low moisture, Lotus roll, XM roll,
Bagasse dryer.

Abstract

We hereby present a technological innovation that minimizes the

sugarcane juice reabsorption in the sugar mills, increasing its juice
extraction: the XM mill roll. The innovation is based on the Lotus
mill roll, that is not built on steel, but rather on cast iron, similar to the
conventional shells.
The innovation consists on implementing drains directing flow
towards the inner part of the mill rolls in order to rapidly separate the
bagasse juice during the milling cycle. Hundreds or thousands of
nozzles are placed at the root of the mill rolls teeth to capture the
liquid and direct it internally towards wide longitudinal drains that
channel the juice through the exit sides, ending in the juice collecting
tray.
In an initial phase internal drains were built on the top roll since it has
the greatest contact area with the juice, achieving a significant
reduction of the bagasse moisture at exit of the last mill and increasing
sucrose extraction in the first mill. Later on, the other mill rolls were
built (feed roll, discharge roll, fourth roll) with internal drains
increasing, or at least, maintaining good indicators through time. We
have achieved in Colombia extractions up to 75% using mill rolls with
internal drains in the four rolls of the first mill, and bagasse moisture
between 45% and 50%, with internal drains only in the top roll of the
last mill.
We register a special case of a drying mill installed in Ecuador in
which the bagasse exits the diffuser with an approximate moisture of
80% and when passing through the mill, obtained moisture of less
than 50% using internal drains in the feed roll and the top roll.

Other indirect benefits:

• Possibility of increasing water imbibition.
• Improve and stabilize boiler operation.
• Have bagasse surplus.
• Reduced pollution by lower fossil fuel consumption.
• Possibility of increasing milling capacity.
• Achieve positive tandem indicators of 5 mills.
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Introduction.

During juice extraction in sugar mills, sugarcane juice reabsorption in the bagasse is
inevitable, resulting in a reduction in sucrose extraction and an increase in bagasse moisture
exiting the mill. For decades, designers have implemented different methods and devices to
increase and improve juice drainage, obtaining positive results against reabsorption: Lotus
mill rolls, Slitted rolls, Messchaert grooves, lower angles in teeth profile, Vacuum sucking
elements, etc.

Mill rolls with internal drains offer an efficient solution in juice reabsorption by
enabling the juice to separate quickly from the bagasse when compression between mills
occur (Figure 1).

Fig. 1 – Four-rolls mill with internal drains.

A good example are the Lotus mill rolls that for years have been manufactured in
steel cast with low carbon. Extraction and moisture in bagasse results are positive, but
involve long manufacturing times, high production costs, and long periods of maintenance.
Steel shells require more specialized fusion equipment than that required in laminar cast iron;
and the mechanization processes are more extensive and complex. Thus, the manufacturing
cost is high and can only be produced in steelwork plants. During the milling process, the
juices generate corrosion that affect the steel faster than the grey iron. Because of this, it is
necessary to protect the bottoms of the teeth to avoid accelerated wear out. A shell made of
low carbon steel (less than 0,30% C) can be rebuilt with welding in order to recover the
original form and dimensions; nevertheless, this process always results in higher costs and
more complex than simply changing the shell made of laminar cast iron. Additionally, it is
not easy to avoid bagasse accumulation in the axial and radial conduits. Once they are
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blocked, the internal drains lose their functionality. The above-mentioned circumstances are
the reason why these rolls are not more popular in the sugarcane industry, Rein (2007).

The new mill rolls with internal drains referred to in this article as perforated rolls or
XM rolls, have solved the main issues of the preceding models since these new rolls are made
of grey iron similar to the conventional rolls, but with improved metallurgic properties to
allow internal perforations. Laminar grey iron resistant to more than 40.000 PSI traction or
some ductile iron whose mechanical resistance surpasses such amount, must be used. Under
these conditions it is feasible to manufacture XM mill rolls without significantly affecting its
cost following simple operational and maintenance routines. These rolls have nozzles
installed in the bottom of the teeth in order to drain the juices that are then conducted radially
towards some pipes that cross the shell longitudinally. The juice exits on each end of the shell
and finally falls by gravity on the juice collecting tray (Figure 2).

Distribution
flow of juice

Fig. 2 – Top roll with internal drains.

In a factory with sufficient water evaporation capacity in the juice heating processes,
the internal drains allow to increase the amount of water imbibition, maximizing sucrose
extraction in mills. When having a greater draining you can increase the speed of the mills in
order to process more sugar cane, Rein, P. pg 119 (2007).

