INPLANT TRAINING REPORT AT PRABHULINGESHWAR SUGARS

SHRI PRABHULINGESHWAR SUGARS
AND CHEMICALS ltd
INPLANT TRAINING REPORT
Submitted By:
(Shivkumar) Kashinath S Jayadhar
SIT201504

REPORT
ON
INPLANT TRAINING
(Academic year 2015-2016)
AT
PRABHULINGESHWAR SUGARS
JAMKHANDI, DIST: BAGALKOT,
KARNATAKA
SUBMITTED TO
“INSTRUMENTATION DEPARTMENT”
VASANTDADA SUGAR INSTITUTE
PUNE
---------------------------------------------------------------
SUBMITTED BY
NAME:- (SHIVKUMAR) KASHINATH S J
ROLL NO:- SIT201504

CERTIFICATE
This is to certify that Mr. KASHINATH S JAYADHAR has carried out his Inplant
Training from 23rd
NOVEMBER 2015 to 22nd
JANUARY 2016 at SHRI
PRABHULINGESHWAR SUGARS AND CHEMICALS LTD; SIDDAPUR,
JAMKHANDI, satisfactorily and submitted the work report as partial fulfillment of Post
Graduate Diploma Course in Sugar Instrumentation Technology at VSI Pune during the
academic year 2015-16.
(Shri S.R. Mahajan) (Shri D.N. Gare)
Technical Officer (Instrumentation) Head Instrumentation Dept.
VSI, Pune VSI, Pune

ACKNOWLEDGEMENT
I am very much grateful to express my sincere thanks to Shri. D.B.Ghule Registrar of
VSI, Pune and Shri D.N.Gare Head of Instrumentation Department for giving me an opportunity
to take Inplant training at Shri Prabhulingeshwar Sugars and Chemicals Ltd; Siddapur,
Jamkhandi,
I would like to express my true sense and sincerest gratitude to Mr. S.R.Mahajan
Technical Officer (Instrumentation) for his guidance for completing the Inplant Training
Program. Also it’s my duty to express grateful thanks to Chairman, Executive Director, Chief
Engineer, Chief Chemist, Assistant Engineer, Instrument Engineer, Electrical Engineer and to all
Employees of sugar factory for giving me a co-operation and guidance for completing my In
plant Training.
Last but not the least I express my sincere thanks to the Institute for providing me such a
platform for implementing the ideas in my mind.
Place: VSI Pune
Date: 15/11/2016
(SHIVKUMAR) KASHINATH S JAYADHAR
(SIT201504)

DEDICATED TO MY
PARENTS, FRIENDS
AND TEACHERS

PRABHU SUGARS JAMKHANDI KARNATAKA
TABLE OF CONTENTS
SERIAL TITLE PAGE NO
1. Location of the sugar factory and historical background IP 1
2. Organization structure and responsibilities IP 4
3. Introduction to sugar manufacturing process IP 10
4. Details of the manufacturing process IP 15
5. Details of steam generation unit IP 46
6. Mill Turbine and Power Turbine Details IP 54
7. Molasses conditioning unit IP 61
8. Sugar godown IP 63
9. By products IP 64
10. Flow diagram of sugar manufacturing Process. F D 1
11. Photos SP 1
12. Schedule of machinery I(1) Form PAGE 1

INPLANT TRAINING SEASON REPORT 2015-16
SPSCL JAMKHANDI KARNATAKA I P 1
I. LOCATION OF FACTORY AND HISTORICAL BACKGROUND
A. Location of the factory : Shri Prabhulingeshwar Sugars & Chemicals LTD
Siddapur, Tq.Jamkhandi, Dist. Bagalkot.
Karnataka.Tel.No.08353-238004/238146
Website: http://www.prabhusugar.com
B. Registered office : 1st
Floor “SUKRUT” Building,
Opp: K.C.Park, Main Gate, P.B.Road,
DHARWAD-580008, Karnataka
Tel.No. 0836 - 2745036, 2742833, 2743703
Website: http://www.prabhusugar.com
C. Plat manufactures : Skyline Developers Bangalore
D. Nearby factories : Nirani Sugars 10 Km
SaiPriya Sugars 20 Km
Nandi SSK 18 Km
Jamakhandi Sugars 28 Km
ICPL Uttur 30 Km
E. Nearby Cities : Jamakhandi 06 Km (Towards North)
Mudhol 12 Km (Towards South)
F. Nearby Railways : Belagavi 130 Km
Bagalakote 88 Km
Vijayapur 80 Km
Miraj 107 Km
G. Year of commissioning : 1999.
H. Registration Number : No 17861 of 1995 DT 25/May/1995.

I. Cane potential : 12500 TCD
J. Soil type : Black soil and red soil.
K. Source of water : Bore wells and from Krishna river Via Pipeline.
L. Business type : Manufacturing type.
M. Type of unit : Large Scale Agro Based Manufacturing Unit.
N. Initial investment : 400crore.
O. Land : 250 acres.
P. Workdays : 180-230 days.
Q. Sulphitation Process : Double Sulphited Sugar.
R. Activity undertaken : 1. White crystal Exportable Quality sugar.
: 2. Co-Generation of Capacity 38 MW.
S. Number of employees : 762 – 780 (above).
T. Capacity variation till date :
YEAR CAPACITY IN TCD POWER DETAILS
1999 3500 (installed) --
2000 ----- Co-Gen Establishment of 12MW
2006 6000 --
2009 7500 Power expansion to 27MW
2010 -- Power expansion to 38 MW
2013 10000 --
2017 12500 (Extension in Progress) NA

U. Year wise Cane Crushing Sugar Bagging And Average Recovery Details:
Season Start date
Of
Crushing
End Date
Of
Crushing
Work
Days
Cane
Crushed
(MTS)
Sugar
Bagging
(Quintals)
Average
Recovery
%
99-2000 21-10-1999 15-05-2000 208 354979 36548 10.86
2000-01 19-10-2000 05-06-2001 230 480166 576260 12.015
2001-02 18-10-2001 02-05-2002 197 623616.43 726150 11.655
2002-03 23-10-2002 18-05-2003 207 725992.39 866250 11.940
2003-04 11-10-2003 23-02-2004 136 365751.72 388620 10.620
2004-05 09-10-2004 10-05-2005 213 437285.368 644500 10.17
2005-06 09-10-2005 31-05-2006 234 789909.233 900270 11.40
2006-07 09-12-2006 17-06-2007 190 843404.646 1022600 11.96
2007-08 24-10-2007 31-05-2008 220 962851.84 1186380 12.33
2008-09 17-10-2008 13-03-2009 147 574352.591 606600 10.55
2009-10 19-10-2009 24-04-2010 187 1051645.126 1186400 11.28
2010-11 12-11-2010 18-05-2011 188 1206469.53 1407600 11.67
2011-12 14-11-2011 11-04-2012 152 1103485.129 1332500 12.00
2012-13 28-10-2012 18-03-2013 142 969603.311 1064700 11.00
2013-14 22-11-2013 10-04-2014 140 1172534.187 1355500 12.04
2014-15 30-11-2014 21-04-2015 143 1256070.033 1543800 12.30
2015-16 15-11-2015 25-04-2016 163 1442673.953 1624962 11.95
V. Year wise Power generation and power export details:
Season Start Date
Of
Crushing
End Date Of
Crushing
Work
Days
Power
Generated
(KWH)
Power
Exported
(KWH)
Power
Used
(KWH)
99-2000 21-10-1999 15-05-2000 208 28576937 19595639 08981298
2000-01 19-10-2000 05-06-2001 230 31506226 13147300 18358926
2001-02 18-10-2001 02-05-2002 197 57240200 34270700 22969500
2002-03 23-10-2002 18-05-2003 207 67050000 39734800 27315200
2003-04 11-10-2003 23-02-2004 136 37525500 22313500 15212000
2004-05 09-10-2004 10-05-2005 213 36605000 17282400 19322600
2005-06 09-10-2005 31-05-2006 234 61439000 32023000 29416000
2006-07 09-12-2006 17-06-2007 190 52911000 24528000 28999866
2007-08 24-10-2007 31-05-2008 220 64836000 31657000 33383708
2008-09 17-10-2008 13-03-2009 147 40957500 19810000 21428889
2009-10 19-10-2009 24-04-2010 187 65590500 29110390 36747262
2010-11 12-11-2010 18-05-2011 188 87572400 45552000 42396360
2011-12 14-11-2011 11-04-2012 152 81867800 43354000 38777832
2012-13 28-10-2012 18-03-2013 142 87357900 52619000 35130324
2013-14 22-11-2013 10-04-2014 140 108511500 69452250 39343230
2014-15 30-11-2014 21-04-2015 143 104646300 62578250 42131050
2015-16 15-11-2015 25-04-2015 163 113473984 68642931 44831053

II. ORGANIZATION STRUCTURE AND RESPONSIBILITIES:
Organization structure is a basic frame work within which the decision making behavior of
an executive takes place. It is an established pattern of relationship among the components of
the organization. SPSCL is headed by the chairman and M.D. and technical Adviser This crew
guides the G.Ms of all departments.

BOARD OF DIRECTORS
1 Shri Jagadeesh S. Gudagunti Chairman & Managing Director
2 Shri Rajendrakumar S. Gudagunti Executive Director
3 Shri Sudheer S. Gudagunti Technical Director
4 Shri Nagappa. G.Sanadi Director
5 Shri Satish S. Gudagunti Director
KEY MANAGERIAL PERSONS:
1 Shri Jagadeesh S Gudagunti Chairman and Managing Director
2 Shri V. Subbu-Ratnam Executive Vice President & C.F.O
3 Shri Mahendra B. Horaginamani Company Secretary & G.M.(F&A)
HEAD OF THE DEPARTMENTS:
Name Qualification Designation
1 Shri A. Gurunatha B.E. (Mech), BOE,AVSI Sr. General Manager (Engg)
2 Shri S. C. Hipparagi B.E. (Ele. & Comm.) General Manager (Elect&Inst)
3 Shri B. S. Khyadi D.M.E Dy.Gen Manager (Engineering)
4 Naveen Mudkavi B.E (E & C) Dy. Chief Engineer (Inst)
4 Shri S B Dalawai B.E (Mech) Chief Engineer
5 Shri S.S.Holapagol M.Sc, AVSI Chief Chemist
6 Shri R.P. Hiremath B.com, M.Com Sr. Manager (F&A)
7 Shri B.S. Khandekar B.Sc Sr.General Manager (Cane)

RESPONSIBILITIES:
 Chairman and Managing Director (C.MD):
He is the only higher authority in the plant, He takes every details and records from
every department and the executive director for proper guideline and suggestion. And he has
the capacity to handle and order.
 Executive Director:
His responsibilities are to handle official and legal matters of the factory and also take
decision and making policies for developing work. has guided by CMD.
 Administration officer:
He is the head of the administration section he has the authority to handle all the
accounts and manage the factory economic condition along with the guidance of legal adviser.
The administration control of factory is affected through administration department of sugar
factory. This consists of managing director and executive president whose take decision and
making policies for developing work.
 Chief Accounts:
His responsibility is to do transaction of final payment of the working staff‟s and as
well farmer bill payment. Sanction or grant the payment of sugarcane to former, scrap
material, molasses, etc. and he has to collect all the present details from the time office of all
the working employs of the plant for the proper payment.
 Agriculture officer:
This officer has visit to field and advice the formers about the good variety of cane,
purchase of seed and required fertilizers pesticides & even makes arrangement of cane
transportation to the factory.
 Civil Department:
The civil engineer plans the design and then constructs depending upon the
requirement in the various departments of factory needs providing at a suitable manner and
keeps record of factory area, build area, and even plans for the requirement over the factory
capacity extension

 Purchase officer:
This person purchases the machinery, equipment & spare parts and all accessories as
per the factory requirement and sends the purchased bill to account department for further
payment to the entrepreneur.
 Time officer:
His responsibility is very much important because he takes every person responsibility
that works in the factory and maintains the daily records of duty time of the working staff in
the factory by punching arrangement and assigns salary as per their presence and he must
submit the same to chief accounts for the proper payment of all employs that working in
factory.
 Security officer:
Here the factory area is large enough therefore a large security force required in the
factory premises. Their responsibility is to provide a good security service and he has to check
the persons and vehicles entering inside and leaving the plant and no persons/vehicles shall
enter without his permission in the factory area other than worker.
 Store Keeper:
His responsibility is to maintain all kind of stocks of material in store house as per
needed material requirement in the plant. And he must deliver all the material requirements
immediately and must continuously keep tracking about the stocks in the store and inform the
purchase officer for on-time needs for the factory.
 Engineering Department:
This department consists of production section such as Instrument section, Electrical
Section, Mill section, Boiling House Section, Centrifugal Section, Sugar House Section and
Co-Generation section. Engineers of various departments observes and maintains all the plant
working equipment in his section for the proper and safe working condition of overall sugar
production at the factory.

