Pinionless Mills

FE17 Presentation @ ISSCT Congress
Sao Paulo,, Brazil
Innovative Energy Efficient

Milling Train
Speaker
D K Goel
D.K.
Isgec Heavy Engineering Ltd.
27 June 2013
Authors
D. K. Goel
Advisor
Sugar Machinery Division
Isgec Heavy Engineering Ltd, Noida, India
dkgoel@isgec.co.in
and
d
J K
J. K. Kharbanda
Design Head
Sugar Machinery Division
Isgec Heavy Engineering Ltd, Noida, India
2
Background
 Milling accounts for 50% of the total power
consumption in a Sugar Plant.
 Co
Co-generation
generation demands energy efficient milling
 We have innovated design of mills with a view to
 Improve extraction efficiency
 Reduce
 Investment
 Energy
e gy co
consumption
su pt o
 Maintenance cost
3
Isgec Innovation: Pinionless Mill
 Feature:
 Individual drive for each bottom and
top roll, without using crown pinions
4
Mill...…
 Advantages
 Higher extraction efficiency, due to:
 Free float of top roll
 Operation of top and bottom rolls at
differential speed
 Smaller foot prints
 50% saving in cost of civil works
5
Mill...…
 Advantages…
 Lower friction losses:
 15% Reduction in energy consumption
 Substantial reduction in wear and tear of
mill components
 15% reduction in consumption of lubricant
 Lesser risk of mill chokes
6
Pinionless Mill: Drive Options
 Types of Drive:
 Variable speed AC electric motor
 Variable flow hydraulic
y motor
 Drive mounting configurations:
 Individual
I di id l shaft
h ft mounted
t d drives,
di
• 2 on top roll, 1 each on bottom roll
 Assist drives
• Foot mounted for top roll,
roll
• Shaft mounted, 1 each on bottom roll
7
Ease of Maintenance: Inter Carrier
8
Swiveling Rake Inter Carrier: Addax, Sierra Leone
Ease of Maintenance: Drive sprocket
Cane Carrier head shaft:

Sprocket with girth
type bolted teeth
9
Ease of Maintenance: Inclined Set Mill
45” x 90” Mill: Xinavane, Mozambique

10
Pinionless Mill: Design Methodology
 Preparation of 3-D model of mill with drive
 Computation of forces on 42” x 84” head stock
and top bearing for 340 tons cane / hr at 3.5 rpm
 Finite Element Analysis of head stock assembly
 Evaluation of stresses on top roll assembly
Strengthened the head stock and roll shaft in

high stress areas, while optimizing overall weight
11
Pinionless Mill: 3D Model
12
42” x 84”, 4 Roll Mill: Jay Mahesh Sugar, India
Radial Force Comparison: Top Bearing
C
Conventional
ti l Mill Pi i l
Pinionless Mill
Horizontal force on top bearing

of Pinionless mill is 40% lower
13
Stress Comparison: Head Stock
14
Stress Comparison: Top Roll
Stress Diagram: Top Roll Assembly

15
Stress Comparison: Summary
Mill Max Stress ((kgf

kgf/cm²)
g /cm²)) Stress
Component Reduction
Conventional Pinionless
Mill Mill
Headstock 2634 1728 35 %
Top Bearing
1213 863 29 %
Housing
Top Roll Shaft 1248 610 51 %

