Allied-Tek CANE MILL

Allied-Tek Cane Mill_V 5.1 27.07.2012

Cane Roller MillA roller mill for extracting juice from cane sugar with 4 or 6 rolls of which three are crushing rolls, one is underfeed roll and the other two at the same time feeding and pre-crushing rolls. For 4 roller mill, there comprises of three crushing rolls sitting on cheeks in triangular form. The top roll is placed on top position where pressure is applied on, one at the position of cane feeding so called feed roll and there is the delivery roll placed at cane outlet. Underfeed roll is the forth roll being placed in the front of feed roll.For 6 roller mill, there comprises of 3 crushing rolls, two in front of top and feed rolls being for feeding so called pressure feed (PF) rolls and the underfeed roll is placed in the front. PF rolls installed with separated drives from crushing rolls are so called heavy duty pressure feed and light duty pressure feed where they are driven through chain by top and feed roll.

6-Roller Mill

4- Roller Mill

DesignThe latest development at Allied-Tek was in 2010 that an included angle of the 3-crushing rolls has been reduced to 73 degree in order to reduce the length of turner plate as well as the length of pressure feed chute, aiming at better juice extraction as well as lower power consumption. Mill cheeks are modified for higher strength by increasing throat depth as well as placing of stiffeners at the right positions. Corrosion resistant steel, 3Cr12 is clad on inside cheeks' surface at juice contact area. Top caps are redesigned in order to suit for contunous operation up to 220 bars hydraulics pressure being for higher juice extraction as well as lower bagasse moisture. Experiences show that first mill extraction is > 75% while bagasse moisture is in between 47 – 50%.ConstructionMill cheek comprises of two pieces high strength steel plate quality EN S355JR, each is cut from a single piece plate. Fabrication is by low heat input welding process, MAG with mixed shielding gas 82/18 Ar/CO2. The latest welding technology of arc dynamics or forced spray arc which is designed for application root welidng is under practiced for the fabrication of mill cheeks.In combination with proper weld sequencing and furnace stress relieving the produced mill cheek is minimized in distortion and residual stress. Pressure feed cheek is manufactured in the same procedure. Stiffeners are additional placed at sensitive failure areas like top cap and throat of the headstock assuring its strength as well as rigidity.

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Allied-Tek Cane Mill

Single piece cut steel plate for fabrication of mill cheeks

MAG Welding under proper sequencing

Mill Rollers and Journal BearingsCrushing rolls and pressure feed rolls are flangeless type, grey cast iron shell shrink fitted with solid forged steel shaft. Underfeed roll is hollow cast iron shell with end discs and key fitted with steel shaft.

Material for shaft is either forged 28Mn6 or AISI 1030/1035. Top roll is vertically movable by hydraulics at top cap with two accumulators and automatic pressure control. Gauges showing

floating of top roll can be either mechanical or electronic means.

Perforated or Lotus Top Roll is widely used. Side rolls are fixed in positions by side caps and removable pins.

Arcing or roll surface roughening by arc welding with carbide alloy helps in wear resistant and better gripping of cane or

bagasse during feeding.

Rings bolted onto the end of rolls are for passage of juice to juice tray as well as deflecting juice away from roll journal. Side wear plates bolted on inside surface of mill cheek are for guiding cane or bagasse to pass through crushing rolls,fighting against abrasion. Side wear plates are manufactured by weld surfacing of carbide alloys. Journal bearing is of bronze material, LBC-3 with independent lubrication grooves and water cooling system.Bearing for top roll is square half at top position and shell at bottomposition. Side roll bearings are in the opposite way.

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Allied-Tek Cane Mill

Trash Beam and Turner Plate Trash beam and turner plate are of cast steel, machined and

rigidly tightened in position by high tensile steel bolts. The beam is vertically and horizontally adjustable by shims.

Setting of turner plate is by dead eye bearings, linkages and adjusting arms. There developed a technology at Allied-Tek that turner platehardfaced with martensitic and complex carbide alloys attooth side as well as top faces and the whole top surface ofturner plate.