 Instrument Engineer:
His responsibility is to observe and maintain the proper working of instruments
automation process and its control systems they may be operated on PLC, DCS and micro-
computer based equipment such as (ACFC,Boiler Automation, mill automation, boiling house
automation, pH control, pan automation, centrifugal automation, sugar silo and weighment).
 Electrical Engineer:
Electrical engineers check and maintain the electrical network condition and its
implementation for proper working of all machineries. He has the major role in the factory to
provide safe electrical connections for proper working.
 Chief Engineer:
He must be more knowledgeable and experienced person. His responsibility is to check
and maintain all the equipment for proper working and to guide/instruct shift engineers and the
labors to avoid stoppages and problems. And if any problem persists he has to guide the
workers for proper working and avoiding the damage to the products in his premises.
 Shift Engineer:
This person looks over all plant he checks and maintains the proper working like mill
house, boiler section, turbine generators, electrical and instrumentation section as guided by
chief engineer.
 Co-generation Manager:
He keeps the hourly record of steam generation, bagasse and water consumed,
electricity exported & electricity and steam consumed by factory and distillery and even co-
gen authorized process. And he has to instruct the labors for proper working and to inspect it
 Chief chemist:
His role is towards the process side chief chemist inspects the manufacturing process
& suggest manufacturing chemist about the quality of production of sugar maintaining the
standard syrup concentration conditions such as brix% and so on….

 Manufacturing chemist:
Manufacturing chemist work is to maintain the good quality of sugar and work as
guided by CC.
 Lab chemist:
This person periodically checks about the Brix %, pol%, water pH & TDS.
 Technician :
This person has to check and maintain all the electrical and Instrument Equipment for
proper working during the season. And he has to check, repair /calibrate or replace the
equipment during off season time.
 Transport department:
This department ensures the proper communication over the transport facility of the
working labors this department has a major responsible i.e. to pick-up and drop the faculties
/staffs/labors in time irrespective of climatic condition. And as well as all the necessary
equipment related to factory or agriculture.

III. INTRODUCTION TO SUGAR MANUFACTURING PROCESS
The sugar manufacturing process is described as follows:
 The sugar cane is used as the input or as the source of production to the factory and the
white crystal Exportable Quality sugar is the main output or the factory product along with the
by-products such as Bagasse, Final molasses and the Filter cake.
 The exportable sugar grades are M30, S1-30 & S2-30.
 The power and steam is produced in the plants Co-Generation Section of 38MW
power. And 220 tons of steam per hour.
 The sugar cane of required varieties is received from the cane yard through sources
such as Tractors (75%), Lorries (20%) and bullock carts (05%). But now-a-days bullock carts
are minimized.

1. CANE WEIGHMENT SYSTEM:
Weigh bridge:
The cane is weighed on electronic Weighment systems called weigh bridges that
basically uses electronic load cell system. Cane Weighment system is very essential step for
making cane payment to the formers and for Chemical control.
2. CANE HANDLING SYSTEMS:
a. Cranes:
Cane Unload device called crane is used for lifting & unloading device. This lifts and
transports the cane from the tractor trailer & truck and feeds it on the feeder table.
b. Feeder table :
Feeder table is the large table which is used for Uniform (regulation) feeding of the
cane to the cane carrier. It is located at the right angle to cane carrier.
c. Cane carrier
The function of a moving apron type cane carrier is to convey sugar cane from the
feeder table to the mill house through the set of cane preparatory device called Kicker,
Chopper and Fibrizer.
3. CANE PREPARATORY DEVICES:
a. Leveler
Cane Leveler is installed on the cane carrier to prevent excessive cane being fed to
cane chopper which causes jamming in the arrangement.
b. Chopper
It is installed next to the Kicker and the cane carrier itself and it cuts/chops the hard
rind cane& breaks the too short pieces which will increase the mill efficiency.
c. Fibrizer
It cuts the cane to very small pieces it breaks the cells without extraction the juice. The
Fibrizer in the cane preparatory device station helps to improve the mill extraction.

4. MILL HOUSE :
The mill house extracts juice from the prepared cane with squeezing & pressing
operation, it is called milling operation. The disintegrated cane is fed into first mill of milling
tandem the subsequent mills performs the function of extraction of juice from bagasse sucked
in water. The mixture of primary juice & secondary juice are screened through a DSM Screen.
 Primary juice :The juice extracted from the first mill is called primary juice
 Last expressed juice: the juice expressed by the last mill is called last expressed juice.
 Secondary juice: The juice expressed by the last mill is recycled for penultimate & so
on. Finally the juice extracted by the 2nd
mill is called secondary juice.
a. Imbibition:
The process of adding of hot water around temperature of 80⁰C to extract the
remaining juice present in the pre-extracted Bagasse is called imbibitions. This process is
carried between last 2 mills. The imbibition helps to maintain the Pol% Bagasse and Brix%
juice.
b. Rotary screen:
Rotary screen is installed above the mill surface level in the mill house itself. The
rotary screen filters mixed juiced that separates the fine Bagasse particles called Cush-Cush
from the mixed juice.
5. BOILING HOUSE:
The juice from the mill house is sent to boiling house and treated immediately for the
purpose of chemical control.
Cane juice + added imbibition water == mixed juice + Bagasse
Mixed juice consists of H2O, Sugar, In-organic, organic and non- sugar. The juice is
heated/boiled up to a temperature of 72⁰C at the pH maintained around 5.2 to 5.4. In order to
avoid the growth of micro-organisms and inversion of sucrose lead to sugar losses. Weighed
raw juice after addition of required dose of Phosphoric acid (P2O5) is heated. The juice after
boilingin boiling house is sent to the sulphitation process for further operation.

6. JUICE LIMING & JUICE SULPHITATION:
It is the first stage of sulphitation process carried in juice sulphitation tank where the
raw juice which is dark and opaque in color and is treated with milk of lime and bubbled with
SO2 maintaining a pH of 7.0 to 7.2
7. JUICE CLARIFICATION :
Here the muddy content present in sulphited juice is get clarified in the clarifier tank
called rapidorr 444 clarifier i.e. the dust and mud particles mixed in juice is removed.
8. EVAPORATION :
Here the juice received from the clarifier contains about 84% to 87% of water and 13%
to 16% of dissolved solid at a pH rate of 7.00 and this juice is heated to remove maximum
amount of water of about 75% to 82% is been removed after boiling in the evaporator body
then the concentrated juice obtained is called “syrup”
9. SYRUP SULPHITATION :
It is the second stage of sulphitation process this is carried in another tank called syrup
sulphitation tank where the syrup here is again bubbled with SO2 gas and Milk of Lime is
added with required proportion. To maintain a pH about 5.2 to 5.4 and this is heated to a
temperature of 70⁰C.
10. VACCUM PANS :
After Sulphitation of syrup, the syrup is subjected to vacuum pan boiling process. The
pan boiling essentially consists of the removal of remaining water content by evaporation in
single effect vessel known as vacuum pan &crystallizing out sugar by increasing the
concentration. The function of vacuum pan is to produce & develop sugar crystals of desired
size from Sulphited syrup.
11. MASSECUITE CRYSTALLIZER:
Crystallization is a process of cooling the Massecuite slowly by constant stirring nearer
to surrounding atmospheric temperature. Progressive cooling reduces the solubility of sugar.
Continues stirring of Massecuite minimizes the danger of false grain formation.

12. CENTRIFUGAL :
The machine in which crystals in the Massecuite are separated from the surrounding
molasses by centrifugal force is called centrifugal machine. The main function of centrifugal
machine is to separate the sugar crystals and mother liquor (molasses). And the separated
sugar crystals are feed to the hopper trays for further cooling.
13. HOPPERS:
It is a tray like device mounted horizontally below the centrifugal machine provided
with the cooling arrangement called fans the main function of the hoppers is to dry the sugar
crystals received from the centrifugal machine and to separate the pure sugar crystals form the
hard dust particles.
14. ELEVATORS:
The elevators are the vertical columns provided with sucking arrangement that pumps
and lifts the dry cooled sugar crystals from the hopper to the grader which is at the topmost
layer normally above the silo level. Normally 15 meters above the ground level.
15. GRADERS:
This is a device that separates the sugar crystals based on the size of the sugar crystals
namely Large, Medium and Small provided with the suitable sieves installed in the grader
house and the whole arrangement is installed at the top above the silo layer.
16. SUGAR SILOS:
The sugar separated from the grader is sent to the silo these silos are the dry sugar
storing containers with the huge size for the storing of sugar provided with good hygienic
condition. There are separate silos for different size of sugar crystals.
17. WEIGHMENT AND PACKING:
Here the sugar is weighed and packed accordingly separate weigh and packing
arrangement are provided for different sugar silos the sugar is first weighed and packed as per
the market requirement.

IV. DETAILS OF THE MANUFACTURING PROCESS:
1. CANE WEIGHMENT
 Need of equipment: Weighbridge.
 Make: Avery India Limited, Kolkata.
 Installation year: 1997
 Technical specification:
 Operational information: It is electronic type platform.
The cane received from the cane yard or from the field through tractors or trucks is
weighed on the Weigh bridges these are of electronic type and computerized with 2No and
4No load cells used for Trucks (Lorries) and tractors trailers. SPSCL plant is having 4 weigh
bridges 3 bridge of 60MT and 1 bridge of 40MT. The weigh bridge consists of a 5 load cells.
4 load cells at corner and 1 load cells at the center.
Weighbridge can be paired with a pair of 2 or 4 load cells, indicators, software and other
accessories for a complete weighing and data management solution.
Numbers Capacity Platform Size L X W Meter
Weigh
bridges
03 60 MT 16 X 3
01 40 MT 40 X 1

