Mill Material Balance

12.2

THE PROJECTION PROGRAM

It was mentioned that the use of the Projection Program or the Planning Program of a complete
calculation for mill material balance is best to make the projection of an optimal performance of
a milling tandem.
The program made through scientific calculation based upon the existing mill tandem and the
quality of cane crushed obtaining adequate and reasonable values, which is then used for the
operation targets of the sugar factory normally stated in the budgeting purposes; not just taken as
average from the previously milling seasons.
The program is in one file with the Evaluation Program. The Projection Program also consists of
2 (two) sheets that are:
Sheet-III, inputs for the Projection, and
Sheet-IV, the result of the Projection.
12.2.1 Projection Data
All the inputs for the Projection must be typed in sheet-III, which is identical with sheet-I for the
Evaluation inputs. Here all the data must also be typed replacing the blue letters in the red lined
boxes only, first the name of the sugar factory, the tandem composition, operational year
(crushing season), the period (usually bi-weekly) number or purpose of projection, etc.
Then the technical data of the mill rollers in use, the projected mill rotation per hour based upon
the drive nominal speed, the hydraulic pressure, the top angle, the shaft dimensions and so on
(the same dimensions for the Evaluation Program is used here).
M I L L M A T E R I A L B A L A N C E
I N P U T F O R P R O J E C T I O N ( a v e r a g e o r t o t a lize d o f d a t a a c h ie v e d )
A TTENTION:

Ty p e i n t h e d a t a ( b l u e l e t t e r s ) i n t h e r e d l i n e d s q u a r e b o x e s o n l y .

Sugar Factory
M ill Tra in

E X A M P LE
2 CC + 5 MILLS

M illing Se a s o n ( y e a r )
P e rio d o f 1 5 m illing da y s , n u m b e r

1977
X

P e rio d d a t e s e v a lua t e d u p t o
I.

Last date

MILL ROLLERS IN USE (dimension in mm)

M I L L NO: --------------->
I
II

III

IV

1,052.0
1,050.0
1,048.0

1,073.0
1,069.0
1,066.8

1,051.0
1,048.0
1,040.0

1,050.0
1,048.0
1,040.0

1,064.0
1,052.0
1,048.0

2 5 .0
2 5 .0

2 5 .0
2 5 .0

1 5 .0
1 5 .0

1 5 .0
1 5 .0

1 5 .0
1 5 .0

d e liv e r y
top

2 5 .0
1,002.0

2 5 .0
1,023.0

1 5 .0
1,021.0

1 5 .0
1,020.0

1 5 .0
1,034.0

fe e d
d e liv e r y

1,000.0
998.0

1,019.0
1,016.8

1,018.0
1,010.0

1,018.0
1,010.0

1,022.0
1,018.0

L e n g t h o f s h e ll
M ill rolle r s p e e d
H y d r a u lic p r e s s u r e

L
n
ph

2,133
270
180

2,133
270
190

2,133
270
200

2,133
270
210

2,133
270
220

H y d r a u lic ra m d ia .
Transm ission factor

d
r

330
86

330
86

330
86

330
86

330
86

M ill rolle r s h a f t d ia .
M ill rolle r s h a f t l e n g t h

dp
l

420
4,220

420
4,220

420
4,220

420
4,220

420
4,220

T o p a n g le
Top roller lift

a
t

78
6.0

78
6.0

78
6.0

78
6.0

78
6.0

- o n f e e d o p e n in g
- o n d e liv e r y o p e n i n g

tf
td

4.7
4.7

4.7
4.7

4.7
4.7

4.7
4.7

4.7
4.7

O u t s i d e d ia m e t e r ( D o ) :

Groove correction (k):

M e a n d ia m e t e r ( D k ) :

The Computer Program

top
fe e d
d e liv e r y
top
fe e d

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Mill Material Balance

Then further we have to fill in the projected capacity and the quality of cane together with the
projection of mixed juice quantity and its Brix degree, the foam correction factor, imbibition
water rate, etc.
Finally simulation of Brix degrees for each juice extracted by the mills together with its Pol
degrees.
Cane:

crushed, total
crushing duration
pol

brix
fiber
Mixed juice:

gross

brix
dirt corr.
Imbibition water, total
A pplied on:

Q
jg
pt

4,800.0 TCD =
24.00 hours
10.32 %

bt
f
Gnm

13.41 %
16.07 % cane
4,800.0 Tons =

bnm
knm
Gi

12.60 %, pol =
1.00308
1,581.3 Tons =

bagasse 1
bagasse 2
bagasse 3

bagasse 4
A verage value of fiber density
Bx ratio juice#1 to cane
bn1/bt =

J uice:

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

200.00 TCH

Purity =

76.96 %

200,000 kg/hr =

1 0 0 . 0 0 % cane

10.04 Purity =

79.68 %

65,887 ltr/hr =

2 0 5 . 0 0 % fiber

32.94 % cane

0 %
0 %
30 %
70 %
1.60000 kg/dm3
1.19
Last mill bagasse juice to fiber =
I
16.02
12.98

II
9.82
7.65

III
5.60
4.05

IV
3.10
2.10

1 0 5 . 0 0 % ----->

V
1.90
1.18

Unit
%
%

gnhs =
khar =
PSHK =

100%
32.97 %
1.05 %
97.44 %

During the simulation please observe the values underneath, which shall be met with the limits.
J uice:

purity
HK
extraction
En
brix distr. coeff.
kB
Normal value
Compression ratio
K
Bagasse: no-void density
da
absorp.ability factor
r
ditto, normal
r'
fiber content
kf
fiber index
c
red. fiber loading
q'
pol
pa
brix
ba
dry matter
zk

81.02
77.90
72.32
67.74
62.11 Decreasing from one to the following mills
53.42
66.12
65.89
66.23
60.72 Best > 60% (decreasing to the following mills)
1.000
0.935
0.830
0.715
0.607
0,9-1,1 0,8-1,0 0,7-0,9 0,6-0,8 0,5-0,7
Decreasing from one to the following mills
2.56
3.24
3.08
3.01
2.55
1.1851 1.2015 1.2154 1.2232 1.2322 Increasing from one to the following mills
1.3501 1.3316 1.3164 1.3081 1.2985 Decreasing from one to the following mills
1.3492 1.3380 1.3269 1.3158 1.2962
29.13
36.25
41.18
44.68
48.78 Increasing from one to the following mills
Increasing from one to the following mills
0.47
0.58
0.66
0.71
0.78
134.89 129.41 129.92 130.17 126.67 q' = 120-130 gr/dm2 - normal
8.19
4.75
2.90
1.72
0.94
q' = 130-140 gr/dm2 - Donnelly chute
11.33
40.46

7.51
43.77

5.27
46.46

3.74
48.42

2.58
51.36

q' = 140-160 gr/dm2 - light pressure feeder

q' = 150-170 gr/dm2 - heavy pressure feeder

When the values match or lies between the limits, then the projection of mill material balance
shown on the Projection sheet (sheet-IV, page 1 through page 3) for overall as well as the
individual performance is final and good. Otherwise, simulation has to be redoing until all the
values are relevant to the limits.

The Computer Program

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Mill Material Balance

12.2.2 The Simulation Steps

To be more clear and speeding up the simulation, the steps below are necessary to be followed
during the data inputs:
Step
1

Step descriptions
Type in the file name.

Remarks
First row, say: "Jat-2000"
Meaning SF Jatiroto, milling season 2000, or
"Jat00-XI"; means SF Jatiroto milling season
2000, period of 15-days, Nr. XI.
File name max. 8 digits.

Type in the sugar factory name, the mill

Understood.

tandem composition, milling season

year, period and the date of evaluation.
3

Type in the data of the mill rollers in The outside diameter, groove correction,
use.
roller length, projected roller speed (rph)
based on 90-95% from the prime mover
nominal speed, top roller lift and top angle of
triangle formed by the rollers.

The cane and its quality.

- Total cane crushed or the milling capacity,

in ton per day exclusively within 24 hours
or 22 hours.

The mixed juice.

Imbibition water (Wi)

The Computer Program

- The projection of cane quality based on the

pre-analysis and previous millings.
- Define the quantity of mixed juice expected
(e.g. = 100% cane).
- Type in the average dirt correction factor of
the mixed juice.
- Simulate the brix value of mixed juice to get
the value of gnhs around:
30-36% for 5 mills tandem, and
34-42% for 4 mills tandem.
- Define the quantity, likely 200% fiber, to
obtain approx. 100% ratio of juice to fiber in
last mill bagasse (nss) and dry matter of
50%.
- Define in percentage on which bagasse of
each application.

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Mill Material Balance

Simulate the value of Brix degree for

each mill juice.

Simulate the value of Pol degree for

each juice extracted by every mill.

Finally, check again thoroughly for the

whole tandem.

To obtain the value of kB between:

0.9-1.1 for mill#1 (average = 1.0)
0.8-1.0 for mill#2
0.7-0.9 for mill#3
0.6-0.8 for mill#4
0.5-0.7 for mill#5
During the simulation, observe and try to
obtain the followings:
a. Increasing value of no-void bagasse
density (da), from the first to the last mill.
b. Decreasing value of the absorption ability
factor (r), from the first to the last mill.
c. The value of the normal absorption ability
factor (r'), especially for the last mill must
be smaller than (r).
d. Especially for the first mill, simulate the
juice Brix to obtain kB =1.0
The purity of juice#1 > than purity of mixed
juice, and the purity of juice#2 is normally 3-4
points below the purity of juice#1. Hence,
gradually decreasing to the last mill, which is
about 58-64%.
When simulating the Pol degrees, observe and
maintain the value of khar < 4% and the
PSHK between 96-98%.
Otherwise, re-do the simulation to maintain
the values matching its limitation.

