Profile

Personal Details
Name Yaqoob Ali
Department Mechanical
Joining Date 15 December 2014
PEC Registration Applied for
Home District Jhang

Academic Record
Degree/ Certificate University/ Board Session CGPA/Marks
B.Sc. Mechanical Engg. UET Lahore 2010-2014 3.01/4.00
F.Sc. Pre-Engineering BISE Faisalabad 2008-2010 86.00%
Matriculation BISE Faisalabad 2006-2008 89.65%

Shakarganj Mills Limited II

Strictly private and confidential
Bhone
 List of Contents
• Brief description of mill house
• Definitions
• Factors influencing milling of cane
• Quality of the raw material (Cane) and supply
• Cane preparation
• Cane milling

Shakarganj Mills Limited II

Strictly private and confidential
Bhone
 Brief Description of Mill House
Length 18.4 m Cane leveler Motor power 75 hp
Width 5m RPM 1480
No. of slats 780 No. of arms 30
Angle of inclination 18⁰ Cane cutter no. 1 Motor power 90 kw
Motor power 60 hp RPM 594
RPM 970, 980, 1470 No. of knives 40
Lateral feeding
tables ( 1,2,3) Idler pulleys 3*15 = 45 Swing dia 1.52 m
Linear Speed 6.15 m/minute Cutter clearance 203 mm
Cane carrier no. 2 Length 33 m
Width 2.13 m
Depth 1.9 m
Length 62.48 m Motor power 110 kw
Width 2.13 m RPM 1480
Depth 1.63 m Inclination 18⁰
Linear speed 24 m/minute No. of slates 450
Cane carrier no. 1 Inclination 9⁰ Idler pulley 13
Motor power 110 kw Linear speed 24 m/minute
RPM 1480
Strictly private and confidential Shakarganj Mills Limited II Bhone
Idler pulley 28
 Brief Description of Mill House
Motor power 1100 kw Tramp iron Electro magnet 17 kw
RPM 590 separator

Cane cutter no. 2 No. of knives 80 Mill drive (steam turbine) 1200 kw, 5500 rpm

Swing dia 1.52 m

Mill unit 1,2,3 Roller size 42’’x 84’’
clearance 45 and 4
Mill center 11.5 m
Drive (steam turbine) 3000 kw, 5500 rpm
Mill lift 10 mm
No. of hammers 228
Hydraulic pressure 2500 psi
RPM 600-1200 Mill hydraulic
shredder Accumulator pressure 2500 to 2700 psi
Swing dia 1.52 m unit
(nitrogen gas pressure)
No. of bars 8
Motor power 75 kw
No. of holders 47
RPM 1480
Length 31 m
Length 10.8 m
Width 2.16 m
Intermediate Width 2.185 m
Depth 1.39 m carriers
Cane carrier no. 3 Depth 1.34 m
Linear speed 24 m/ minute
Linear speed 37.6 m/minute
Motor power 75 kw
Inclination angle 42⁰
Inclination angle 18⁰

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Brief Description of Mill House

Length 3.6 m Capacity 3 of 230 Ton/h & 1 of

150 Ton/h
Diameter 1.8 m Maceration Head 2 of 15 m, 1 of 25 m &
Rpm 11 chokeless pump 1 10 m
Rotary juice screen (4) Motor power 3 of 18.5 & 1 of 22 kw
Aperture .5 mm
Motor 22 kw Motor power 75 kw
Power 1200-1500 kw RPM 950
Bagasse elevator
Auxiliary gear box Linear speed 17.37 m/ minute
Ratio 1:5
Carrier angle 40⁰
Power 1000 kw
Intermediate gear box
Ratio 1:32.15
Capacity 540 Ton/h
Head 40 m
Raw juice pump ( 2 )
Motor power 290 hp, 1480
rpm

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Flow Chart Mill House

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Basics of good milling
Terminologies
• Bagasse pole: The apparent sucrose content expressed as a mass percent measured by the optical rotation
of polarized light passing through a sugar solution.
• Imbibition: The process of adding imbibition water to the extraction plant to increase extraction. Water added is
called imbibition water.
• Bagasse: Cane residue leaving mills after extraction of juice.
• Bagacillo: Fine fraction of bagasse obtained by screening or pneumatic separation.
• Brix: Measure of dissolved solids in sugar juice, liquor or syrup using a refractomer. For solutions containing only
sugar and water, Brix = % sugar by mass.
• Cush cush: The stream of wet bagasse or bagacillo separated from raw juice by the juice screens.
• Fiber: The dry fibrous insoluble structure of the cane plant.
• Raw juice: Juice obtained from the cane extraction process. Also referred to as mixed juice from mills.
• Trash: Cane tops, leaves, dead stalks of cane and any other vegetable matter delivered with the cane.