2. CANE HANDLING DEVICES:
i. Cranes And Bridges
 Make : Extract Engineers (I) Pvt. Ltd, A‟nagar.
 Installation year : 1997
 Technical specification
 Operating information:
The cane is often loaded in packets or bundles tied with its leaf itself. Cane Un loader
is a lifting & unloading device which lifts the cane from the tractor trailer & truck and feeds
on the feeder table. The unloading device called cranes at the factory site lifts the cane bundle
from trailer /truck with the aid of a steel bar/slings fitted with adjustable hooks of Hydraulic
de- hooking arrangement, And lifts this bundle into the horizontal feeder table.
This type of crane is used for handling & moving a maximum specified weight of the
components called capacity of the crane within a specified area. The crane can be operated
manually by means of electric power.
Type of motion : Vertical &Horizontal
Type of crane : Electric Overhead Travelling (E.O.T) crane.
Thickness of the cable : For the 14 tons of capacity 16 cables of 25 mm each.
No of Bridges : 3 Bridges
Numbers of Cranes : 6 Cranes
Number of motions : Two motion crane
Capacity : 20 MT. Safe Working Load
Height : 14600 mm
Crane gantry span : 27 Meters.
Operating speed : 11 meters/min.
Hoisting drum drive. : 50 HP/960 rpm
Holding Type : Hydraulic de- hooking arrangement, 2HP
Cross travel drive : Cross travel – 20 meters /min. 10 HP/960 rpm

ii. Hydraulic Truck & Trolley Un-Loaders :
 Make : S.K.S ENGINEERS PVT. Ltd. New Delhi
 Technical specification :
 Operational information:
Hydraulic Truck & Trolley Un-Loader is a lifting and revolving device at an
inclination angle of 55 degrees which unloads the cut cane from the trailer or truck with a
hydraulic lifting mechanism up to a pressure of 200 kg/cm₂
. And it has a 90 degree angle of
rotation in horizontal axis. It has the dimension of 28.48 square meters. This is used to lift and
dump the cut cane directly to the cane carrier. In this arrangement the feeder table is not
required.
Numbers : 02 Numbers
Capacity : 40MT
Type : Double frame type
Operating Pressure : 200 kg/cm2
Hydraulic pump capacity : 53 lpm
Motor make : ABB make, 25HP, 1440
Platform size : 3200mm wide X 8900mm long
Angel of tilt : 55 degrees
Platform Size(Top Frame) : 3200mm X 8900 mm
Hydraulic System capacity : Pump- 53lpm
Hydraulic Oil : Servo System 68

iii. Feeder table:
 Make : SPSCL
 Installation year : 1997 (02), 1999 (01)
Numbers : 3 Tables
Length x Width : 8 Meter X Meter (64 Metre2
)
Drive : 2 X 15 HP
Drive type : Duel Drive
Gearbox ratio : 70:1
Inclination : 3 degrees at rear end
Number of strands : 8 Nos.
Pitch of chain : 150 mm
Chain breaking load : 45 Tons
 Operational information:
Feeder table is the large table which is used for Uniform (regulation) feeding of cane to
the cane carrier by movement of 8 Stranded chain in feeder table, whenever the cane feed to
the feeder table it moves the cane by sliding chain alignment and the cane feeding is controlled
by manually for uniform feeding. Mainly use the quality components like chains, Gear boxes,
Motors and VFDs. For the chain the appropriate breaking load ranging from 30MT to 60 MT
The feeder table is installed 90 degrees proportional to the cane carrier such that cane
from the feeder table must flow easily into the cane carrier.

iv. Cane carrier:
 Make : ELECON
Numbers : 01
Width : 2,300 mm = 7.659 feet
Length of carrier : 81000mm (81meter)
Angle of inclination : 18deg
Feeding depth : 1320 mm
Number of Strands : 4 No‟s
Four strand chain pitch : 200 mm
Breaking load of chain. : 60000 Kgs.
Drive : VFD drive 150 HP / 1450RPM
Speed : 3-10 meters/min.
Gearbox : SCN-450, 80/1
Gear teeth : 108T X 210 FSW X 1” DP
Pinion teeth : 23 T X 210 FSW X 1” DP
The function of moving apron type cane carrier is conveying sugar cane from the
feeder table to the mills via the preparatory devices installed in it. Commonly the cane carrier
should have horizontal portion of 30 meters suitable for cane feeding & inclined portion has a
slope of about 18⁰ to 21⁰.

3. CANE PREPARATORY DEVICES:
i. Cane leveler:
Number : 01
Drive : 60 HP/1450RPM
Final RPM : 72
Clearance between Knives & Carrier slats : 250mm
Swing Diameter : 2200 mm
Cane leveler on the cane carrier is to prevent excessive cane being fed. which
avoids jamming of the leveler side it consist of steel shaft directly coupled to the
motor with arm & knives mounted on, It is revolving normally 50 to 100 RPM in the
reverse direction to the flow of the cane carrier. The motor capacity of cane leveler is
60 HP.
ii. Chopper :
Number : 1
No. of Knives : 48
Final RPM : 300
Gear box : Helical gear box 2:1
Clearance between Knives & Carrier slats : 1050 mm
Diameter of tip of rotation : 1600 mm

Cane preparation by knives essentially consist of disintegrating the hard rind & nods &
breaking the too short pieces which will increase the mill capacity & efficiency of mill
extraction it revolves 300 RPM, The preparatory index increases 56 to 60% in the case of two
sets of knives (Chopper & leveler) as the same movement of cane if the two sets of knives
(chopper & Leveler) is rotates reverse direction of cane movement the preparatory index can
be 65 to 70%. Cutting knives = Standard IS 8461, material of knives manganese (Mn),
Chromium (Cr), Cobalt, Steel. And shaft = forged Steel Quality 40C8 is commonly used.
iii. Fibrizer :
 Installation year : 1998
 Technical specification :
Number : 1 No.
Type : Heavy duty swing hammers
Swing diameter : 2130 mm
No. of hammers : 150
Wt. of each hammer : 22 Kgs
Speed : 750 rpm
Motors (4020HP) : 2 Nos. of 1500 KW each, HT Motor 11KV
Clearance : 100 mm, 20mm
 Operational information :
The preparatory device which combines the function of cutter knives & secured to the
Hubs & serve the duel function of cutting & shredding cane which has passed through knives
set special futures of this machine are
 Revolving in the opposite direction of cane flow
 The casing is so design as to ensure cutting action on the cane which is thrown into
rear chute & anvil where shredding is brought.
 The total H P of the Leveler & Fiberizer Combination is 35 to 40 Hp/ton of fiber/hr
 Heavy Duty Fiberizer manufactured up to 15,000 TCD Sugar Plants.

4. MILL HOUSE:
i. Mills:
 Make : S S Engineers Pune (I mill and VI mill )
Krupp Engineering, Pune (II, III, IV & V mill)
 Mill No 1
Size of Rollers : Dia1250 mm X 2300 mm
Speed : 4.31 RPM
Drive : 1000 KW / 1000 RPM DC
 Mill No 2
Size of rollers : 1066 mm X 1980mm
Speed : 5.31 RPM
Drive : 750 HP / 1000 RPM DC
 Mill No 3
Speed : 5.31 RPM
 Mill No 4
Speed : 5.31 RPM
 Mill No 5
Speed : 5.31 RPM

 Mill No 6
Size of rollers : 1300 mm X 2300 mm
Speed : 5 RPM
Mill Drive : 600 KW / 1000 RPM AC VFD
TRPF Drive : 200 KW / 1000 RPM AC VFD
The mill house extracts juice from the prepared cane with squeezing & pressing
operation, it is called milling operation. The disintegrated cane is fed into first mill of milling
tandem the subsequent mill perform the function of extraction of juice from Bagasse sucked in
water. The crushing rate of prabhu sugars was 10000 TCD now extended to 12500 TCD and
mill house is having 6 mills.
The plant machinery and equipment‟s supplied the first or five mill having 6 rollers
with GRPF and second third, fourth mill having 4 rollers. The cane feeding is controlled by
Auto cane carriers.
All mills are provided with individual rake carrier along with toothed chain conveyer
for scrapping (lifting) the prepared cane/Bagasse. And all mills are suitably arranged with an
individual planetary gearbox arrangement from the drives. That reduces the speed from 900
RPM to 6-7 RPM. The Top and Feed rollers are provided with chevron grooves for the proper
extraction and feeding of prepared cane/Bagasse. The mill head stock housing is the vertical
round head housing each mill lift controlled by two hydraulic head system which consist of
hydro pneumatic accumulator the pump gauge and suitable control valves. The Top and
Discharge roller for the scrapping of Bagasse in the roller grooves. Each roller shaft support
on the gun metal bearing with housing which is lubricated by individual forced feed oil
lubricator and the bearing housing is covered with water jacket for proper cooling .
Objectives of Cane Milling
 Maximum possible extraction of sucrose
 Minimum extraction of non-sugars
 Minimum sucrose in final Bagasse
 Optimum power of the energy consumption
 Optimum moisture in final Bagasse

ii. Mill Drive Details: Electric Motors
 Make I and VI Mill : S.S Engineers Pune
II, III, IV &V Mill : Krupp Mills
 Drive Make : ABB Make
I Mill (SSE) : ABB motor,
Type : VFD Drive 01No,
HP : 1000KW
RPM : 1000 RPM
II, III, IV & V Mill Krupp Mill : ABB motor,
Type : D.C Drive 4 No
HP : 750 HP each
RPM : 1000 RPM Shunt Motors
VI Mill (SSE) : ABB motor,
Type : VFD Drive01No
HP : 600KW
RPM : 1000 RPM
The Electric drives are used to run the individual mills and these all 6 drives are DC
drive /VFD Drive that runs by the DC power supply but prabhu sugars only DC drives are
used but here mill T G sets are not used here. Mills run by DC drive through individual
planetary gear box system provided that reduces the speed from 900 RPM to 7 RPM.
iii. Pressure Feeders
Total hydraulic load on top roller : 180 Kgs/cm² (g)
GRPF I Mill
TRPF II, III, IV, V & VI Mills are driven integrally.

iv. Mill Gear Box: Planetary Gear Box:
 Make : Elecon gears systems(All 6 mills)
Premium Gears (TRPF of VI Mill)
 Technical Specification :
i. 1st
SSE Mill : 1 No,
Type : A40/BZ2 X 71,
Ratio : 48.669/1
ii. Krupp Mill Gear Box : 4 Nos.
Type : SCN 710
Ratio : 56:1
iii. 6th
SSE Mill : 1 No, (Planetary gear box)
Type : SA-280/PCF0-170,
Ratio : 400/1 PGLS 03, Sl no: WHG953127SP
iv. TRPF : 1 No, (Planetary Gear box)
Type : P41310/Sr No. HG-14381
Ratio : 250/1
v. Roller speed
1st
Mill : 4.31 RPM
2nd
Mill : 5.31 RPM
3rd
Mill : 5.31 RPM
4th
Mill : 5.31 RPM
5th
Mill : 5.31 RPM
6th
Mill : 2.00 RPM

vi. Gear Arrangement:
SSE Mills : 1 set mill
Pinion : 40M, 29T, 700FSW
Gear : 40M, 138T, 700FSW
: 1 set GRPF
Pinion : 30M, 61T, 400 FSW
Gear : 30M, 86T, 400FSW
Krupp Mills : 4 sets.
Pinion : 39 TEETH, 30 M, 600 FSW
Gear : 130 TEETH, 30 M, 600 FS
 Operational information :
From1st
mill, to 5th
Mills have the helical gear box & worm wheel master gear boxes
Last 6th
Mill top Roller & pressure feeder have a Planarity gear box system are used
vii. Juice Rotary Screen Filter :
 Make : KRUPP Industries Ltd, 1No Indigenous make
 Installation year : 1999 (02 filters) 2003 (01 filter)
 Technical Specifications
Numbers : 3 filters
Type : Welded edge, wire rotary drum type
Model : 18 x 36
Screen size : 1800 mm x 3600 mm x 0.35 mm slit width
Capacity : 450 m3
/ hr each

viii. Imbibition:
 Equipment : Volumetric flow meter
 Weighing Capacity : 4003
/Hr.
The process of adding of hot water around temperature of 70⁰C to extract the
remaining juice present in the pre-extracted bagasse is called imbibition, the process is carried
between last 2 mills.
ix. Juice Weighment :
 Equipment : Mass flow meter
 Make : Promass-F
Line size : 10”
Weighing capacity : 100-500 m3
/hr
Temperature : 50 to 200 degrees
Pressure : 10 kg/cm2
or 10 bar or 147 psi
Display : Digital display
The juice to be sent to the boiling house from the from the mill is weighed with the
Equipment called Mass flow meter it is a U shaped tube that measures the accurate amount of
juice been flowed to the boiling house it is in terms of tons per hours TPH