Design and manufacture of perforated rolls

Each XM mill roll has a unique design since it is necessary to modify the roll in order
to allow for new internal drains. The design includes the location of the nozzles and
longitudinal pipes, the modification of the flanges, and the lateral channeling of the juices
through the installation of deflecting trays (Figure 3).

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 Deflector
of juice Bronze Modified
nozzles Drainage
tubes flange

Fig. 3 – XM top roll, details

The nozzles are sprays with a central 1/4” to 5/16” orifice, installed in a radial
direction of the diverging cone towards the interior of the shell, and in the external part take
the same angular form of the rolls’ teeth. The length depends on the thickness of the shell
and the location of the longitudinal drains, normally measuring 2” and 3”. These can be made
of a hard plastic, but it is best if made of steel or bronze to facilitate the shielding of the teeth
using hard coatings.

The majority of XM mill rolls are made of grey iron; the bronze nozzles are ideal for
these since they can be easily installed and their life span is very similar to that of the steel
shell, lasting between 12 and 24 months through different milling periods.

Some sugar mills regularly use cast iron shells and in these the XM mill rolls can be
installed. Regardless of the nozzle material it is recommended to use steel nozzles, to extend
their duration according to a better wear out rate of the steel shell. Aside from the nozzles’
material, these should be protected during the shielding process to avoid blocking them with
welding residue.

The number of nozzles depend on the mill’s dimensions and are directly proportional
to the spacing between the teeth, width and external diameter of the roll. It is desirable to
install the greatest possible number of nozzles to capture the juice and avoid its reabsorption
in the bagasse. It is also convenient to have nozzles in excess since it is unavoidable that
some will be blocked with different solid materials during the milling process. A good design
of an XM mill roll will prevent juice overflow above the top roll and will last longer. The
nozzles must be placed one right next to the other in all teeth bottoms but should not be

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perfectly aligned to avoid the embedding of the ends of the scraper and to reduce the risk of
shell fracture. These cannot be placed near the lateral ends, either.

The longitudinal drains are tubes that cross the shell in an axial direction, their
diameter must be the greatest possible and is limited by the shell’s thickness. A special
casting process is required to empty the liquid metal of the grey iron over the steel tubes that
will become the internal drains. It is also possible to make these drill-bored over the shell, but
this will increase manufacturing times and costs.

The quantity and location of the conduits that make the longitudinal drains are limited
by the shaft’s diameter and by the amount of screws required to mount the lateral flanges. A
redesign is necessary to position each element and to free the lateral exit of the juice with
enough width to avoid the formation of bagasse clogs. It is also key to install deflecting trays
to channel the juice and avoid it from entering the bronze bearings and the shaft’s supports
(Figure 4). Usually this zone is very tight and cleaning platens must be installed in each end
of the XM mill roll so that these will continuously remove the bagasse that tends to get stuck
there. In the top rolls these platens can be fixed to the bearing retainers to avoid jarring
during the roll’s flotation.

Platens
cleaning

Deflector
of juice

Modified
flange

Fig. 4 – Juice deflector and platens cleaning installation.

In Figures 3 and 4 you may note the modifications that were made to the flanges of an
XM top roll to allow lateral juice displacement. In many mills there is not enough room for
these new drains, the flanges are too close to the bearing retainers or to the seals installed to
avoid the juice from entering the bearing supports. In this case, it is necessary to adjust each
element to provide the space required for the juice to exit carrying some bagasse. Almost
always it is required to reduce the flange’s thickness to gain such space and at the same time
to channel the juice. It is crucial to verify the flange’s mechanical resistance to guarantee the
unit’s rigidity. It might be necessary to change the material to a more resistant steel to
compensate for its minor transversal section. In some sugarcane mills, these have been
manufactured in 410 stainless steel that offers a traction resistance of more than 100.000 PSI
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with hardness of up to 400 Brinell; gaining more corrosion resistance since these are
permanently exposed to the corrosive attack of the sugarcane juice. It might also be necessary
to relocate and recalculate the screws that hold the flange; an alternative is to reduce the
diameter but the quantity has to be increased in order to preserve that total area of the screws
without losing the flange’s fastening to the XM mill roll.

The deflecting platens are installed as close as possible to the bearings or bearing
retainers so that the juice channeling is as wide as possible. These can be mounted on the
shell ends as shown on Figure 3 or on the flanges as shown on Figure 4. As in the case of the
flanges, it is convenient to manufacture them in some type of stainless steel to improve its
resistance to corrosion and to extend the product’s life.