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Basics of good milling
The efficient milling is to extract maximum sucrose contents from the
prepared cane, minimizing the bagasse pole and bagasse moisture,
with minimum possible energy consumption.

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Basics of good milling
There are many factors which influence the milling of cane
• Quality of the raw material (Cane) and supply
• Cane preparation
• Cane milling

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Quality of raw material and supply
• Supply should be regular and in timely manner that meets the processing unit’s
capacity
• Deliver product that satisfies the processor’s quality requirements
• Sugarcane degrades relatively quickly after harvest, so harvest to crush time
should be minimum
• Free of trash, dirt, leaves or any foreign body

Suggestions:
• Washing on feeding tables
• Suck the trash or leaves

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Cane preparation
Preparation index: The percentage of
cane plant cells which are ruptured by cane
preparation equipment is used as a measure of
the effectiveness of preparation equipment.
• Preparatory device at SML Bhone is shredder
and the preparation index is 89 to 90
• It depends on the swing dia of the equipment
• Speed of the equipment
• Weight of hammer
• It should be as high as possible

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Juice drainage or reabsorption
In a sugar cane mill, juice is extracted from bagasse under pressure between two or more rollers. In order to
increase extraction, higher pressures are required to be applied between the rollers. However, in such a mill
reabsorption of extracted juice back into the blanket of bagasse passing between the rollers is a common
phenomenon, and it is well known that reabsorption in creases with increase in pressure and reduces
extraction efficiency and crushing capacity of the mill besides increasing power consumption by the mill
• Reabsorption is the ratio of fiber % bagasse in the mill to the fiber % bagasse after the mill

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Pressure in the mills
To ma
• Spring force
• Hydraulic
Maximum lift
The mill caps are generally constructed so as to permit of a maximum lift of top roller of 2-4 cm
Maximum hydraulic pressure:
The accumulator piping and mills are generally designed for oil pressure
of 3500-5000 psi

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Milling
• Mill settings, cane quality, imbibition etc. plays a vital role in extraction.
• The extraction depends on the operation of the mills on the one hand and the characteristics of the bagasse on the other.
• Fiber % discharged bagasse forms either directly or indirectly the basis for the calculations of mill settings.
• Typical operational parameters are:
• the number of mills in a tandem
• cane throughput
• applied hydraulic loading
• mill speed
• amount of imbibition
• roller roughness and mill lift.
• Typical bagasse characteristics affecting the extraction are:
• fibre percent cane
• pol percent cane
• cane preparation

Feeding of mills:
• Force feeder is used for the feeding purpose in 3 roller configuration with forced feeder
• Smooth and uninterrupted supply of cane
• Best possible preparation index
• Tramp iron separation

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Sanitation at the mills
In order to minimize the purity drop between crusher and mixed juices,
proper sanitation at the mill was made a routine with the use of
steaming, hot water washing, use of bleaching powder and biocide.

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Imbibition and Maceration
• The purpose of imbibition is to extract sugar from bagasse as much as possible
• Maximum extraction possible with simple pressure has been obtained
• Extraction increases rapidly first as imbibition is increased and then slowly
• Steam consumption increases with imbibition
• The quantity depends upon the price of sugar and the price of fuel
• A good temperature for imbibition with hot water is 80 to 85⁰C
• Bagasse moisture is increased which is a loss

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Milling
Mill configurations:
Conventional 3 roller mills with force feeder are working at SML Bhone
• Various configurations of mills include 2 roller mills, 3 roller mills, 5 roller mills
and 6 roller mills

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Milling
Mill drives
Steam turbines
Electric drives

Strictly private and confidential Shakarganj Mills Limited II Bhone

 Milling
Mill setting
Mill setting means to give most favorable relative positions to the three
rollers and trash plate. Its purpose is to obtain best conditions for
feeding and the best extraction results. It depends on the mill speed
Main adjustments:
1) The setting of feed and delivery opening
2) The setting of trash plate
Feed opening should be greater than the delivery opening

Strictly private and confidential Shakarganj Mills Limited II Bhone

Strictly private and confidential Shakarganj Mills Limited II Bhone
 Basics of good milling
Milling
Optimum mill setting according to required load
Mill configuration
Donnelly chute height
Juice drainage or reabsorption
Hydraulic pressure
Mill sanitation and its role in dextran development
Imbibition
Maceration
sucrose loss control along the mill train
Strictly private and confidential Shakarganj Mills Limited II Bhone