5. BOILING HOUSE:
i. Juice heaters:
 Equipment : Juice Heaters
 Installation year : 1999 2002 And 2006
Type Dead End Dynamic
Numbers 4 2 6
Heating surface M2
300 670 300
No. of tubes 560 828 560
No of passes 14 18 14
Total no of tubes per pass 40 46 40
The juice from the mill house is sent to boiling house and treated immediately for the
purpose of chemical control.
Cane juice + added imbibition water == mixed juice + Bagasse
Mixed juice consists of H2O, Sugar, In-organic and organic and non-sugar. And the
juice is heated/boiled up to a temperature of 72⁰C at the pH maintained around 5.2 to 5.4. In
order to avoid the growth of micro-organisms and inversion of sucrose lead to sugar losses.
Weighed raw juice after addition of required dose of Phosphoric acid (P2O5) is heated. The
juice after boiling in boiling house is sent to the sulphitation process for further operation.
The juice received from mill house is pre-heated in the juice heaters to about 70o
C
remove excess water content present in it. Provided with the heating surface of about 300 M2
and 670 M2
and has 560 to 820 tubes present in it the juice is heated by the super-heated steam
providing the vacuum medium inside the heaters respectively.
Juice heating media is either exhausting or vapour. Generally raw juice is heated in two stages
1. First stage: juice is heated upto 30 degree to 45 degree using vapors
2. Second stage : juice is heated upto 45 degree to 72 degree using vapors

6. JUICE SULPHITATION AND SYRUP SULPHITATION:
i. Juice And Syrup Sulphiters:
 Installed year : 1999 and 2006
 Technical specification of juice Sulphiters :
 Technical Specification Of Syrup Sulphiters:
Numbers 1 No. Old 1 No. New
Working capacity 15 m3 26.027 m3
Dia X height 3.57 meter X 2.7 meter 4.7 meter X 2.7 meter
Height 1.5 meter
Type Continuous syrup Sulphiters
It is the first stage where the juice which is dark and opaque in color. After heating raw
juice is then sent to sulphitation tank in this tank Milk of Lime and SO2 gas are added and
final pH of around 7.0 is maintained. The sulphitation tank is cylindrical vessel juice from the
re-absorption tower is entered in this tank from the bottom. SO2 gas is bubbled in juice from
the bottom. The over flow of the treated juice is collected in the receiving tank on the ground
floor, the capacity of the sulphitation tank should be suitable for 7 min to 8 min retention time
of the juice in order to have proper mixing of MLO and sulphur-di-oxide gas with suitable
stirrer provided with motor arrangement
Sulphiters 1 No. (Old) 1 No. (New)
Type Continuous Continuous
Diameter X height 4.68 meter X 2.7 meter 5.8 meter X 2.7 meter
Working volume 46.45 m3
71.34 m3
Circulation arrangements Mechanical stirrer Mechanical stirrer
Stirrer RPM 24 24

There are different methods of addition of these two chemicals
1. Pre liming at 72o
and pH-7 is maintained and liming and sulphiting is done
simultaneously.
2. Shock liming and pH of 9.5 to 10 is maintained fallowed by neutralization of SO2.
Finally treated juice is heated to 102o
C and is sent to Clarifier for mud settling here
the microprocessor based automatic pH control system is used for maintaining the final pH
accurately at the desired set point.
Action of sulphur dioxide on juice
 Eliminates coloring matter
 Reduces to colorless compounds
6.1 So2 Gas Production:
i. Sulphur Burner
 Year of installation : 1999 and 2006
Type Film Type- 1 Film Type-2 Continuous
Make Digital Utilities Radiant Vishwa SPSCL
Numbers 01 01 02 01
Capacity 200 Kg/Hr 300 Kg/Hr 200 Kg/Hr 160 Kg/Hr
Coolers 5 coolers
Utility Juice / Syrup Syrup Juice / Syrup Syrup
 Melter and feeder:
Dry sulphur is melted in melter and molten sulphur is taken into feeder. Both vessels
are steam jacketed (there will be a steam jacket) charging and feeding valves are of gun metal
both the valves should not be kept open at time.

 Combustion chamber /furnace.
Molten sulphur is feed to t6his combustion chamber it is made of cast iron [C.I] and
water jacketed on the top. The compressed air inlet is near the entry of sulphur melt and so2
gas outlet will be from other end. The temperature is around 450 degrees to 550 degrees.
 Coolers:
This comprises of CI pipes with water jacket and used for cooling the hot SO2 gas.
 Scrubber:
It is water jacketed cylindrical tank and packed with bricks gas inlet is at the bottom
and allowed to rise through the layers of bricks to trap the sublimed sulphur the outlet gas
temperature should be 60 to 70 degrees.
 Air dryer and air compressor:
Air drier is required to supply dry air to the compressor the air compressor supply air at a
pressure of 0.6 kg/cm2. And 4.3 kg of oxygen is required to produce I kg of sulphur.
 Preparation of sulphur-di-oxide:
Sulphur melting point is 115 degrees so2 gas is generated by burning sulphur in excess
of air in sulphur burner. The reaction takes place at a temperature of 365 degrees the
temperature of the furnace is maintained around 400 degrees to control the furnace
temperature and water is circulated over top tray of furnace.
S+O2 ------- SO2 + HEAT
The gas generally contains 12 to 16% SO2 depending on the proportion of the air used. The
continuous type sulphur burner is suitable for burning 70 Kgs per hr. of sulphur. Each burner
having a 0.6 sqm burning area. The melting chamber of burner is made of 12mm thick MS
plate. The combustion chamber is 16mm thick. The burner connects with electric motor drive
stirrer, water jacket counter current cooling arrangement for the vertical gas, pipe, scrubber
etc. SO2 lime from the entire burner is installed so that both syrup and juice could be sulphited
from any of the furnace either separately or jointly.

6.2 Lime Preparation Unit: Milk Of Lime Plant
 Installed year : 1999
a) LIME SLACKER
Number : 1
Type : Horizontal rotary
Rpm : 6.375
Capacity : 2000 Kgs/hr.
Lime grit separator : Hydro cyclone grit separator
Flow rate : 1.7 liters/second
b) VIBRATORY SCREEN FOR MILK OF LIME
Number : 2
Model : RGVB - 72
Screen size : 72 Inch
Screen mesh no. : 20 X 26 SWG
c) M.O.L PUMPS
Number : 3
Make : KIRLOSKAR
Type : KPD 40 / 26 QF
Capacity : 18 m³/hr
Head : 20 meters
Motor : 3 HP
 Operational information
 Lime: it is used universally in cane sugar industry as a juice clarificant. In India we
use a lime having an active CAO content of more than 75% lime used for clarification should
be fresh. High degree of purity and free from grit (Un-burnt lime)& stones
 Lime slacker:
The equipment used for the preparation of Milk of Lime is called lime slacker it is
cylindrical M.S drum revolving at about 6 RPM provided with baffles on the inner side of the
drum. The baffles move the lime in forward direction at the same time allowing lime for
slaking

 Preparation of Milk of Lime
Fresh lime is charged in rotary slacker and just sufficient quantity of hot water is added
to the charged lime by the smooth carry forward to0 the discharge side the MOL is discharged
at other end the un-slaked pieces of lime stone are lifted by mechanisms and discharged
outside. The MOL emerging from the slacker contains grit and un-burnt pieces of lime It has
to be strand through mesh fixed at the discharged into storage tank where final dilution is
carried out.
6.3 Steam Generating Unit
Numbers : 02
Make : Vishwa
Type : Electrical
Capacity : 200 Kg/Hr

7. CLARIFICATION:
 Installation year: 1999, 2006
Numbers 1 (Old) 1 (New)
Type 444 444
Make Universal Heavy Engg Saharanpur(UP) SPSCL, Siddapur
Dia 36 ft. 40 ft.
Compartments 4 4
Volume 576 m3
7103
The factory has two 444 clarifier one is of 36 feet and other is of 40 feet diameter.444-
Door type. This 444- Door consists of one flocculating chamber at the top and 4 juice
compartments, each compartment consist of mud draw and juice overflow line. The treated
juice after heating upto 102C – 105C is fed into the flocculating chamber of the Door
through a flash tank. The flash tank is provided with a U-shaped outlet which connects the flue
chamber to reduce the velocity of the juice which otherwise will disturb the settling in the
clarifier.
Treated juice enters the clarifier through the flash tank, when the isolation valve in the
control. Shaft of the second, third and fourth compartment successfully when the juice in the
Door reaches the overflow level it can be converted to work as 444 Rapi-Dorr single Dorr by
closing isolation valve.
When the clarifier is working (fed continuously mud will settle in all the
compartments. Mud can be drawn from the compartments simultaneously. The advantage of
working the clarifier 444 as Rapi-Dorr single Dorr is to get a clear and brilliant juice.
In the case of liquidation of juice from the clarifier the 444-Dorr should be converted
into single Dorr. There is a central shaft being rotated by a drive mechanism. The central shaft
is connected to the arms of each compartment which have scrapper blades to scrap thick mud
settled without disturbing the clear juice. The mud and clear juice are drawn from the clarifier
by overflow. The clarity and the color of the clean juice is good and the juice is of golden
yellow color.

During shut down Milk of Lime is added to the clarifier to maintain the pH of clear
juice at 7.0. Formaldehyde is also added to minimize the sugar loss in clear juice due to
inversion. Though the treated juice is heated upto 105C the temperature of clear juice coming
out of the clarifier is only 96-98C. The drop in temperature is more than normal.
Vent pipes are provided (3”) to all the compartments apart from the vapour releasing
pipe from the flocculating chamber to the atmosphere. An inclined chute of (5 to the
horizontal) 1½ feet width and fleet weight is connecting mud overflow box and the
flocculating chamber to remove the form and other suspended materials if any the cylindrical
portion and perfectly lagged. All the juice and mud drawl pipelines are also protected with
lagging material.

8. EVAPORATORS : EVAPORATOR BODY
A. Evaporator’s Arrangement & Vapour Bleeding System
Body No. 1 2 3 4 5
Effect Quint-I Quint-II Quint-III Quint-IV Quint-V
Heating surface m² 4500 2750 X 2 900 X 2 900 X 2 350X 2
Vapour bleed to
Quint-II
SJ-II
heating
Quint III
SJ-I
heating
Quint–IV
RJ-II
Through
Dy.Juice
Heater
Quint –IV
RJ-I,
Through
Dy. Juice
Heater
Condenser
Body height above
Calendria (mm)
6500 6000 4000 4000 5000
Dia. Of vapor
Pipe (mm)
1400 1200 500 550 900
SS tube sizes (mm) 45OD*5000L*16 SWG 45OD*2000L*18 SWG
No. of tubes 6572 6860 X 2 3420 X 2 3420 X 2 1350 X 2
Spare bodies 1600 & 1500 900 m² 710 m² 350 m²
Evaporation is performed in two stages: initially in an evaporator station to concentrate
the juice and then in vacuum pans to crystallize the sugar. The clarified juice is passed through
heat exchangers to preheat the juice and then to the evaporator stations. Evaporator stations
consist of a series of evaporators, termed multiple-effect evaporators; typically a series of five
evaporators. Steam from large boilers is used to heat the first evaporator, and the steam from
the water evaporated in the first evaporator is used to heat the second evaporator. This heat
transfer process continues through the five evaporators and as the temperature decreases (due
to heat loss) from evaporator to evaporator, the pressure inside each evaporator also decreases
which allows the juice to boil at the lower temperatures in the subsequent evaporator. Some
steam is released from the first three evaporators, and this steam is used in various process
heaters in the plant. The evaporator station in cane sugar manufacture typically produces syrup
with about 65 percent solids and 35 percent water. Following evaporation, the syrup is
clarified by adding lime, phosphoric acid, and a polymer flocculent, aerated, and filtered in the
clarifier. From the clarifier, the syrup goes to the vacuum pans for crystallization

