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Summary
In this paper comments and observations on the first year's performance of a new shredder at Farleigh have been set down, together
with an assessment of its operating characteristics.
The shredder is of recent, heavy duty design having an anvil bar and
breaker section covering an arc of 85" and is driven by two motors having
a combined rating of 1400 horse-power.
The results of test runs taken during the 1969 crushing operations
were analysed and a relationship established between cell breakage in
prepared cane, fibre rate and power consumption.
Introduction
With increasing factory throughputs in recent years a satisfactory
level of extraction has become increasingly difficult to attain. A decrease
in the fineness of prepared cane was recognized as one of the contributing
factors.
A series of modifications was made to the Searby shredder previously in operation, including the use of hammers of increased effective
weight and length, modification of the breaker section, and the provision
of prime movers of greater horse-power. Some improvement in results
was obtained, but cell breakage in the shredded cane was still estimated
at below seventy per cent: and no noticeable improvement in milling
extraction was evident.
In considering possible solutions to this problem, due attention was
given to shredder developments reported from overseas, particularly
from Hawaii. From these reports, and a comparison of our experiences
with shredder operation, it was felt that a shredder of much more robust
construction than that of current local designs, with power input considerably upgraded, would be required.
However, during 1968 season the opportunity was afforded the
authors of observing a new heavy duty shredder in operation at C.S.R.
Co. mills in the Ingham area. This machine had been designed to run at
a maximum speed of 1100 revlmin, and was originally provided with one
anvil bar and hammers up to 42 lb in weight. A breaker section covering
60"-70, and of saw tooth design had been added. This shredder was
claimed to be giving cell breakage figures of 85 per cent and over at a
crushing rate of 250 tons of cane per hour with cane of 13 per cent fibre
content. The prime mover was a turbine of 1,000 hp.
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An anvil bar and six breaker bars cover a breaker section of approximately 85" of the arc swept by the hammers. The anvil bar is adjustable
externally and breaker bars are detachable. By using bars of different
thickness, setting variations can be made with each breaker. The shredder
is driven by two 700 hp motors at 960 revlmin. This power requirement
was based on a figure of 32 hp per ton of fibre per hour. Eighty-seven
hammers having a double cutting edge, as shown in Figure 2, were used,
each hammer being approximately 36 lb weight. A further setting variation was possible by having pivot rods and through rods interchangeable
but on different pitch circles.
Feeding of the Shredder
The shredder is mounted with the anvil bar under the vertical casing
of the top knife box as shown on Figure 1. Cane discharged under the
top knives, which are at the head of the carrier, strikes the casing and
falls into the shredder.
Fig. I-Cross
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Fig. 2-Double
183
Shredder Settings
Initial settings were 3 in over the anvil bar, 4 in over the first two
breakers, 3 in over the riext two and t in over the final two. These
settings have been progressively reduced to 3 in over the anvil bar, in
over the first breaker and 1in over the remainder.
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door, mixed on a table by hand for about one minute, and about f removed as a subsample into a covered container. The subsample included
every particle of cane down to the table in the section taken. This sample
was then removed and a further sample taken, and so on until the time
for the run had elapsed. About four to six subsamples were taken on each
test. After collecting the subsamples the table was cleared and all cane
tipped back and mixed again by hand. A final subsample was taken and
removed for analysis for p01 per cent open cells (Henderson, 1970) and
fibre (Blake, 1964).
4. Samples of No. 1 mill first expressed juice were taken from the
sampling trough about six times per test period and mixed in a container.
Samples of last expressed juice from this mill were taken from under the
delivery roll using a long handled dipper.
5. A sample of first mill bagasse was taken and the p01 per cent
bagasse found using disintegrater analysis.
6. The nominal shredder setting was known for each run.
Dimensional Analysis of the Operation of Shredding
Before undertaking the investigation, the classical methods of
dimensional analysis were applied to the situation to help in organizing
the data and to reduce the number of variables to be correlated.
The criterion by which shredder performance will be judged is P, the
percentage of broken cells in the prepared cane. The physical nature of
the situation demands that the following variables be taken into account.
(a) fibre rate, ton/h, f
(b) power consumed, ft lbf/h, p
(c) a shredder setting, ft, 1
(d) cane density, lbm/ft3, d
(e) cane strength, lbf/ft2, k
(f) a hammer wear factor, dimensionless, W
(g) conversion factor, 1.862 X 10' ft ton/lbf h', g
The derivation of the dimensionless groups is gven in Appendix 3.
These groups are:
1.
