Internship Report

Shakarganj Mills Limited

Submitted by:
Hamza Ashraf
(2012-ME-237)
Department:
Mechanical Engineering
 Mill House
There are two portions in mill house.

 Mill tandam 1
 Mill tandam 2

“Procedure while preparing the cane

leading to Mill “
Mill Tandam # 1:
Introduction:
It was constructed in 1973. Its capacity was 1500 TCD
(Tons of cane crushed per day). Earlier Uni-grator was used in this tandam
but now Fibrizer is used. Tandem 1 has five numbers of mills. First mill has
six numbers of rulers while other four have five rulers each. These mills are
36 inches in width and 72 inches in length.

The main parts of this tandam are:

 Cane weighing
 Dump-in cane carrier
 Main cane carrier
 Cane leveler
 Cane pusher
 Cane fibrizer
 Cane fibrizer carrier
 Magnet iron separator
 Rack-bar feet carrier
 Milling units (5)
 Fibrizer steam turbine
 Inter carrier (4) & Rack-bar feedback carrier
 Mill rollers
 Steam turbine
 Bagasse elevator
 High speed gear
 Rotary screen or spanner
Electric hoist:
With the help of this cane is unloaded from trolleys and is send
to Dump-in carrier, where further process takes place. Electric hoist is driven
by back type motor.

Dump-in carriers:
There are three dump-in carriers. All have same speed
of 26 ft/min. Carriers are slate type. Each carrier has six chains and 6 spockets.
Specifications of three carriers are:
Name of carrier Length Width
Carrier 1 60 feet 18 feet
Carrier 2 60 feet 15 feet
Carrier 3 60 feet 17 feet
Main carrier:
The main carrier is shown in figure. Plates of this carrier are
separated for check & balance. The specifications of this carrier are:
Length 110 feet
Width 72 inches
Length of elevated portion 40-45 feet
Angle of elevation 7.90
Linear speed of carrier 30 feet/min
Levelers:
There are two levelers used in this tandam which maintains the
quantity of cane. These move in the direction of main carrier. There
specifications are given:
 Levelers No. of arms Speed Motor power

Leveler 1 26 39 rpm 60 HP

Leveler 2 23 39 rpm 60 HP

Cane Fibrizer:
It is used to fibrize the cane. Its picture is given. Its direction of
motion is in the direction of main carrier. It is driven by fibrizer turbine.
There are two main tools in it.

 Maschart knife
 Pusher
 Fibrizer bars

Fibrizer Turbine:
This turbine supplies the power to fibrizer.

It is impulse turbine which is operated by steam.

Then two reduction spear gears are used to reduce the revolutions and it is
connected with fibrizer.

Its specifications are given below:

Power 3000 KW
Speed 5500-10,000 rpm
Weight 5000 Kg
Diameter 550 mm
Fibrizer Carrier:
After fibrizing cane is carried with the help of this
carrier towards the Rackbar feedback carrier. The specification of this
carrier is:
Length 60 feet
Width 72 inches
Linear speed 45 feet/min
Angle of elevation 120
Magnetic separator:
This bar used to separate the iron pieces and other iron
things so that material & machine parts may not be affected. These iron
things can stick in machines and stop the working of mill.
Mill # 1:
The carrier used in this mill is named as “Rack-bar feedback
carrier”. It has six rollers.
Backpressure type turbine runs this mill. Its specifications are given
Mill speed 1200-1500 rpm
Backpressure 1 Kg
Power 850 KW
Speed 5000/2000 rpm
High speed Gearbox:
When turbine is run then the speed of turbine
increases due to this gearbox. It has gear of small diameter which increases
its speed. Its specifications are given below.
Weight 6600 Kg