16
Drive Efficiency Comparison: Summary
Conventional Pinionless Mill
Drive Equipment Mill Hydraulic Planetary
Drive Gear Box
Hydraulic
H d li Motor
M t
Not Applicable 78 Not Applicable
with Power Pack
AC Motor with VFD 94 Not Applicable 94
Planetary Gear
95 Not Required 90
Box
Tail Bar 98 Not Required Not Required
Mill Crown Pinions 92 Not Required Not Required
Total Efficiency 80.5 % 78 % 84.6 %
17
Pinionless Mill: Commercial Installations
 42”x84”, 4 roll Pinionless mill, with individual
shaft mounted planetary drive, Jay Mahesh, India
 1st Mill commissioned in Feb,
Feb 2008
 Two repeat orders
 Full fledged milling train since Oct, 2010
 45”x90”,
45” 90” 4 roll
ll Pi
Pinionless
i l mill,
ill with
ith assist
i t drives
di
at Santa Ana, Guatemala.
 Commissioning: May, 2014
18
Pinionless Mills: Jay Mahesh
Mahesh, India
19
Success Story at Jay Mahesh
Mahesh, India
Operating results:
 Crush Rate: 250 tons / hr
 Energy Consumption: Only 1.1 kWh/ton cane/mill
 Reduced Extraction: 96
96+ with 3 mills in operation
 Bagasse moisture: 49% with 3 mills in operation
 Negligible wear on mill roll journals and bearing
li
liners even after
ft completion
l ti off 4 crops
20
Pinionless Mill: Assist Drive System
21
45” x 90”, 4 Roll Mill: Santa Ana, Guatemala
Innovative Efficient Milling Train
 Configuration:
 Single preparatory device, whole stick shredder
 92 PI
PI, operating
ti att 94 m/sec
/ ti
tip speed
d
 Smaller foot print of cane preparation system
 4 nos Pinionless mills with individual AC VFD
 15% reduction in energy consumption
 Smaller foot prints of milling tandem
 Swiveling type rake inter carrier
22
Innovative Efficient Milling Train….
Train
 Advantages
 50% lower cost of foundations and building
 Higher extraction efficiency
 Higher energy efficiency
 Ease of maintenance
This milling train consumes only 12 kWh/ton cane

23
Tandem Size: Crushing Vs Efficiency
Sr. Mill Size Tandem Size

no. 3 Mill 4 Mill 5 Mill 6 Mill
1 42 x84 , 4 Roll
42”x84”,
1.1 Crush rate (tons / hr) 250 350 500 600
1.2 Roll Speed (RPM) 2.5 3.5 5.0 6.0
3 Reduced Extraction 96.0 96.5 96.5 97.0
2 5 90 , 4 Roll
45”x90”, o
2.1 Crush rate (tons / hr) 400 500 650 750
2.2 p
Roll Speed ((RPM)) 3.0 4.0 5.0 6.0
2.3 Reduced Extraction 96.0 96.5 96.5 97.0
24
Conclusions
 Pinionless mill consistently delivers:
 Higher extraction efficiency
 Higher
g energy
gy efficiency
y
 Flexibility in through put
 Longer life of components
25
Conclusions
Conclusions…..
 Pinionless mill with shaft mounted planetary
y
gear boxes has higher transmission efficiency
and lower capital cost Vs Hydraulic drive
 Pinionless Mills with shaft mounted planetary

gearboxes working satisfactorily for 4 years
 Innovative Milling
g Train is 10% cheaper
p and
26
consumes only 12 kWh per ton of cane
Thank You
Gracias
Obrigado
I
Isgec Heavy
H E i
Engineering
i Li it d
Limited
www.isgec.com
27

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FE17 Presentation @ ISSCT Congress

Sao Paulo,, Brazil

Innovative Energy Efficient

Cane Carrier head shaft:

45” x 90” Mill: Xinavane, Mozambique

 Computation of forces on 42” x 84” head stock

and top bearing for 340 tons cane / hr at 3.5 rpm

 Finite Element Analysis of head stock assembly

 Evaluation of stresses on top roll assembly

Strengthened the head stock and roll shaft in

Horizontal force on top bearing

Stress Diagram: Top Roll Assembly

Mill Max Stress ((kgf

Top Roll Shaft 1248 610 51 %

 Energy Consumption: Only 1.1 kWh/ton cane/mill

 Bagasse moisture: 49% with 3 mills in operation

 Negligible wear on mill roll journals and bearing

 50% lower cost of foundations and building

 Higher extraction efficiency

 Higher energy efficiency

This milling train consumes only 12 kWh/ton cane

Sr. Mill Size Tandem Size

 Pinionless mill consistently delivers:

 Higher extraction efficiency

 Flexibility in through put

 Longer life of components

 Pinionless Mills with shaft mounted planetary

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