9. VACUUM PANS:
 Make : Extract engineers Dharwad and SPSCL siddapur
 Installation year : 1999 and 2004
After Sulphitation of syrup, the syrup is subjected to vacuum pan boiling process. The
pan boiling essentially consists of the removal of water by evaporation in single effect vessel
known as vacuum pan &crystallizing out sugar by increasing the concentration. The function
of vacuum pan is to produce & develop sugar crystals of desired size from syrup or the
molasses known as mother liquor.
 Height of pans: The Massecuite level above the top level tube plate of the pan should
not be more than 1.5 meter A vapour space equal to 85% of the maximum height of the
Massecuite above the top tube plate to the provided.
 In-condensable gases: For better heat transfer the removal of non-condensable gases
from vacuum pan Calendria is essential
 Syrup for molasses unit:
Feeding to the pan is made by a pipe terminating in the center near the bottom.
Numbers 5 1 1 2 1
Capacity 80 MT 100MT 120 MT 35 +30TPH 40 TPH
Duty for boiling
03 Pan „A‟ Boiling,
01 Pan „C‟ Boiling,
01 Pan „C & B‟
Graining
„A‟ Boiling
„B‟ Boiling „C‟ Boiling
Type Low head Calendria Continuous
Heating surface 380 m2
466 m2
584 m2
700+600 m2
1320 m2
S/V Ratio 6.9 6.9 6.9 10.5 9: 5
Number of tubes 1520 2186 2740 2688 3720
Size tube in mm 102 OD X 850 L X16 SWG 102 OD X 900 L X16 SWG
Vapour pipe 1400 mm diameter 1500 mm diameter 1200 mm
Strike capacity 540 HL 660 HL 760 HL ----

 Discharge valve:
The discharge valve of a vacuum pan is provided for dropping Massecuite after
completion of the boiling.
10. CONDENSTION PLANT :
 Make : Spray Engg. Devices. Chandigarh
 Numbers : 14
 Type : Single entry
A PAN:
Sl Particulars A PANS
01 Capacity 120 MT 100 MT 80 MT
02 Steam condensing 33 27 15
03 Diameter 1500 1500 1400
04 Designed vacuum 660 660 660
05 Air ejection 960 720 290
06 Water consumption 1244 1022 648
07 H20 pressure at 350
C 0.2 to 0.3 0.2 to 0.3 0.2 to 0.3
B PAN
Sl Particulars B PANS
01 Capacity 35 30 TPH 80 MT
03 Diameter 1500 1500 1400
04 Designed vacuum 660 660 660
C 0.2 0.3 0.2 to 0.3
C PAN
Sl Particulars C PANS Old Evap. NewEvaporators X 2
01 Capacity 80 MT 40 TPH
03 Diameter 1400 1200 1050 900
04 Designed vacuum 660 660 660 660
C 0.2 to 0.3

11. MASSECUITE CRYSTALLIZER:
Batch type Massecuite crystallizers : 14 Nos
Type Massecuite XLR Capacity Planetary Drive
Stirrer RPM Motor HP
Air cooled A 140 MT X 2 Nos. 1 10
120 MT X 2 Nos 1 10
90 MT X 4 Nos 1 7.5
Air cooled B 90 MT X 3 Nos 0.55 3
Water cooled C 90 MT X 3Nos 0.50 5
Vertical crystallizer : 3 Nos
Number 1 1 1
Duty „C‟ M/c Holding „B‟ M/c Holding „A‟ M/c Holding
Capacity 400 MT 500MT 500MT
Cooling Type Water Water Water
Stirrer RPM 0.27 0.33 0.33
Motor HP & RPM 30 & 1440 7.5 & 1440 7.5 & 1440
Seed crystallizers : 2 Nos.
For Dry seed : Cap-65 MT (stirrer RPM: 1, HP: 7.5)
For B-seed : Cap-40MT (stirrer RPM: 1, HP: 5)
Vacuum Crystallizers : 4 Nos :
a) 3 Nos. (AF-1, B-grain-1, and C-grain-1) 65 MT each (stirrer RPM: 1, HP: 5)
b) 1 No, for A footing 80 MT (Stirrer RPM 1, HP 5)
Crystallization is a process of cooling the Massecuite slowly by stirring nearer
to surrounding atmospheric temperature. Progressive cooling reduces the solubility of
sugar. Continues stirring of Massecuite minimizes the danger of false grain formation.

12. CENTRIFUGAL :
 Continuous Centrifugal Machine:
 Batch Type Centrifugal For A And B- Massecuite Curing:
Number 6 (5 A & 1 B M/C) 2 1
Make FCB/KCP FCB/KCP FCB/KCP
Type Fully Automatic Fully automatic Fully automatic
Basket Size(D*H) 1370 mm*940 mm 1700 mm*1060 mm 1700 mm*1060mm
Drive D.C. drive, 212 HP D.C. drive, 295 HP A.C. drive, 390 HP
Centrifugal Speed 50 to 1200 RPM 60 to 1050 RPM 60 to 1050 RPM
Capacity 1250 Kgs/charge 1750 Kgs/charge 1750 Kgs/charge
No. of cycles/hour 18 to 20 18 to 20 18 to 20
The machine in which sugar crystals from the Massecuite are separated from the
surrounding molasses or syrup by centrifugal force is called centrifugal machine.
Numbers 09 2 2
Make NHEC NHEC Walchandnagar
Model NK-1302 NK-1503 WK-1500
Distribution C' fore worker - 05 RPM-1800 'B' fore worker - 2 No‟s RPM-1550
'C 'after worker -02 RPM-1650
Floating - 01 RPM-1800
'B' fore worker 01 RPM-1800
Drive motor 100 HP 120 HP 150 HP
Basket speed 1600 RPM 1900RPM 2100

The centrifugal machine comprises of
 Pug mills for Massecuite receiving:
The pug mill is a u shaped provided in centrifugal section with constant stirring
arrangement. At 5 to 6 rpm these pugmills are equipped with arrangement to keep the
Massecuite in constant motion the level of Massecuite in pugmills is always kept at about
3/4th
of the vessel so as to provide +ve Massecuite head when charging to centrifugal
machine.
 Transient heaters
For heating low grade Massecuite upto saturation temperature a heat transfer unit used
is called transient heater. A low grade Massecuite is heated uniformly with vapour oblique
steam.
 Magma mixers
The sugar separated from Massecuite after centrifugation is to be mixed with syrup or
clarified juice or hot water to form magma. This is done in magma mixers these mixers are
double padded type.
 Molasses receiving tanks
The molasses receiving tank are of usually one to two cubic meter capacity are of M S
construction the function of these tanks is to receive the molasses from centrifugal machine
and pumps this to huge molasses storage or supply tankers
 Air compressors
For pneumatic controls air compressors with receiver is installed shall be of suitable
capacity and is generally operated at a pressure of 6kg/cm2
to7 kg/cm2
.
 Pumps for magma /molasses
This magma is pumped to a pugmills or sent to seed crystallizers or to Melter
depending upon the boiling scheme with the help of pumps.
 Water wash system
To get better quality of sugar crystals a super-heated steam or a super-heated water is
sprayed for washing

 Construction And Working:
The basket of these centrifugal is in the form of an inverted cone with an angle of 30
and 34o
C, mounted with its axis vertical and driven by 'v' belts from a motor also mounted
vertical. The basket rotates at speed of 1500to 2100 rpm. The Massecuite is heated at 520
C is
fed in to the accelerating cup from vertical zero movement. The Massecuite is gradually
accelerated while it is spreading out to the actual separating surface of the basket. This
completely prevents damage to sugar crystal. In order to reduce the viscosity of Massecuite,
the hot water or diluted final molasses is also added or sprayed with Massecuite for better
centrifugation. This hot water or diluted final molasses prevent the Massecuite from adhering
to surface of basket. The quantity of wash water used is about 35 –50 lit / m3
of
Massecuite ( 2.5 to 3.5 % on mass max. ) with water pressure of 2 kg/ cm2 .
It is specified
that the wash water is to be applied with nozzle( having orifice of 1.2 to 2 mm ) at the
lowest point of basket and it may be extended up by 150 to 200 mm. This length may
vary as it will again depend upon Massecuite viscosity.
The cold Massecuite when reaches near the bottom cone of centrifugal basket, strikes
the bottom plate and it is thrown outwards against the wall of basket and get disintegrate in to
fine stream and this fine stream passes over the working screen of centrifugal force get
separated out and collected in molasses chamber. If required the use of secondary wash water
or steam may be used (This may be done at 4" to 6" distance from bottom of centrifugal
basket.)The angle of basket to horizontal is generally 30o
for B Massecuite and 34o
for C
Massecuite. The speed of centrifugal machine used for B Massecuite is 1500 RPM, while for
C Massecuite 2100 RPM and having a motor 45 KW. Basket is conical with sides at an angle
of 28o
to 34o
from the vertical. Angle is chosen such that Massecuite will climb up basket
screen under the influence of centrifugal force. The thickness of Massecuite layer is very
small i.e. 2 to 5 mm and at the discharge it almost equal to the dimension of biggest
crystal. Sugar is discharged over the top lip of basket whereas molasses flows through filter
screen and out of inner casing via a molasses discharge pipe. There is stationing baffle or seal
arrangement close to basket top lip to prevent remixing of molasses and sugar within the
casing. Filter screen is located on a backing mesh in similar way to that of batch Centrifugal.
Drive mechanism is simple belt drive. Basket speed ranges between 1500 to 2100 rpm with
basket diameter from 1000 mm to 1500 mm (39" to 59").

13. HOPPER
Number 3 3+3
Type Grass hopper,
1 No. single tray, 2 Nos. multi tray
Grass hopper,
1 No. single tray, 2 Nos. multi tray
Size 1800 mm widthx12000mm long-each 2000 mm width X 11000mm long-each
Drive 20 HP for each Hopper 25 HP for each Hopper
It is a tray like device mounted horizontally below the centrifugal machine
provided with the cooling arrangement called fans the main function of the hoppers is
to dry the sugar crystals received from the centrifugal machine and to separate the pure
sugar crystals form the hard dust particles.
14. SUGAR ELEVATOR:
Numbers 5 1
Type Bucket type with belt, centrifugal discharge
Capacity 40 T/hr .each 35 T/hr. each
Utility
02 Between Hopper and Grader
03Between grader and silos
Between Hopper and Grader
The elevators are the vertical columns provided with sucking arrangement that
pumps and lifts the dry cooled sugar crystals from the hopper to the grader which is at
the topmost layer normally above the silo level. Normally 15 meters above the ground
level.
 Lifting from hopper to grader: That lifts 115 tons per hours the sugar
through centrifugal discharge system
 Lifting from grader to silos : this conveys the sugar form grader to silos with
a capacity of 115 tons/Hr through bucket type belt system

15. SUGAR GRADER :
Specifications of Sieves used
Grades Rori M-30 S1-30 S2-30 Dry Seed
Sizes 05 08 12 16 , 18 28
This is a device that separates the sugar crystals based on the size of the sugar crystals
namely Large, Medium and Small provided with the suitable sieves installed in the grader
house and the whole arrangement is installed at the top above the silo layer.
16. SUGAR SILOS :
 Make : Shrike, Pune
Number : 3 Nos.
Type : Cylindrical G.I. Bins.
MOC : GI corrugated plates
Capacity : 2 Nos.200 Tons holding capacity for S1 & S2
1 No. 100 Tons holding capacity for M-30.
The sugar separated from the grader of all size is send separately to the individual silos
these silos are the dry sugar storing containers with the huge size for the storing of sugar
provided with good hygienic condition. There are separate silos for different size of sugar
crystals. These are made from G.I Corrugated Plates of cylindrical in size. Which are
mounted/installed at the height of about 7 meters above from the earth surface These silos has
a sugar holding capacity of 200 tons of sugar each.
Each silo is specifically engineered to withstand seismic forces, environmental
changes, wind loads etc. Welded silos can be fabricated using skirt, leg or structural support.
Numbers 3 2
Type Mogensen, model SL-1566 Mogensen, model SL-3608
Make International Combustion, Hyderabad
Capacity 15 T/hr. each 35 T/hr.