Speed 1673 rpm

Oil type 320

Mill # 2:
It also contains a carrier. But it is simple carrier. It has 5 rollers.
The KKK type turbine runs this mill. Its specifications are given
Power 600 KW
Mill speed 1500-1900 rpm
Mill# 3:
It also contains a carrier. But it is simple carrier. It has 5 rollers. The
KKK type turbine runs this mill. Its specifications are given
Power 600 KW
Mill speed 1400-1700 rpm
Mill # 4:
It also contains a carrier. But it is simple carrier. It has 5 rollers.
The KKK type turbine runs this mill. Its specifications are given
Power 673 KW
Mill speed 1300-1500 rpm
Mill # 5:
It also contains a carrier. But it is simple carrier. It has 5 rollers.
The KKK type turbine runs this mill. Its specifications are given
 Power 597 KW
Mill speed 1500-2100 rpm
Mill Rollers:
The diagram of mill rollers is shown below.

1# = Force feeder 2# = Pressure feeder Top

3# = Pressure feeder Bottom 4# = Top Mill roller

5# = Mill feed roller 6# = Mill discharge roller

7# = Trash plate 8# = Pressure shoot

Mescerration of Juice:
When juice is extracted from mill #1 then it is
sent to “sprinter” which filters the juice. When juice is extracted from mill # 2
it is sent to mill # 1. When juice is extracted from mill # 3 it is sent to mill # 2
which further sends to mill # 1 and then all this juice is sent to spanner for
filtration. When juice is extracted from mill # 4 it is sent to mill # 5 and when
juice is extracted from mill # 5 then the juice of both these mills is sent to mill
# 3 and the process carries on. The following diagram will explain more about
the process.
 Rotary screen

Mill # 5 Mill # 4 Mill # 3 Mill # 2 Mill # 1

Tank Tank Tank Tank Tank

Rotary Screen:
Rotary Screen is used to screen the juice and to free the
juice from the baggase.
Screen speed 14 rpm
Mesh no. 0.5
Motor power 15-20 HP
Motor speed 1400 rpm
Baggase elevator:
When juice is extracted from cane then the baggase is
carried out with the help of this carrier. It takes the baggase to boilers where
it is used as fuel to run the boilers. Baggase is also used in making boards.
Tandam# 2:
Introduction:
It was constructed in 1993 as there was a need of increasing
the crushing capacity. Tandem, # 2 has four numbers of mills and all these
four have six numbers of rulers each. It is 38 inches in width and 78 inches in
length. Its capacity is 8500 TCD.

The main parts of this are:

 Electric hoist
 Dump-in carrier
 Main carrier
 Cane leveler
 Cane pusher
 Cutters (3)
 Shinko turbine
 Before shredder carrier
 Shredder
 After shredder carrier
 Magnet iron
 Rubber belt conveyor
 Mill units (4)
 Mill rollers
 Inter carrier (3) & rack-bar feedback carrier (1)
 Steam turbines
 Baggass elevator
 Rotary screen or spanner

Cane:
Cane is just purchased by the mill from farmers. Drivers take the
tokens and enter into mill. 250-300 trolleys can stay easily in the mill.
Cane weighing:
Next step is involved is cane weighing. 2 weighers are
involved in this process. 50 tons is the capacity of weighers. The scales are
made by AVERY.

1# for gross weight and 2# for tare weight. Now the formula is

Net weight = gross weight – tare weight

Cane unloading:
Then cane is unloaded with the help of electric hoists and
then dropped on dump-in carrier. It takes the cane for further process.

Electric hoist:
Electric hoists are used for lifting the trolleys. Its specifications
are
Lift height 20 feet

Lift speed 13-20 ft/min

Main carrier:
Electric hoists put all cane on dump-in carrier. There are three
dump-in carriers. Then it comes to main carrier. Its specifications are:
Length 19 feet
Width 150 feet
Horizontal 100 feet
Elevated 50 feet
Angle of elevation 7.90
Cane leveler:
It is used to get smooth feeding of cane and moves opposite to
the direction of to dump-in carrier. Only 1 leveler is used here. The
specifications are:
Drive motor 60 HP
No. of arms 36
Leveler speed 39 rpm
Cutter:
These are used to cut the cane sugar in a specific size as
recommended. These cutters are run with the help of turbines. There are
three numbers of cutters. Clearance becomes smaller from cutter 1 to 3.their
specifications are as follows:

Cutter # 1
This type of cutter is run with the help of KKK type turbine.
Crushing capacity 8000 TCD
No. Of knives 70
Power of turbine 1200 KW
Weight of 1 knife 20 Kg
Cutter speed 6000 rpm

Cutter # 2
This type of cutter is run with the help of Shinko Type Turbine.
Crushing capacity 8000 TCD
No. of knives 70

Power of turbine 900 KW

Weight of 1 knife 20 Kg

Cutter # 3
This type of cutter is run with the help of motor.
Crushing capacity 8000 TCD
No. of knives 52
Power of motor 400 KW
Weight of 1 knife 20 Kg
Cutter speed 600 rpm
Before shredder carrier:
This carrier is used to take the cane to the
shredder. Its specifications are:
 Length 66 feet
Width 90 inches
Angle of elevation 150
Linear speed 30 ft/min
Shredder:
The function of cane shredder is to rupture the structure of
cane. It opens the cells of cane. Its specifications are:
Design BMA
No. of shredder hammers 228
Weight of 1 hammer 16 Kg
No. of s.s. bars 8
Design speed 1000-1100 rpm
Working speed 1000 rpm
Clearance of hammers with the anvil 10 mm
plate at outlet

After shredder carrier:

After shredding the cane, it is taken by this
carrier for further process. Its specifications are:
Length 60 feet
Width 78 inches
Angle 230
Linear velocity 38 ft/min
Motor power 100 HP
Magnet iron:
This bar used to separate the iron pieces and other iron
things so that material & machine parts may not be affected. These iron
things can stick in machines and stop the working of mill.
Design ANDRIN
Capacity 18.5 KW
Rubber belt conveyor:
It is placed under the magnet. Cane moves over
it and metal particles are separated by magnet.
 Length 9350 mm
Width 2000 mm
Total thickness 15 mm
Total layers 5
1 layer thickness 3 mm
Linear speed 88 m/min
Mill units:
There are four mills in this tandam. All have six mill rollers.

Different turbines run these units according to their working. Their details
are given below.
Mill # 1
This mill contains rack-bar feedback carrier. Back-pressure turbine
runs this mill. It has six rollers. Its specifications are:
Length 43 feet 10 inches
Width 78 inches
Angle of elevation 580
Linear speed 120 ft/min
Motor power 40 HP
Speed of motor 960 rpm
Reduction gear ratio 1:40
Mill # 2
This mill contains simple carrier instead of rack-bar feedback carrier.
Shinko turbine runs this mill. It has also six rollers.
Mill speed 1000-1600 rpm
Turbine power 800 KW
Angle of elevation 580
Mill # 3
This mill contains simple carrier instead of rack-bar feedback carrier.
KKK type turbine runs this mill. It has also six rollers.
Mill speed 1000-1700 rpm
Turbine power 750 KW
Angle of elevation 580
Mill # 4
This mill contains simple carrier instead of rack-bar feedback carrier.
KKK type turbine runs this mill. It has also six rollers.
Mill speed 1000-1350 rpm
 Turbine power 1044 KW
Angle of elevation 580
Mill rollers:
The diagram of mill rollers is shown below.
1# = Force feeder 2# = Pressure feeder Top 3#

= Pressure feeder Bottom 4# = Top Mill roller

5# = Mill feed roller 6# = Mill discharge roller

7# = Trash plate 8# = Pressure shoot

Mescerration of Juice:
After milling the juice of MILL, # 4 is drained in a hose
under this mill where it is pumped back to the Mill # 3. Then the juice of Mill
# 3 combines with the juice of Mill # 4 in a hose under this mill where it is
again pumped back to the mill # 2.