The technical designer must choose the best option to setup each of the elements
according to the mill’s dimensions and materials availability to manufacture the juice nozzles,
flanges, and deflectors. A good design must guarantee the draining of the perforated roll, the
mechanical resistance of all of its components, and greater product life of its elements; at least
during the milling period. Every sugarcane mill must establish maintenance routines in order
to inspect and clean periodically the solid materials that get stuck on the nozzles’ openings
and to assure that the drains work correctly.

The shell weakens as a result of the nozzle and internal conduits installation; thus it is
crucial to calculate the mechanical efforts and establish the safety factors to guarantee the
perforated roll’s reliability. A stress analysis is made on the finite elements using Solidworks
Simulation version 2012. Factors considered are: milling conditions, shell’s material, and
rolls position in the mill’s tandem. The simulation is based on estimating the loads that
attempt to separate that rolls when bagasse passes through the mill. The variables used are:
milling rate, fiber percentage, mill’s angular velocity, adjustment measurements between rolls
and main blade, top roll flotation, piston pressure and diameter on hydraulic headstocks, shaft
and shell materials and dimensions. Based on this information bagasse compacting is
calculated (measured in kilograms/mt3) and from here, the resulting forces on each roll’s area
is estimated. It is important to highlight that the bagasse compacting will be greater in the
last roll (approx. 1000 kg/mt3) and less in the initial rolls (approx. 500 kg/mt3), thus,
mechanical effort is greater in the XM roll of the last mill. The results of the simulation are
the values of the efforts measured in different areas of the roll. Special attention must be
given to critical points found in the nozzle holes and juice drains (Figures 5 and 6).

Once obtaining the efforts, static and dynamic safety factors can be calculated
considering the shell and shaft manufacturing materials.

The calculation of the static safety factor is based on the energy distortion theory for
ductile (shaft) materials and the Von Mises σ´ general formula:

where σ1,2,3 represents each of the main individual efforts, Budynas, R. pg. 214 (2007).

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 Fig. 5 – Stress analysis of final elements, Solidworks 2012

Fig. 6 – Effort simulation on XM mill roll, sectional view, Solidworks 2012

Likewise, the Mohr-Coulomb theory is used for fragile materials (shell); design
equations are:

where σA,B are the efforts, , n is the safety factor, Sut y Suc are the material’s resistance limits
under tension and compression, Budynas, R. pg. 227 (2007).
The dynamic safety factor uses Soderberg Fatigue Criterion:
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where σA is the alternate effort, σm is the medium effort, Se is the fatigue resistance limit, Sy
is the fluency limit and n is the safety factor, Budynas, R. pg 298 (2007).

Designer’s experience is required for both safety factors in order to determine which
are the minimum acceptable values that guarantee the proper functioning of the perforated
rolls. A minimum value of 2.5 for the static safety factor and 1.2 for the fatigue safety factor
are suggested. Steel and ductile iron shells will easily surpass these values; nevertheless,
shells made of laminar cast iron will have very low safety factors, slightly higher than the
minimum accepted values.

Results obtained from perforated rolls

XM mill rolls have been installed in Colombia since 2007; the first sugarcane mill to
use it was Ingenio Providencia in the top roll of the sixth mill. Since then, almost all
sugarcane mills in Colombia have installed these rolls, obtaining excellent sucrose extraction
and reducing bagasse moisture at the mills.

At the beginning, only XM top rolls were manufactured, since these provide the
greatest option to obtain juice and direct it towards the internal drains. It was necessary to
solve multiple issues in the construction, mounting and during the milling process, to avoid
nozzle and drain clogging. Positive results in humidity reduction and high sucrose extraction
motivated the continuity and perfection of this development despite the initial problems that
arouse during the first years of manufacture. Furthermore, XM feed and discharge rolls were
manufactured, including some XM fourth rolls, each having its own particular design and
providing different inputs of the mill’s indicators. Also, XM feed rolls were produced
maintaining the Messchaert grooves for every two bottoms of teeth. It is ideal to replace such
grooves for nozzles, since the Messchaert debilitate the shells and facilitate the teeth breaking
when solids during the milling cycle are present.

In a sugarcane mill with bagasse moisture above 52%, a top XM mill roll can reduce
by 2% the humidity in the last mill, representing an approximate increase of about 12% in the
caloric energy delivered by the bagasse when burnt in the boiler (estimated growth 400 BTU/
pound of bagasse). It is possible to keep bagasse inventory for those periods in which there is
no milling; or, can reduce the consumption of fossil fuels that are mixed with the bagasse,
reducing environmental pollution.