18. WEIGHMENT AND PACKING :
Numbers 2 Nos. for S1 & S2. 4 Nos for S1& S2. 2 Nos. for M-30
Make Chronos Richardson India Read Midway Hi-Tech Engineers, Chennai.
Type
E-55 Full load cell
weigher
E-55
Mettler-Toledo Controller
(2 load cell)
Capacity 25Kgs to 100kgs adjustable
Here the sugar is weighed and packed accordingly with separate weighing and packing
arrangement is provided for different sugar silos the sugar is first weighed and packed as per
the market requirement. It is automated type weighing machine. That weighs the sugar of 25
kg, 20kg and 100 kg as per the requirement.
The “PLC based weighing automation” system is used here to perform the above
operation which is efficient.

v. DETAILS OF STEAM GENERATION UNIT
A. SPECIFICATION OF THE BOILER
BOILER I AND BOILER II: IGSEC JOHN THOMPSON LTD. (IJT)
Numbers 2 boilers
01 Make IJ T Delhi
02 Working pressure 66 Kg/ Cm2
03 Steam generating capacity 50(TPH) each
04 Steam temperature 485  5( 0
C ) each
05 Heating surface 3000 sq. Meter
06 Grate area for bagasse & coal 25.9sq.meter
07 Soot blowers 0 2Long Rectangular Soot Blower,
06 Rotary soot blower
08 Super heater heating surface 417 sq. Meter
09 Feed water pumps 03 No‟s
Capacity 63m³/hr. Each
Head 983 Mtrs
Motor 250 KW
10 Boiler water treatment 2 No‟s RO each of 20 m³/hr.
11 Economizer Type Integral
Heating surface 1242 sqmtr. Counter flow
Feed water heater --
12 Auxiliary fuel Coal burning for Boiler No.2
13 Chimney 1Nos
Type R.C.C. Chimney
Numbers 1
Height 54000 mm
Dia 3060/3610mm
14 S.A. fan 2 No‟s ( one for each boiler )
Capacity 8.9 m3
/ Sec
Motors 150 HP, RPM – 1430,

15 Pneumatic Air Fan 2 No‟s (one for each boiler.)
Capacity 3.2 m3
/ Sec
Motors 50 HP, RPM – 2955
16 Induced draft fans 2 No‟s
Capacity 62 m3
/ Sec
Motors VFD type 350 HP, 960RPM, Balanced draft,
17 F. D. fans 2 Nos. 125 HP Balanced draft
Capacity 32.5 m3
/ Sec
Motors VFD type 125 HP, 960RPM, Balanced draft,
18 Gas Burner 1 No of 500cu.m/hr each boiler
BOILER III: S S MAKE
Numbers 1
01 Make SSE, Pune
02 Working pressure 67 Kg/ Cm2
03 Steam generating capacity 120 TPH
04 Steam temperature 510  50
C
05 Heating surface (m2
) 6610
06 Grate area for bagasse & coal (m2
) 57
07 Soot blowers 04 Long Rectangular Soot Blower,
10 Rotary soot blower
08 Super heater heating surface (m2
) Primary-740 Secondary-400
09 Feed water pumps 3 + 1
Capacity 75 m³/hr + 25 m³/hr
Head 920 + 950
Motor 300 KW + 132 KW
10 Boiler water treatment 1 No, RO followed by DM 30m3
/hr
11 Economizer Type Integral
Heating surface 1930
Feed water heater --
12 Auxiliary fuel --

13 Chimney
Type RCC chimney
Numbers 1
Height 74000 mm
Dia 4660/5260 mm
14 S.A. fan 2 No‟s
Capacity 18 m3/sec
Motors VFD & Damper control 202 KW X 1440
15 Pneumatic Air Fan 1 No
ii) Capacity 6 m3/sec
Motors 110kwX1440
16 Induced draft fans 2 nos
i) Capacity 56 m3
/ Sec
Motors 187kwX1440 Damper control
17 F. D. fans 2 Nos
i) Capacity 28 m3
/ Sec
Motors 110 KW X 1440 Damper control
18 Gas Burner 1 No of 500cu.m/hr
B. OPERATIONAL INFORMATION
Definition of boiler
It is defined as a closed metallic vessel in which water is converted into steam above
the atmospheric pressure by the application of heat generated by the combustion of fuels.
Definition of boilers as per IBR (Indian Boiler Regulation) act 1923
According to IBR Boiler is a closed vessel having the holding capacity 22.75 liter of
water & pressure 3.5 kg/cm² and above is used for steam generation under pressure, having
installed mountings. At a feed water PH of 8.5 to 9.5.

i. BOILER AUXILIARIES
Accessories are devices which form an integral part of an industrial boiler but are not
mounted on it. Accessories help in controlling and running the boiler efficiently.
 Air Pre heater:
It is a device in which the waste heat of the flue gas is utilized for pre heating the air
supplied for the combustion of the fuel in the furnace or to recover heat from exhaust flue
gases which increases the thermal efficiency of the boiler by reducing the useful heat loss in
the flue gas.
 Economizer :
It is a device in which the waste heat of the flue gas is utilized for pre heating the air
supplied for the combustion of the fuel in the furnace and economizer is a mechanical device
which is used as a heat exchanger by preheating a fluid to reduce energy consumption. In a
steam boiler, it is a heat ex-changer device that heats up fluids or recovers residual heat from
the combustion product. The feed water from the high pressure heaters enters the economizer
and picks up heat from the flue gases after the low temperature super heater.
 Super Heater:
A super heater is a device used to convert saturated steam or wet steam into dry steam
used in steam engines or in processes, It is integral part of boiler and is placed in the path of
hot flue gases from the furnace. The heat recovered from the flue gases is used in superheating
the steam before entering into the turbine Generators (i.e., prime mover). Its main purpose is
to increase the temperature of saturated steam without raising its pressure.
 De-Super heater:
If accurate control of the degree of superheat is required, as would be the case if the steam
is to be used to drive turbines, then an attemperator (de-super-heater) is fitted. This is a device
installed after the super heater, which injects water into the superheated steam to reduce its
temperature. In steam boiler, desuperheater can be known as attemperator which has function
reduce and control temperature of superheated steam. Temperature of superheated steam must
suitable for turbine generator. If temperature of superheated steam is overheated,
De-super-heater will sprays amount of water from steam boiler feed water pump into
steam flow to reduce its temperature.

 Boiler feed pump:
Water feed to boiler is known as feed water. It is collected in feed water tank and pumped
to steam drum via feed pump. The pressure of feed pump is so chosen that the water shall
enter to drum against the steam pressure in the drum. The pumps are generally multistage
centrifugal type and reciprocating pump driven by electric motor
 Injector
It is used to feed water in the boiler. It is commonly employees for vertical boiler and
does not find its application in large capacity high pressure boilers. it also uses more space is
not available for the installation for feed pump.
It consists of spindle, a steam cone, a combine cone, a delivery cone and a handle
the lower end of the spindle works as the valve and the upper end is fitted with the handle. The
rotation of the handle causes an upward or downward movement of the steam cone.
 Steam separator :
A Steam separator, sometimes referred to as a moisture separator, is a device for
separating water droplets from steam. The simplest type of steam separator is the steam dome
on a steam locomotive. Stationary boilers and nuclear reactors may have more complex
devices which impart a "spin" to the steam so that water droplets are thrown outwards by
centrifugal force and collected.
 Fans (Mechanical draught systems)
 F.D fan: F.D fan is placed after the APH & its air comes through the APH at the
furnace bottom. It is used to supply fresh air (O2) to combustion of fuels inside the furnace
 I.D. fan: I.D fan is placed between Electrostatic Precipitator & chimney which is used
to induced the draught through chimney from the Electrostatic Precipitator. i. e. used to out the
flue gas into the atmosphere by the chimney.

 De-aerator:
A De-aerator is a device that is widely used for the removal of oxygen and other
dissolved gases from the feed water to steam-generating boilers In general dissolved oxygen in
boiler feed waters will cause serious corrosion damage in steam systems by attaching to the
walls of metal piping and other metallic equipment and forming oxides called rust.
Dissolved carbon dioxide combines with water to form carbonic acid that causes further
corrosion. In most boiler systems the de-aerators are installed to remove oxygen down to
levels of 7 parts per billion by weight (0.005 cm³/L) or less as well as essentially eliminating
carbon dioxide.
 Chemical dosing pumps:
The boiler supplied with two chemical dosing systems one for high pressure dosing
and other for low pressure dosing. Each mixing tank rubber linings from inside and fitted with
motorized stirrer and complete with piping and fittings. The chemical dosing system
equipment located near feed water station on the ground floor.
 Soot blowers:
The boiler supplied with chemical dosing system one for high pressure dosing and
other for low pressure dosing. Each system consist of chemical proportioning tanks, two nos.
positive displacement type dosing pumps (one as standby), valves and measuring instruments.
Each mixing tank rubber linings from inside and fitted with motorized stirrer and complete
with piping and fittings. The chemical dosing system equipment located near feed water
station on the ground floor.
ii. BOILER MOUNTING
These are the fitting, which are mounted for its proper and safe functioning. Though there
are many type of boiler mounting yet the following some important as below
 Water level indicator
This is a sensor fitted to the boiler drum to indicate the water level present in the drum
of the boiler. It is recommended that the drum level must be always 50%. To maintain the
water level the sensor is fitted.

 Pressure gauge :
A Bourdon tube type pressure gauge is the simplest form of PG it consist of a C tube
bent into an arc circle of 270 degrees, the tube is provided with the pressure inlet at the
bottom of the tube. Pressure gauge is fitted to the steam pipe line to measure the stem
pressure flowing through it.
 Temperature sensors :
Temperature sensors or Resistance Thermometer Detector (RTD) are the devices used
to indicate the temperature rating of the feed water as well as steam here a 3wire pt100
temperature sensors are used . It has very high temperature range about -200 to 600°c. It will
continuously give the signal to PLC/DCS
 Safety valve:
These are the devices attached to boiler chest for preventing explosion due to excessive
internal pressure of steam. A steam boiler is usually provided with two safety valves. In brief,
the function of safety valve is to blow off the steam when the pressure of steam inside the
boiler exceeds the working pressure.
 Stop valve :
The supply of steam to the turbine generators generated in the boiler can be regulated
by the stop valve and this stop valve is made of cast iron. This spindle passes through a gland
and stuffing box the boiler pressure acts under the valve so that the valve must be closed
against the pressure. Here the non- return valve is fitted to avoid the reverse flow of steam
back to the boiler that may cause serious hazard to the system.
 Feed check valve :
It is non-return type of valve fitted to the screwed spindle to regulate the lift. Its
function is to regulate the supply of water which is pumped into the boiler, by the feed pump.
These valves must have its spindle lifted before the shell slightly below the normal water level
of boiler.