Here the juice of mill # 3 and mill # 2 combines then it is

mixed with the juice of mill # 1 in a hose under this mill from here all the juice
is pumped to the “Rotary Screen”
 Rotary screen

Mill # 4 Mill # 3 Mill # 2 Mill # 1

Rotary Screen:
Rotary Screen is used to screen the juice and to free the
juice from the baggase.
Screen speed 12 rpm
Mesh no. 0.5
Motor power 15-20 HP
Motor speed 1400 rpm
Baggase elevator:
When juice is extracted from cane then the baggase is
carried out with the help of this carrier. It takes the bagasse to boilers where
it is used as fuel to run the boilers. Baggase is also used in making boards.
 Boiler House
There are five boilers working in boiler house. They are all water tube
boilers. They have constant pressure.

Boiler Capacity
Boiler 1 40 tons
Boiler 2 80 tons
Boiler 3 80 tons
Boiler 4 80 tons
Boiler 5 80 tons

Procedure of making steam

Water Filtration

Water Storage

De -aeration of
Water

Feeding of water

Production of
steam
Portions & parts of boiler house are given below.

 Demining plant
 R.O. plant
 Sand filters
 Bag filter
 Storage tank
 Make-up water pumps
 De-aeration tanks
 Water supply headers
 Feed pumps
 Economizer
 Steam drum
 Mud drum
 Furnace
 Steam generation
 Anti-priming chamber Super heater chamber
 Suit blower
 Safety valves
 Bagasse carrier
 Burners
 Tubes
 Steam headers
 F.D. fans
 Secondary fans
 I.D. fans

Deming plant:
This plant is used for filtration of water. It reduces the
hardness and total dissolve salts (TDS) in water. It has two portions. With the help of
cat-ion and ann-ion resins we do the process of filtration. For cat-ion resin we use
hydro-caloric acid (HCl) and for ann-ion resin we use caustic soda (NaOH ). Raw water
contains 1100-1200 TDS and reduces to 150 TDS.
Portion Design Capacity Reduced TDS
Portion 1 CBI 15 ton/hr 150
Portion 2 CBI 30 ton/hr 150
R.O. plant:
R.O. plant stands for reverse osmosis plant. It also reduces hardness and
TDS in water. Memrines are used for filtration. This water is not worthy of drinking
because it has less TDS which require for human body. Its specifications are given:
Capacity 30 ton/hr
Reduced TDS 150
Pump power 40 HP
Sand filter:
It uses old method of filtration. It has 3 gravels which are placed in the
forms of stages. Water drops gradually on these stages which filter and remove the salts
and reduce the hardness.

Bag filter:
It has a bag type filter so that it is called bag filter. It is also used in homes.
The filter is called five micron filter because it has five micro-meter pores which filter
the water.
Storage Tank:
There are three storage tanks. After passing from filtration process
the water is stored in these tanks. These tanks supply the water to whole boiler. Water
in these tanks has near about 150 TDS and pH scale of 7.

Make-up water pumps:

These tanks take water from storage tank and take to the
de-aeration tank. Total five pumps are working here. Gate valves, non-returning valves,
glob valves are working here.
Pump Capacity
Pump 1 145 ton/hr
Pump 2 145 ton/hr
Pump 3 165 ton/hr
Pump 4 165 ton/hr
Pump 5 165 ton/hr
De-aeration tank:
It removes extra air and gases from water. It also preheats the
water so that it could prepare for further process. It increases the temperature up to 110
C. In this tank water is being showered water from the top of tank and water falls in the
form of drops then from sides of tank exhaust steam is passed from it with the high
pressure. It heats up the water and removes the gases like nitrogen, excess of oxygen
and other gases. There are two tanks working here. Pump # 1, 2, 3 sends water in tank #
1 & pump # 4, 5 sends water in the tank # 2.