In the first mill, an XM top roll can increase sucrose extraction up to 5%. At Ingenio
Providencia the four rolls of the first mill are perforated, obtaining extractions greater than
75% (this sugarcane mill has a dry cleaning system for the sugarcane, utilizing a semi-light
shredder, with automatic feeding control in the Donellys shuttes, and the mills are electrified).

This technological innovation has been implemented in 11 countries throughout Latin

America: Colombia, Venezuela, Peru, Ecuador, Argentina, Panama, Guatemala, Mexico,
Martinique, Dominican Republic and United States. To date, some 500 XM mill rolls have
been manufactured for more than 50 Sugar mills in these countries.
The design has been improved to maximize the drains and increase the amount of
nozzles. Currently XM mill rolls are manufactured with more than 1.200 nozzles for
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Okeelanta in USA and Valdez in Ecuador, both mills with 84” tooth profile of 1-1//2”,
representing a density of 17 nozzles per sq. ft. of external surface (Figure 7).

Fig. 7 – XM top roll with 1.248 draining nozzles.

An XM top roll was manufactured in ductile iron that in addition to draining the juice
resulted in a material with greater mechanical resistance to reduce teeth breaking and an
appropriate safety factor in a very thin XM mill roll that could not be manufactured in laminar
cast iron.

Currently a new roll with internal drains is being developed. Its shell will be
manufactured in two sleeves, the first one mounted on the shaft will have longitudinal
conduits and the second one mounted on the first will have the grooving with the nozzles.
This will simplify the manufacture of the perforated roll and will reduce time and
manufacturing costs.

Table 1 shows the results obtained by some sugarcane mills that use XM rolls with
different milling conditions. The information was updated on oct. /2012. It has been studied
that almost all of the Colombian sugarcane mills have a bagasse moisture under 50%, the
sucrose in bagasse below 2% and the reduced extraction higher than 97%. Another important
piece of information is the performance of the XM rolls in the drying mills of sugarcane
diffusers in Casagrande and Valdez, a moisture of 50% or less with a single mill. The bagasse
comes out of the diffuser with a moisture close to 80% and passes by a dewatering cycle that
reduces it by 5%. In previous times two mills in series were needed to dry the bagasse and
build under 50% moisture.

It is worthy of mention that the information shown on Table 1 are the result of various
factors and improvements made on each sugarcane mill. For example, in Ingenio San Carlos
XM mill rolls were installed, fourth roll in all mills, some planetary transmissions and electric
engines, level sensors in the Donellys shuttes, some flexible couplings, speed controls at the
macerating pumps, etc.

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 Water Extraction
Sugarmill / Milling Number Mills with XM Fiber % Moisture in Sucrose in
XM roll position in the mill imbibition % reduced at
Country TCD of mills rolls cane bagasse % bagasse %
cane 12.5% fiber
Mayaguez /
7.600 6 All Top 16,0% 32,0% 49,0% 1,9% 97,0%
Colombia
Risaralda /
5.000 6 First and sixth Top 13,5% 24,0% 47,0% 1,7% 97,0%
Colombia
La Cabaña /
5.600 6 All Top 16,5% 30,5% 49,5% 1,8% 97,0%
Colombia
Providencia / Top in all and all 4 rolls of first
9500 6 All 15,5% 28,0% 47,0% 1,6% 97,1%
Colombia mill
Incauca Fulton/
7.400 6 All Top 15,6% 30,9% 47,3% 1,8% 97,0%
Colombia
Incauca Farrel / Top in all and discharge in first
4.400 6 1, 3, 4, 5 and 6 15,6% 29,8% 48,0% 1,7% 97,0%
Colombia mill
Castilla /
7.200 6 3, 5 and 6 Top 15,4% 30,5% 50,3% 1,8% 97,2%
Colombia
Riopaila /
8.500 6 2, 5 and 6 Top 14,8% 29,5% 46,5% 2,1% 96,8%
Colombia
Carmelita /
2.000 6 Sixth Top 17,0% 31,2% 50,2% 2,1% 96,6%
Colombia
La Troncal / Feed in mill 1, top in mill 2,
10.500 6 1, 2 and 6 16,6% 20,9% 48,2% 1,8% 96,2%
Ecuador feed and top in mill 6
Valdez /
9.000 1 One dryer mill Feed and top 13,2% Diffuser 50,5% N/A N/A
Ecuador
San Carlos TB/ Top in all and discharge in 2, 3
9.000 5 All 13,5% 32,3% 49,2% 1,7% 96,2%
Ecuador and 5
San Carlos TA/ Top in 1, 3, 5 and 6, discharge
4.300 6 1, 3, 4, 5 and 6 13,5% 33,5% 49,1% 2,0% 95,5%
Ecuador in mill 4
Santa Rosa /
7.500 6 1, 2, 5 and 6 Top 15,3% 26,9% 49,7% 2,1% 95,7%
Panama