 Blow off cock:
The blow-off cock is fitted at the bottom of boiler drum and consists of conical plug
bears on the packing.
The principle of blow-off cock is
 To empty the boiler whenever required
 To discharge the mud, scales or sediments which are accumulated at bottom of the
boiler.
 Fusible plug:
It is fitted to the crown plates of the furnace. The main objective of fusible plug is to
put off the fire furnace of the boiler. When the level of the water in the boiler falls to unsafe
limits and thus avoids the explosion which may take place due to overheating of the furnace
plate.
Working of the boiler.
The water flow inside the tube & firing takes place surrounding of the Water tubes
these types of boilers are called water tube boiler.
In water-tube boilers the rack of tubes are positioned vertically in the furnace and
water flows through these tubes which gets heated, these vertical pipes are called risers and
these extends from the water drum which is at the bottom of the boiler to the steam headers
which are at the top of the boilers. These typically surround the fire box in many layers like a
dense forest. As steam bubbles form they rise through the steam drum, where the steam exits
through the steam header. There exist a mono-tube boiler pump is used to circulate water
through a succession of coils this type of boiler has very fast production of steam but has very
less storage capacity. Water tube boilers are preferred for the high pressure application
because of the high pressure steam/water is contained in smaller diameter pipes which
withstand the high pressure.
Fuel used in boilers
There are different sources of heat for the boiler. Source of heat can be natural gas,
wood coal or oil. Nuclear fission is also used as a source of heat for steam generating. Our
source of fuel used in our cogen plant is a Bagasse and coal.

vi. MILL DRIVES AND POWER TURBINE DETAILS:
A. MILL DRIVE DETAILS :ELECTRIC MOTORS
i. Purpose :
The purpose the mill drives are used to run the mills in the milling tandem at the
required speed in RPM usually individual drives prefer to each mills and the mill drives
are of DC motors these drives run on DC power supply generated by the turbine generator
in plants cogen itself.
ii. Technical specification:
 Drive Make :ABB Make
I Mill (SSE) : ABB motor,
Type : VFD Drive 01No,
HP : 1000KW
RPM : 1000 RPM
II, III, IV & V Mill Krupp Mill : ABB motor,
Type : D.C Drive 4 No
HP : 750 HP each
RPM : 1000 RPM Shunt Motors
VI Mill (SSE) : ABB motor,
Type : VFD Drive01No
HP : 600KW
RPM : 1000 RPM
The Electric drives are used to run the individual mills and these all 6 drives are DC
drive /VFD Drive that runs by the DC power supply but prabhu sugars only DC drives are
used but here mill T G sets are not used here. Mills run by DC drive through individual
planetary gear box system provided that reduces the speed from 900 RPM to 7 RPM.

B. GEARBOXES
 Make : Elecon gears systems(All 6 mills)
Premium Gears (TRPF of VI Mill)
 1st
SSE Mill : 1 No,
 Type : A40/BZ2 X 71,
 Ratio : 48.669/1
 Krupp Mill Gear Box : 4 Nos.
 Type : SCN 710
 Ratio : 56:1
 6th
SSE Mill : 1 No, (Planetary gear box)
 Type : SA-280/PCF0-170,
 Ratio : 400/1 PGLS 03, Sl no: WHG953127SP
 TRPF : 1 No, (Planetary Gear box)
 Type : P41310/Sl No. HG-14381
 Ratio : 250/1
C. ROLLER SPEED
1st
Mill : 4.31 RPM
2nd
Mill : 5.31 RPM
3rd
Mill : 5.31 RPM
4th
Mill : 5.31 RPM
5th
Mill : 5.31 RPM
6th
Mill : 2.00 RPM

D. GEAR ARRANGMENT
SSE Mills : 1 set mill
Pinion : 40M, 29T, 700FSW
Gear : 40M, 138T, 700FSW
: 1 set GRPF
Pinion : 30M, 61T, 400 FSW
Gear : 30M, 86T, 400FSW
Krupp Mills : 4 sets.
Pinion : 39 TEETH, 30 M, 600 FSW
Gear : 130 TEETH, 30 M, 600 FS
From1st
mill, to 5th
Mills have the helical gear box & worm wheel master gear boxes
Last 6th
Mill top Roller & pressure feeder have a Planarity gear box system are used.
Individual gear boxes are used for all mill drives. These gear wheels are of typically 30
to 130 Teethed gears. These gears are used to reduce the speed of the drive and to adjust the
speed of the mill drive in RPM. The speed is decided based on the crushing rate of the mill.
Usually the speed of the drive is about 1000 RPM so the arrangement called planetary gear
box is installed with the mill drive to run the mill smoothly to perform the required crushing
rate.

E. POWER TURBINES:
 Purpose :
The purpose of power turbines or steam turbines in the power house is used to generate
the power supply from the steam. The steam itself is a super-heated steam. And to operate the
machines may be the mill drives. And all power/steam consuming equipment in the factory.
Particulars T.G.- I T.G.- II T.G.-III T.G-IV T.G –V
Name of manufacturer BHEL
Jinma
Turbine
Worthington
Turbines
Pentagon
Turbines
Arani
Powers
Type Condensing
Back pressure cum uncontrolled
extraction
Triple
Extraction
&Condens
in
Turbine normal rating 6000 KW 11500 8000 2500 27000
Turbine speed RPM 9000 6000 5518 7562 5400
Inlet Steam pressure 63 Kg/cm2
65 Kg/cm2
Inlet steam temp o
C 480 480 480 480 480
I/L steam flow Kg/hr 23140 66860 56000 22000 153600
O/L steam flowKg/hr 23140 60489 56000 22000 107810
No of stages 21 07 10 3 -
1) Impulse 14 07 -- 1 -
2) Reaction 07 0 -- 2 -
Max Steaminlet Kg/hr 25000 66860 56000 28000 154000
GEAR BOXES:
Manufacturing WIL, Pune
Nanjing Triveni
Mysore
Pentagon
Bangalore
Triveni
Mysore
Type Helical
Double
Helical
Double
Helical
Single
Helical
Double
Helical
Rating KW 6600 13200 8000 2500 27637
Gear Ratio 9000/1500 6000/1500 5518 / 1500 7562 / 1500 5400/1500
Governor make Woodward 505 Woodward Woodward

Max I/P Steam pressure 64Kg/cm2
63Kg/cm2
63Kg/cm2
65Kg/cm2
64Kg/cm2
Exhaust steam pressure 0.1 2.6 2.5 Kg/cm2
Ext -5:6 Ext -5:6
Exhaust steam Temp 36o
C 141 o
C 141 o
C 160 o
C 160 o
C
ALTERNATORS:
Sl Particulars T.G.- I T.G.- II T.G – III T.G – IV T.G – V
01 Make BHEL TDPS Andritz Hydro
02 Type Synchronous
03 Capacity KVA 7500 15000 10000 3125 33750
04 Rated Volt 11000 11000 11000 415±5% 11000
05
load current A
394 787 525 4348 1771
06 Frequency 50 Hz
07 Power factor 0.8 0.8 over excited 0.8
08 RPM / pole 1500 / 4 1500 / 4 1500 / 4 1500/4 1500/4
09 Excitation method Brush less
10 Excitation Voltage 139 148 143 138 207
11 Excitation current 450 517 398 194
12
Insulation class of
Rotor/stator
F-class
13 Output rating 6000 11500 8000 2500 27000
14 excitation voltage 108 111.8 154 103 193
15 excitation current 3.6 3.7 4.5 7..2 2.7
 Operating information:
Steam Turbine:
It is a Mechanical Revolving device which is converts steam energy into rotary energy,
it is called steam turbine. It is also referred to as a prime mover. When the superheated steam
from the boiler with a certain high pressure hits the turbine rotors blades gets rotated in the
direction of steam flow.

Basically steam turbine works on
 Rankin cycle
 Carnot cycle
 Brayton cycle
Turbine working layout:
1. Pressurized and superheated steam to set conditions from Boiler generally:
 Temperature of 485+ deg C*
 Pressure of 63 kg/cm2
*
 Steam passes through a series of protection valves
 Main isolation shuts down the system in an emergency
 Governor valves regulate the inlet steam for consistent operation.
2. Steam enters the HP (high pressure) turbine through nozzles.
*
Mechanical energy is generated by the steam passing over a series of fixed and rotating
blades. Fixed blades on the stator guide steam through the rotor blades, causing the rotor to
turn. The steam expands and cools as it moves through the blades. Steam leaves at a reduced
pressure and temperature, approximately
3. Steam re‐enters the boiler through a dedicated „re‐heat‟ system. This raises the steam
back to inlet temperature, but does not change pressure.
4. Re‐heated steam enters the IP (intermediate pressure) turbine under the re‐heated
conditions, approximately:
*Steam exits the IP turbine through the ‘cross over pipe.
5. Steam from the cross over pipe enters the center of the LP (low pressure) turbine at a
further reduced pressure and temperature, approximately:
 Temperature of 350deg C

 Pressure of 9-10 kg/cm2
*Steam expands out in both directions along the IP blades. By the last set of blades, the steam
has lost enough energy that it is no longer superheated.
6. The condenser rapidly cools the steam leaving the LP turbine. As the steam condenses
it vastly reduces its volume, creating a vacuum. Condenser conditions may be approximately
 Temperature of 40 deg C*
 Pressure of 10 kPa (abs)
*This vacuum draws steam through the LP turbine, extracting more mechanical power.
7. Condensed water is passed through a series of pre‐heaters on its way back to the main
boiler. Though it may seem counter‐intuitive to deliberately cool the steam in the condenser
only to re‐heat it again, a more in depth analysis of the thermodynamics and re‐heat process
will show that this increases the efficiency of the system
8. The turbine extracts power simultaneously from the HP, IP and LP rotors. The shaft is
coupled directly to a generator. This outputs 3 phase power to a step up transformer, and
finally the electricity grid.

vii. MOLASSES CONDITIONING UNIT:
a. Need:
These conditioning units are required to preserve the molasses is highly flammable so
it is preserved in a large reservoir tanks provided with the water circulation to maintain the
required temperature the molasses is used to prepare the ethanol or rectified spirit in their
respective distilleries usually the molasses to avoid burning that leads to large losses in
production.
b. Technical specification
MOLASSES STORAGE TANKS
Numbers : 03
Size (D*H) : 80 feet * 34feet
Volume : 4500 m3
FINAL MOLASSES WEIGHMENT & F M STORAGE TANKS
Molasses weighing scale:
Final Molasses storage tanks
Number of tanks : 18 Nos
Capacity : 200 HL each
AL 03 AH 08 BH 04 CL03
Weighing Scale : 01
Type : Dead weight
Capacity/charge : 3 MT

c. Operational information:
Molasses: it is considered has the mother liquor left after removal of sugar crystals in
the centrifugal machine and used as a raw material for manufacture of alcohol it is of dark
brown colored thick semi liquid fluid. Its pH is about 4 to 4.5
These tanks are installed below the vacuum pan or may below batch type centrifugal.
The molasses (mother liquor) is sent and stored to these tanks from the centrifugal. The
molasses coming out the centrifugal machines will be at low temperature and must not contain
any sugar. These tanks preferably rectangular tank of 200 HL. And then it is sent to the large
storage tanks located beside the factory with the proper conditioning for further ethanol and
rectified spirit production.
The tanks made of 10 mm thick mild steel plate duly cross braced at bottom. Molasses
storage tank with steam heating coils with necessary non-return valves, draining arrangement,
pipes, gutters valve etc.
The molasses sent is weighed through dead weights or electromagnetic flow meters to
get the exact flow rate. This system includes Brix control system and temperature control
system for molasses conditioner tanks for each molasses conditioner the system include two
control loops consisting of various control system component as specified.
Recorder: A DEVICE USED TO record the collected data of Brix and temperature of the
molasses received.