Feed pumps:
These pumps send water to the boiler where it changes into steam so
that these are called feed pumps because these feed the whole boiler. There are total
nine pumps working here. These pumps take water from headers. These headers take
water from de-aeration tank. Turbine pumps have 2900 rpm. Their other specifications
are:
Pumps Type Capacity/Power
Pump 1 Electric 100 ton/hr
Pump 2 Electric 96 ton/hr
Pump 3 Electric 96 ton/hr
Pump 4 Electric 100 ton/hr
Pump 5 Electric 50 ton/hr
Pump 6 Turbine 365 KW
Pump 7 Turbine 250 KW
Pump 8 Turbine 100 KW
Pump 9 Turbine 100 KW
Economizer:
Feed pumps send water to economizer initially. It also preheats the
water so that we have some economical benefits. With the help of exhaust gases coming
from combustion chamber raise the temperature of water up to 135C. It is located above
the steam drum.
Steam drum:
Then water enters in steam drum. Some other components are in the
steam drum or connected to steam drum.

Mud drum:
Mud drum is kept below the steam drum. Both are connected by bank
tubes. All heavy impurities remain in the bottom of mud drum. It always remains full of
water.
Combustion chamber:
It is the portion where heat is produced with the help of
fuel. This portion is like a room which has tubes on each side of it. Here steam is produced.

Anti-priming box:
It is situated in the steam drum. It separates the
steam and water. Then it sends the steam to super heat chamber. There are two types of
boxes are used.

In 1st type there is square box having distance in milli meters between any two
consecutive plates from where the steam passes. Then in boxes diffusers are used, when
saturated steam passes through them the moisture stick to the plates of box and come
back through a pipe to steam drum. This type of box is being used in boiler 3, 4, 5.
Picture on left side shows this type of box.

In 2nd type there are number of plates joined together. The distance between any two
plates is in micro-meters. The saturated steam passes through these plates and moisture
of steam stick to these plates and come back to steam drum with the help of a pipe. This
type of box is being used in boiler 1, 2. Picture on right side shows this type of box.
Super heated chamber:
It is the portion where saturated steam
becomes super heated steam. High temperature gases coming from combustion
chamber do this job.
Suit blower:
It is pipe line having live steam. At the end of it there is a nozzle which
injects the steam. It is used to clean the super heated chamber. It is operated at least one
time in 8 hours.

Procedure of making of steam:

First of all service pumps supply
water to purifying plants where hardness and TDS are reduced. Then it goes to storage
tanks. Make-up water pumps take water from those tanks and take it to de-aeration
tanks where gases are removed from water and pre heated up to 110C.

Then from a supply line (Header) it is distributed to all feed pumps. Feed
pumps take this water to the boilers, where it enters into economizer. Economizer
increases its temperature up to 135C with the help of exhaust gases coming from
combustion chamber. Then this water comes to steam drum which is further connected
to mud drum with the help of Bank tubes & down comer tubes. A net of tubes is coming
out of the steam drum as shown.

When mud drum fills up then it sends water to front, side & back
headers. These headers send water to the tubes inside the combustion chamber, where
steam generates in these tubes. Then this steam is collected in steam drum over the
water surface. This steam is saturated steam having moisture in it. This moisture is not
good for turbines so we remove it from the steam. For that purpose we pass it through
the anti-priming box.

The steam moves to

super heater chamber and water-drops fall in steam drum. When steam comes from
anti-priming box it enters in tubes in super heater chamber. The tubes here are in zigzag
shape. The exhaust gases directly coming from combustion chamber strike with these
tubes and raise the temperature of steam up to 350C. These tubes have zigzag shape so
that the time and area between tubes and exhaust gases could be larger.

When exhaust
gases pass through the super heater chamber, they contain ash and when it strikes with
tubes, the ash falls in this chamber which causes heat loss. To avoid this loss and clean
this ash we use suit blower. When steam comes out from all these processes and is
collected it steam header, from where it is distributed to whole mill, it has the
temperature of 350C and pressure of 26 Kg/cm2.