12.2.3 The limit values

To simplify and speeding up the Projection of mill material balance, the following limit values
will be use as guidance for the simulations:
1. The no-void density of mill#1 bagasse
Depends on the existence and use of the fore worker and its roller material:
1 Crusher
1 Unigrator

1.15 - 1.16
1.15 - 1.17

1
2
1
2

1.15
1.15
1.15
1.15

Crusher + 1 Unigrator
Cane Cutter
Cane Cutter + 1 Unigrator
Cane Cutter + 1 Unigrator/Shredder

The Computer Program

1.18
1.18
1.19
1.20

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Mill Material Balance

2. The absorption ability factor (r)

The value of r is between 1.38 1.4. Decreasing from the first to the ensuing mills. The
value also depends on the fiber content of the cane crushed. For higher fiber content of cane
will have a rather high value of r.
The value of normal absorption ability factor (r) for any mill (mill#n) is lower than its value
for the ultimate mill (mill#n-1). It has decreasing graduation values up to the last mill.
It is very important to observe, that the value of the normal absorption ability factor r for the
last mill bagasse must be less than the value of its r. It is anticipated in practice that if the
calculated value of r > r, then it is definitely juice will spraying off from the last mills
delivery opening. Decreasing the value of the total mixed juice or the total water imbibition
for such condition will retain the last mills delivery opening from spraying off juice.
3. Juice extraction (En)
The juice extraction (En) for each mill is best when the value in average > 60 %.
When the extraction in every mill is less than 60%, then consider adding the amount of
imbibitions water. But then reference shall also be made to the capacity of the existing
evaporator tandem for the maximum quantity of imbibitions water.
4. The ratio of Ved to Vedo:
Ved
Vedo

= max. 1. And if > 1, the top roller is deflected.

5. Fiber fraction (kf) of bagasse in each mill.

The following table indicates the ranged value of kf that increasing from the first to the
ensuing mills:
4 mill tandem
Mill No.1
0.25 Mill No.2
0.30 Mill No.3
0.35 Mill No.4
0.45 -

5 mill tandem
Mill No.1
0.25 Mill No.2
0.28 Mill No.3
0.32 Mill No.4
0.37 -

0.35
0.40
0.45
0.50

Mill No.5

0.35
0.38
0.42
0.47

0.45 - 0.50

6. The Brix distribution number (kB)2)

The value of kB is defined from the following formula:
Extracted juice Brix weight (Bej)
Original juice Brix weight (Bij)

Original juice weight (Wij)

Extracted juice weight (Wej)

The value of kB is decreasing to the ensuing mills:

Mill No.1
Mill No.2
Mill No.3
Mill No.4/last
Mill No.5/last
2)

0.900
0.900
0.800
0.600
0.500

1.100
1.000
0.900
0.800
0.700

Extracted from C.R. Murray & J.E. Holt, The Mechanics of Crushing Sugar Cane, 1967

The Computer Program

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Mill Material Balance

It is advised when simulating the Brix degree of juice#1, the value of kB for mill#1 shall be
made equals to 1.0 (one point zero).
7. The ratio of extracted juices between the feed and the delivery openings (y):
y = positive, juice is extracted by the feed opening.
y = negative, juice is not extracted by the feed opening.
In the projection the value of y should be positive with an average between 0.10 and 0.30.
8. Cofficient of friction ()
Cofficient of friction between bagasse / cane and the roller surface depends on the
number of rotation of the roller, normally between 0.32 and 0.38.
9. The Compression (K)
The value of compression K is between 3.50 and 2.00; defined from the following formula:
Vim
Ved
Whereas: Vim = no-void volume of incoming material per hour.
K

Ved = actual escribed volume of delivery opening per hour.

Normally it decreasing from mill#1 to the ensuing mills, but some-times mill#2 has to work
harder than mill#1. In this case the value of K for mill#2 is higher than the value of K for
mill#1.
It has a straight conformity with the value of fiber index (c). When the value of K is low then
the value of (c) also low.
Same as the value of K the value of fiber index (c) also indicates the ability of the rollers to
grab bagasse / cane feeds efficiently, which depends on the roller shell material in use;
whether it made of cast steel or cast iron should posses the ability to perform raw surface and
against acid condition.

The Computer Program

XII-16