(g)
3. P
4. W
A relationship should exist whereby:
P = KA"BbWW
where K, a, b and W are all constants.
At this point we now have four variables to handle, P, A, B and W,
whereas there were eight before grouping.
In practice it was not possible to measure all these variables and the
dimensionless groups used were modified as follows:
A was modified to
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Discussion
Some comments on the various aspects of shredder operation and
results of the tests carried out are set out below.
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data
No.
TABLE Il-Correlation
equations
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Fig. 3-Relationship
TABLE Ill--Predicted
P values
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in the furnaces of a hard pressed boiler station. The levels of fuel beds
on t h e flat grates had to be more closely controlled, and the draft
pressure difference between furnace and combustion chambers of the
sloping grate furnaces had to be reduced to prevent bagasse carryover.
The finer bagasse tended to compact into the juice grooves of the
final mill rollers and difficulties were experienced with worn juice
grooves in delivery rollers not being cleaned by new apron plates. The
apron plate teeth wore heavily on the tips in these mills which have
3 in pitch grooving on the delivery rollers.
Actual Worse-power Usage: The figures given in Table 1 for hp, have not
been corrected for power factor. As shown in Appendix 1 the power
factor is expected to be about 0.83 and so the power input is about 22
hp per ton of fibre per hour. As explained in Appendix 2, the fibre
figures taken are likely to be low so a more realistic value would be
about 20. This compares with the value of 17 given by Nicklin (1967).
The Influence of Extraction: The overall extraction for 1969 showed an
increase of 0.3 units over that of the previous year. A number of influences
come in here, and it is difficult to say how much of an increase in extraction was due to cane preparation. Certainly 1969 will not be remembered
as a vintage year for cane quality and low fibre. For a meaningful
comparison we would have to know what extraction would have resulted
if the preparation this year had been the same as last year's.
The data in Figure 3 show that considerable scatter has clouded
any relationship which may exist. Work done under controlled conditions
by the Sugar Research Institute (1958) has shown that first mill extraction
should increase with degree of preparation because the onset of reabsorption is delayed.
There is a tendency towards this relationship in Figure 3, but the
scatter makes a formal regression analysis seem not worthwhile.
Variations in Crushing Rates: The crushing rates measured over the
relatively short duration of the tests showed surprising variations. A
high value of 294 tons per hour, with average hourly rates from 250 to
260, was regarded with suspicion, but it fits into the correlation quite
well. This was test number 20.
Over all the tests, which refer to bin cane only, the average rate was
246 tons per hour, with a standard deviation of 23 tons per hour.
Interpretation of Dimensionless Groups Used: (a) The group A, which is
kf
pi
could be written as p/, and could be interpreted as the potential
kf
d
for breaking cells, i.e. the energy input divided by the capacity per
volume for absorbing this energy, i.e. the resistwee to breakage. The
value of this group should be highly significant in determining cell
P
breakage.
(b) The group B, which is 1 4 kd'
~
is a little more obscure, and a
little licence has been used to try t; interpret its physical significance.
B can be written as
(A},($),('
constant.
, disregarding
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l89
The term
can be regarded as a measure of the volume rate
passing throughthe area between hammers and bars, or a velocity of
cane through the shredder opening. At a given rotor speed, this term is
inversely proportional to the number of hammer blows a given piece of
material would receive in its passage through the shredder.
The term I is the mass flux per unit area through the shredder.
(h)1;)
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,e
*g F,-
"LZ +m
_/.-
5%.' L e
I
'
,/.-
,
-
__r"
/'
L"
K,sri
gbo
,A
6 2 . 6 AO.lgJ$0".
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191
and that power factor is about 0.83, and engaging in a bit of doubtful
extrapolation of the curves, a target of 90 per cent open a l l s would be
reached on the average with this shredder and fibre of about 14 per cent
if the horse-power was about 1400 average.
However, if the fibre percentage were to drop to 12, i.e. the curve
actually shown as 11 per cent, 90 per cent open cells could be reached
with about 1000 hp input.
A paper submitted to this Society's 1964 Conference (Mackay
Institute of Sugar Milling Engineers, 1964) indicated that a 20 per cent
increase in power input occurred, with shredders in the Mackay area, at
the end of the week. This was not noticed in the course of this work.
Average values of A, with standard deviations, are set out in Table IV.
TABLE IV-Variation
A Comment on Test No. 4: Test No. 4 was done on the day before the
shredder choked. This test stands out as having a high power usage and
good preparation. The hammers were in a very worn state. It is thought
that the high power input and good preparation were caused by the
blunt hammers retarding the continuous flow of feed through the
shredder, resulting in the cane receiving more blows from the hammers
before discharge. This is an unstable condition and choking is likely at
any time. The practical procedure is to rely on close settings to give a
high power input and sharp hammers to give clean discharge.