Force draft fans:

Usually these are called F.D. fans. They suck the fresh air and send
it to air heater chamber and in furnace for burning process.

Secondary fans:
These fans take air from air gallery and distribute in furnace
and baggase carrier so that baggase could shower in chamber properly.

Induced draft fans:

These are usually called I.D. fans. They take out the
exhaust gases coming from combustion chamber. These are placed at the end of boilers.
Air gallery:
It is portion where air is collected when it comes from air heater
chamber. F.D. fan and secondary fan further take air from this gallery and distribute it
there, where it is required.

The pressures of all fans of all boilers are given below:

Boiler Pressure Pressure Pressure
Number of F.D. of of I.D.
fan secondary fan
fan
 Boiler 1 240 milli-bar 500 milli-bar 180 milli-bar
Boiler 2 180 milli-bar 600 milli-bar 220 milli-bar
Boiler 3 240 milli-bar 600 milli-bar 180 milli-bar
Boiler 4 240 milli-bar 600 milli-bar 180 milli-bar
Boiler 5 220 milli-bar 500 milli-bar 180 milli-bar
Procedure of air flow:
The fans used in boiler house control the flow and
direction of air. Total three types of fans are used here. First of all F.D. fans sucks the
fresh air and pass it to the air heater chamber. Where the tubes, having hot exhaust
gases, warm enough this fresh air. When fresh air gets hotter, then it is collected in air
gallery. Now wherever air is required in the boiler is taken from here with the help of
secondary and F.D. fans. Mainly it is required in combustion chamber for creating
pressure so that baggase can enter the chamber and for burning process.

F.D. fan now suck the air from air gallery and
take it to combustion chamber at two places. 1st is under the dumping grade so that the
burning fuel could have oxygen for burning and 2nd it is used with the fuel like natural-
gas, oil.

Now secondary fan sucks the air from air

gallery and take it to combustion chamber at two points. 1st is used in pipes coming out
from front wall and 2nd is used at the entrance of baggase so that baggase could enter
with higher pressure than chamber pressure.
When all
these air combine together, they create a cyclone so that fire in chamber could have
maximum height. The benefit of doing this is that maximum tubes could come in contact
with heat and we have minimum losses of energy & maximum output.

Now the I.D. fan sucks the hot & exhausts gases coming from combustion
chamber. First of all these gases enters in super heater chamber where these strikes
with the super heater tubes and raise the temperature of steam in tubes up to 350 C.
Then with the help of “baffles” we provide the path to gases to flow across the boilers so
that maximum heat could be utilized. Then these gases strikes with the economizer and
raise the temperature of water coming from feed pumps. After all this, these gases
enters the air heater chamber where it heat up the fresh air sucked by F.D. fan. These
gases still contain ash particles which cannot be released in air so these gases pass
through the dust collector chamber where dust and ash particles are separated from the
hot gases. Then these gases are released in air having negligible quantity of ash particles.
Fuel procedure:
There are used four types of fuels in boilers.

 Baggase
 Oil
 Natural gas
 Bio gas

Baggase coming from mill house enters in boiler with the pressure provided by
secondary fans. When it enters the chamber the air coming from front of entrance is at
some angle so that it could spread the baggase in whole chamber. Now the air coming
below the dumping grade makes it suspended in chamber. Then it burns in cyclone
shape.

When we use oil in chamber, before spraying it in chamber we mix it up with

steam. Then it becomes oil steam mixture which acts like spray coming out from
perfume bottle, then air coming from back in the form of whirl spread this fuel in
chamber and then it burns in chamber.

When we use natural gas, we also mix it with air. The nozzles of gas are in a
circle at some angle. The angle is kept so, that all nozzles have same point inwardly.
Then the air coming from back is added with the gas and spread in chamber. Then the
air coming below the dumping grade creates cyclone and then this gas burns in air.

The procedure for fueling bio gas is same like of baggase.