VIII. SUGAR GO-DOWN:
a. Capacity
SUGAR GODOWN
Godown Godown I &II Godown III & IV Godown V&VI
Size (L*W*H) 145*98*34 295*110*34 320*200*34
Capacity 1, 00,000 Qtls each. 2,00,000 Qtls. each 4,00,000 Qtls. Each
GUNNY BAGS STORAGE GODOWN
b. Condition for preserving the sugar
The sugar after bagging is stored in Godown here the sugar manufactured are of three
grades has been stored in respective Godown
Godown for Sugar of grades M-30, S1-30 and S2-30
Grades M-30 S2-30 S1-30
Godown 1 & 2 3 & 4 5 & 6
The condition of the go-downs is maintained such that it must be free from moisture. And
it must be located such that it should not get heat due to high temperatures especially in
summer at the end of the season the production is in large quantity and hence the storage space
increases and the risk of storage in summer increases and the roof is provided with high
quality cement/zinc sheets to avoid heat flow in summer and rain water leakage in rainy days
there must me regular inspection about it. Usually the godown floor is 3 feet height above
ground level in the factory site. The sugar bag conveying systems are established to particular
go-downs from the packing section.
Capacity 1000 Bales of 400 each
Size (L*W*H) feet 16*14*11

IX. BY PRODUCTS
a. Distillery Unit:
The distillery unit of prabhu sugars is of capacity of 60 KLPD located next to the
factory site. This distillery unit receives the required amount of steam supply and power
supply from the factory co-gen itself though it does not have its own co-generation system.
The production of ethanol/rectified spirit from molasses in the distillery is as shown in
following steps below
Fermentation: it is a biochemical process in which chemical changes are brought about in
organic substances through the activity of enzymes secreted by micro organisms
Distillation: it is a process of evaporation and re-condensation as separating liquids into
various fractions according to their boiling point
Absolute Alcohol: it is also known as water free ethyl alcohol and it is generally applied to
the pure product containing water upto 1% and its specific gravity is 0.7930
Vaporization: the conversion of chemical substances from liquid/solid into vapour stage
Alcohol: it is the product obtained from the fermentation of molasses
Rectified spirit: it is the distillation product containing alcohol.
Physical properties of ethanol:
 Melting point: -110oC
 Boiling point: 79oC
 Density: 0.79
 Molecular weight: 46.07 gram
Use of ethanol:
Portable liquor, synthetic rubber, nail paints and homeopathic medicines etc

b. Cogeneration:
Our factory Co-generation has three boilers and five turbines generators of different
specifications and the capacity of Co-generation is the 220 tons of steam per hour and 38MW
of power generation among five Turbine Generators only two TG are used to produce the
power of 38MW power generation, another two TG are used in emergency as shown below.
The specification of the boilers and turbine generators in prabhu sugars is shown below
BOILER BOILER I BOILER II BOILER III
Make IJT IJT SSE
Working pressure 66 Kg/ Cm2
66 Kg/ Cm2
67Kg/ Cm2
Steam generating capacity 50 TPH 50 TPH 120 TPH
Steam temperature 485  50
C 485  50
C 510 50
C
T G MAKE TYPE Rated power
I BHEL Condensing 06.0 MW
II Skoda Jinma Turbine Back pressure cum uncontrolled extraction 11.5 MW
III Worthington Turbines Back pressure cum uncontrolled extraction 08.0 MW
IV Pentagon Turbines Back pressure cum uncontrolled extraction 02.5 MW
V Arani Powers Triple Extraction cum Condensing 27.0 MW

1.Cooling tower 10. Steam governor valve 19. Superheater
2. Cooling water pump 11. High pressure turbine 20. F.D fan
3. Transmission line (3-phase) 12. Deaerator 21. Reheater
4. Unit transformer (3-phase) 13. Feed heater 22. Air intake
5. Electric generator (3-phase) 14.Bagasse conveyor 23. Economizer
6. Low pressure turbine 15. Bagasse hopper 24. Air preheater
7. Boiler feed pump 16. Pulverized fuel mill 25. Precipitator
8. Condenser 17. Boilers drum 26. I.D fan
9. I.P turbine 18. Ash hopper 27. Chimney Stack
Description:-
1. Bagasse is conveyed (14) from an external stack and ground to a very fine powder by
large metal spheres in the pulverized fuel mill (16).

2. There it is mixed with preheated air (24) driven by the forced draught fan (20).
3. The hot air-fuel mixture is forced at high pressure into the boiler where it rapidly
ignites.
4. Water of a high purity flows vertically up the tube-lined walls of the boiler, where it
turns into steam, and is passed to the boiler drum, where steam is separated from any
remaining water.
5. The steam passes through a manifold in the roof of the drum into the pendant super
heater (19) where its temperature and pressure increase rapidly to around 200 bar and 570°C,
sufficient to make the tube walls glow a dull red.
6. The steam is piped to the high-pressure turbine (11), the first of a three-stage turbine
process
7. A steam governor valve (10) allows for both manual control of the turbine and
automatic set point following.
8. The steam is exhausted from the high-pressure turbine, and reduced in both pressure
and temperature, is returned to the boiler re-heater (21).
9. The reheated steam is then passed to the intermediate pressure turbine (9), and from
there passed directly to the low pressure turbine set (6).
10. The exiting steam, now a little above its boiling point, is brought into thermal contact
with cold water (pumped in from the cooling tower) in the condenser (8), where it condenses
rapidly back into water, creating near vacuum-like conditions inside the condenser chest.
11. The condensed water is then passed by a feed pump (7) through a de-aerator (12), and
pre-warmed, first in a feed heater (13) powered by steam drawn from the high pressure set,
and then in the economizer (23), before being returned to the boiler drum.
12. The cooling water from the condenser is sprayed inside a cooling tower (1), creating a
highly visible plume of water vapor, before being pumped back to the condenser (8) in cooling
cycle.
13. The three turbine sets are coupled on the same shaft as the three-phase electrical
generator (5) which generates an intermediate level voltage (typically 20-25 kV).
14. This is stepped up by the unit transformer (4) to a voltage more suitable for
transmission (typically 250-500 kV) and is sent out onto the three-phase transmission
system (3).
15. Exhaust gas from the boiler is drawn by the induced draft fan (26) through an
electrostatic precipitator (25) and is then vented through the chimney stack (27).

FLOW DIAGRAM OF SUGAR MANUFACTURING PROCESS SPSCL
PRABHU SUGARS JAMKHANDI KARNATAKA F D 1
CANE WEIGHMENT
CANE
PREPEARTION
BOILER TURBINES
MILLING BAGASSE Steam Power
Generation Generation
MIXED JUICES
JUICE WEIGHMENT TO PLANT
JUICE HEATING @ 70o
C TO K.P.T.C.L JAMAKHANDI
JUICE LIMING & SULPHITATION
JUICE HEATING @102o
C FILTERATE
CLARIFIER MUD JUICE ROTORY FILTER
EVOPORATION CLEAR JUICE
SYRUPH FILTER CAKE
SYRUPH SULPHITATION
VACCUM PANS
“B” SEED MASSECUITE CRYSTALLIZER
“A” MASSECUITE “B” MASSECUITE “C” MASSECUITE
“A” LIGHT “A” HEAVY “B” MAGMA “B” MOLASSES “CF” MAGMA
“C” LIGHT MOLASSES
MELTER “CA” MAGMA FINAL MOLASSES
SUGAR CRYSTALLS TO DISTILLARY
HOPPERS
GRADING
MARKET AND APMC WEIGHING
GODOWN PACKING/BAGGING

SPSCL FACTORY SIGHT PHOTOS
PRABHU SUGARS JAMKHANDI KARNATAKA S P 1

SCHEDULE OF MACHINERY FORM I (1)
PRABHU SUGARS JAMKHANDI KARNATAKA Page 1
FORM-I (1)
SCHEDULE OF MACHINERY
NAME OF THE FACTORY : Shri Prabhulingeshwar Sugars & Chemicals LtD
Siddapur, Tq.Jamkhandi, Dist.Bagalkot.
Karnataka.Tel.No.08353-238004/238146
Fax-238166 / 64, Website: - prabhusugars.com
Regd office : 1st
Floor “SUKRUT”Building,
Opp: K.C.Park, Main Gate, P.B.Road,
DHARWAD-580008, Karnataka
Tel.No. 0836 - 2745036, 2742833, 2743703.
Fax: 0836- 2740305, Website: prabhusugars.com
REGISTERED NO_ OF COMPANY : No 17861 of 1995 Dt 25/May/1995
CAPACITY : 10000 TCD.
SULPHITATION PROCESS : DOUBLE
I. CANE WEIGHMENT UNIT
1.WEIGHING SYSTEM
Make: Avery India Limited, Kolkata.
Particulars Numbers Capacity Platform Size
L X W Meter
Type
Weigh bridges 03 60 MT 16 X 3 Electronic
platform01 40 MT 40 X 1
Cane consists of trash, tops, dirt and soil etc.
Calibration is done by company service engineer, Bangalore

2. CANE HANDLING SYSTEMS
2.1 CANE UN-LOADERS
Make : Extract Engineers (I) Pvt.Ltd, Ahmadnagar.
No of Bridges : 3 Bridges
Numbers : 6 Nos
Number of motions : Two
Capacity : 20 MT. SWL
Height : 14600 mm
Crane gantry span : 27 Meters.
Operating speed : Hoisting & holding – 11 meters/min.
Hoisting drum drive. : 50 HP/960 rpm
Holding Type : Hydraulic de hooking arrangement, 2HP
Cross travel drive. : Cross travel – 20 meters /min. 10 HP/960 rpm.
2.2 FEEDER TABLES
Numbers : 3 Nos
Length x Width : 8 Metre X Metre (64 Metre2
)
Drive (Duel Drive) : 2 X 15 HP
Gearbox ratio : 70:1
Inclination : 3 degrees at rear end
Number of strands : 8 Nos.
Pitch of chain : 150 mm
Chain breaking load : 45 Tons
2.3 HYDRAULIC TRUCK & TROLLEY UN-LOADERS
Make : S.K.S ENGINEERS PVT. Ltd. New Delhi
Numbers : 02 Numbers
Capacity : 40MT
Type : Double frame type
Operating Pressure : 200 kg/cm2
Hydraulic pump capacity : 53 lpm
Motor make : ABB make, 25HP, 1440
Platform size : 3200mm wide X 8900mm long
Angel of tilt (max) : 55 degrees
2.4 CANE CARRIER
Numbers : 1
Width : 2,300 mm = 7.659 feet
Length of carrier : 81000mm (81meter)
Angle of inclination : 2.5 deg
Feeding depth : 1320 mm
Number of Strands : 4 Nos
Four strand chain pitch : 200 mm
Breaking load of chain. : 60000 Kgs.
Drive : VFD drive 150 HP / 1450RPM
Speed : 3-10 meters/min.
Gearbox : SCN-450, 80/1
Make : ELECON
Gear teeth : 108T X 210 FSW X 1” DP
Pinion teeth : 23 T X 210 FSW X 1” DP

3.PREPARATION OF CANE
3.1 CANE KICKER
Number : 01
Final RPM : 72
Clearance between Knives &
carrier slats : 250mm
Swing Diameter : 2200 mm
3.2 CANE CHOPPER
Number : 1
No. of Knives : 48
Final RPM : 300
Gear box : Helical gear box 2:1
Clearance between Knives &
Carrier slats : 1050 mm
Diamter of tip of rotation : 1600 mm
3.3 CANE LEVELER
Number : 1
No. of knives : 60
Drive : 500 HP + 500 HP (Total 1000HP)
RPM : 600
Clearance between Knives tips &
carrier slats : 280 mm to 350 mm (adjustable)
Dia of tip of rotation : 1600 mm
3.4 FIBRIZER
Number : 1 No.
Type : Heavy duty swing hammers
Swing diameter : 2130 mm
No. of hammers : 150
Wt. of each hammer : 22 Kgs
Speed : 750 rpm
Motors (4020HP) : 2 Nos. of 1500 KW each, HT Motor 11KV
Clearance : 100 mm, 20mm

II. MILLING HOUSE DETAILS
4). JUICE EXTRACTION SYSTEM
TOTAL MILLS : 6 MILLS. (2 SSE + 4 KRUPP)
a. MILL NO 1
No of mills : 01
Make : S S Engineers Pune
Size of Rollers : Dia1250 mm X 2300 mm
Speed : 4.31 RPM
Drive : 1000 KW / 1000 RPM DC
b.MILL NO 2
No of mills : 01
Make : M/s.Krupp Engineering, Pune
Speed : 5.31 RPM
c.MILL NO 3
No of mills : 01
Speed : 5.31 RPM
d. MILL NO 4
No of mills : 01
Speed : 5.31 RPM
e. MILL NO 5
No of mills : 01
Speed : 5.31 RPM
f. MILL NO 6
No of mills : 01
Make : M/s.S S Engineers, Pune
Size of rollers : 1300 mm X 2300 mm
Speed : 5 RPM
Mill Drive : 600 KW / 1000 RPM AC VFD
TRPF Drive : 200 KW / 1000 RPM AC VFD

INPLANT TRAINING REPORT AT PRABHULINGESHWAR SUGARS

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