Some Thoughts on Automatic Control: The strong dependence of degree
of preparation on horse-power input suggests that it would be sound
practice to try to keep the horse-power at a constant value and as high
as practicable. This would mean that the degree of preparation would
vary depending on crushing rate and cane properties. Obviously the
best that can be done in any given situation is to put in as much power as
possible.
Practically this could take the form of a moveable anvil bar and
grid bar system capable of infinite adjustment, within the range required,
by some operating medium such as a hydraulic ram with position control. An averaged horse-power figure, such as that given by a Golds
relay current averaging meter, over a period of about three minutes,
could provide a signal on which the ram could act to close in the settings
very slowly if power is too low, and vice versa. It may also be feasible
to incorporate a fast release of settings at a predetermined high average
peak current value to prevent a choke and heavy motor overloads.
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1970
Fig. 5-Hammer
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Conclusions
1. The factors which have the greatest bearing on the degree of
preparation achieved are :
(a) the energy absorbed per ton of fibre
(b) the nature of the cane.
2. The degree of preparation achieved at a given energy consumption
falls off quite markedly as the fibre content increases.
3. To keep the shredder operating in a stable and eficient manner,
and to maintain a high horse-power input to optimise cell breakage,
attention must be given to the follovving:~
(a) the shape and number of hammers.
(b) provision of a steady feed to the shredder.
(c) provision of some form of automatic control of shredder settings.
The authors wish to thank the management of the Farleigh Cooperative Sugar Milling Association for permission to publish this
paper, the Sugar Research Institute for the use of their computer, Mr.
P. G. Wright for his work in processing the data and those others who
have helped by their discussion and comments.
REFERENCES
Blake, H. J. (1964). Fibre in cane by dry substance method. Proc. Qd. Soc. Sug. Cane
Technol., thirty-first Conf.
Crawford, W. R. (1969). Mechanics of swing hammer design. Proc. Qd. Soc. Sug. Cane
Technol., thirty-sixth Conf.
Henderson, C. (1970). Pol per cent open cells in prepared cane. Proc. Qd. Soc. Sug. Cane
Technol., thirty-seventh Conf.
Mackay Institute of Sugar Milling Engineers (1964). Some notes on preparation plant in
Mackay and district mills in 1963. Proc. Qd. Soc. Sug. Cane Technol., thirty-first
Gonf.
Nicklin, J ~ H(1967).
.
Power and energy requirements for cane preparation. Proc. Qd. Sug.
Cane Technol., thirty-fourth Conf.
Shann, D. and Cullen, R. (1968). Some aspects of shredder hammer design. Proc. Qd. Soc.
Sug. Cane ~echnol.,thirty-fifth-conf.
Sugar Research Institute (1958). The influence of degree of preparation on No. 1 mill
performance. Technical Report No. 49.
Appendix I
Motor Power Factor
At the time of compilation of this paper exact data on power factor
were not available, but the value should be about 0.8 at very low loads
rising to about 0.9 at high loads. Therefore a value of 0.83 was assumed
in the calculations performed for average conditions.
Appendix 2
(A) Analysis of Fibre
This was carried out by the method described by Blake (1964). For
speed of analysis the first expressed juice was not filtered. It is thought
that the fibre figures so produced, while low, are a measure of the changes
in fibre content. The drying of the cane was done in a Spencer oven in
duplicate.
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Appendix 3
Derivation of Dimensionless Groups
The eight variables given above can be expressed in general terms
as a functional relationship
P=F(f,p,l,d,k,W,g).
If the form of the relationship is a product of powers of the variables,
dimensional analysis will allow a logical grouping of the variables.
Therefore, P = K f a pb lc dXkYwt g :
Since P is dimensionless and K is a dimensionless constant, the
product of all the dimensions on the right hand side is zero when the
dimension equation is written.
Appendix 4
Table V sets out the average values of A associated with each shredder setting number, and the number of observations associated with
each average of A.
of A and 1
TABLE V-Dependence
Number
of poinv
b =
El2 - nT2
The averages are weighted averages.
From the above figures,
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=1.872
=1.860
.Zp = 125.178
Z1A = 121.237.
Hence b 0.463
a = 0.993
.: A = 0.993 0.463 1 is the line of best fit.
~igure'
6 shows the scatter of each point about this line.
Fig. 6-Regression