Varela / Panama 640 3 All Top and discharge in all 15,0% 30,0% 48,1% 2,0% N/A

La Victoria /
6.630 5 All Top 15,1% 23,1% 50,9% 2,8% 92,9%
Panama
Alange /
5.300 6 First and sixth Top 14,5% 26,9% 53,0% 2,9% 93,4%
Panama

Laredo / Peru 4.500 6 First and sixth Top 15,7% 33,9% 50,4% 1,4% 97,5%

Paramonga /
4.400 5 1, 2 and 6 Top 13,7% 23,1% 49,1% 2,2% 95,6%
Peru
San Jacinto /
3.000 5 First and fifth Top 13,8% 28,9% 48,2% 1,8% 96,6%
Peru
Casagrande TB/
6.000 6 Sixth Feed, discharge and top 14,0% 26,0% 47,0% 1,7% 96,9%
Peru
Casagrande
5.000 1 One dryer mill Feed, discharge and top 14,0% 28,5% 48,5% 2,0% 96,0%
Diffuser / Peru
First and
Tuman / Peru 4.000 5 Top 13,5% 30,0% 49,0% 2,2% 95,4%
second

Pucala / Peru 4.000 5 All Top in all, feed and top in mill 1 12,1% 16,0% 51,6% 3,8% 91,7%

Table 1 – Milling data from some Sugar mills using XM rolls

Conclusions

Rolls with internal drains improve Sugar mill operation by significantly reducing juice
reabsorption, elevating sucrose extraction, allowing to increase the amount of water by
imbibition to maximize sucrose extraction, reducing bagasse moisture and stabilizing boiler
operation.

When having a greater draining you can increase the speed of the mills in order to
process more sugar cane and increase the production. It is also possible to achieve good
indicators in a short tandem of five units like Paramonga, San Jacinto and Tuman in Peru or
San Carlos in Ecuador.
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 The advances in mechanical and metallurgic engineering have made possible the
construction of perforated rolls by casting them with special cast irons with all the advantages
this material offers for sugar cane mills: low production costs, appropriate production timing,
ease of operation during milling, and simplifying maintenance activities.

It is always necessary to design each XM mill roll to ensure the operation of the drains
without sacrificing the shell’s mechanical resistances. In some cases it will not be possible to
build the XM roll in laminar cast iron, but a low carbon steel or conduit iron may be used.
The design has to be carefully evaluated and calculated so as not to exceed the accepted
efforts of the material and guaranteeing the minimum safety factors acceptable for static and
dynamic factors.

The greatest amount of nozzles that the exterior area of the roll can take must be
installed; this ensures a greater draining capacity and enables to have good extraction
indicators for longer periods of time. After a few weeks, it is inevitable that the roll will
begin to lose some effectiveness when draining the juice since some nozzles will be blocked
with the solids that fall in their central orifice. Installing excess nozzles (without running
risks of breaking, of course) allows enough time until programmed maintenance is arranged to
perform the cleaning activity without affecting the indicators.

It is possible to manufacture any of the rolls of a mill with internal drains. The top roll
will provide the best results because it has greater contact area with the juice. Furthermore,
you can improve the extraction by using additional XM mill rolls and is implemented when
all mills are in tandem.

It is imperative to implement maintenance routines to guarantee continuous draining

of the XM rolls; a regular inspection of the nozzles, lateral exits, and internal tubes is
required. A frequent cleaning of the XM mill roll using a water jet spray, vapor or compressed
air, lasting a few minutes, aimed at the nozzles and lateral juice exits, particularly when the
mill has little fluid or when many solids come with the sugar cane (rainy season): sand, soil,
small pieces of rock, etc. Periodic mill shutdowns may be used for deeper cleaning and solids
that block the nozzles removal: welding residues, rocks, etc.

Acknowledgements

I want to thank Eng. Enrique Velazquez of Ingenio La Union in Guatemala, for his
friendly and efficient cooperation in the year 2007 when we manufactured the first perforated
rolls in Colombia. I must also thank all those engineers who shared their milling data
included in Table 1 and specially to the Sugar mills in Colombia for their support in serving
as laboratory in developing this technological innovation.

REFERENCES

Rein, P. (2007). Cane Sugar Engineering, pages 113, 114, 119.

Budynas, R.G., Nisbbett, J.K., Miller, (2008). Diseño en ingeniería mecánica – Shigley,
eighth edition.

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