Setting or adjusting of trash beam and plate is conveniently one by loosening and tightening of bolts

Scraper Plates and Scraper Blades

There are, at top and delivery rolls Scraper Plates being for removing off bagasse compacting in grooves of roll.

Teeth of craper plate are hardfaced with Cr-martensitic alloy. Scraper blades are provided at the delivery roll.

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Allied-Tek Cane Mill

Top Cap Cylinder & Piston Experience in Thai sugar mills there happens often leakage during operation. Good results from maintenance service by Allied-Tek, the technology has been applied on the manufacture of new cane mill.

Top cap cylinder is shrink fitted with a hard chrome sleeve.

The piston is by copper bronze alloy welded on frictional area in order to reduce wear due to vertical movements during

operation. Additionally, there are two sly ringsplaced on piston to avoid leaks.

Lubrication and Cooling SystemMill and PF roll journals are grease lubricated by an automatic injection system.Bearings are cooling by water where nipples are provided ready for connection.

Lubrication, a central supply system comprises of air pump, motor and grease drum. Lube tubes shall

copper or stainless steel.

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Mill Drives Today, electric motor is a preferable installation for the reasons of mill crushing flexibility.power saving, working environment as well as maintenance. AC squirrel cage induction motors as well as AC Drives are among other technologies are of most interest.

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Allied-Tek Cane Mill

Standard ModelsAllied-Tek Cane Mill : CM 3771 CM 4179 CM 4587 CM 4790 CM 4995 CM 5313Mill Roller, D x L,mm 950 x 1.800 1,050 x 2.000 1.150 x 2.200 1,200 x 2,300 1.250 x 2.400 1.350 x 2.600CRS, mm 2,680 2,940 3,220 3,340 3,480 .. 3,760

TCD min-max + HF (6-Roller Mill) 3.500 – 7.000 4.500 – 9.000 6.000 – 12.000 8.000 – 16.000 10.000 – 20.000 12,000 – 24,000TCD min-max (4-Roller Mill) 2.500 - 5.000 3.500 – 7.000 5.000 - 9.000 7.500 – 12.000 9.000 –14.000 12,000 – 18,000 Mill Shaft Dia x L, mm 530 x 4,540 570 x 4,950 640 x 5,440 680 x 5,680 700 x 5,880 780 x 6,350Journal Size, DxL mm 460 x 560 500 x 620 560 x 680 580 x 700 620 x 740 680 x 800Bearing Lubrication Points 3 3 4 4 5 5

Top Cap Cylinder Dia, mm 380 (15”) 406 16”) 431 (17”) 431 ( 17”) 457 (18”) 482 (19”)Top Cap Pressure, bars 160 – 240 160 – 240 160 – 240 160 – 240 160 – 240 160 – 240 Top Roll Vertical Movement, mm 30 30 30 30 30 30

Square End x Length, mm 390 x 390 x 300 420 x 420 x 320 460 x 460 x 360 480 x 480 x 380 500 x 500 x 400 550 x 550 x 440Pinion Bore, DxL mm 505 x 520 545 x 560 585 x 600 600 x 625 625 x 650 715 x 720Mill Speed, 1/min 1.0 – 7.5 1.0 – 7.5 1.0 – 7.0 1.0 – 7.0 1.0 – 6.8 1.0 – 6.8 Rated Operating Power, kW Single Drive at Top Roll / PF Roll4 rollers Mill 800 1,000 1,200 1.500 1,650 1,8006 rollers Mill, Mill Roll / PF Roll 800 + 315 1,000 + 400 1,200 + 500 1.500 + 600 1.650 + 630 1,800 + 750UF Roll Driven by Chain ATE 1245 ATE 635 ATE 635 ATE 1620-A ATE 1620-A ATE 6042Individual Drive at Top, Feed, Delivery RollPF Top and Bottom RollTop Roll, kW 400 500 650 800 900 1,000Feed – Delivery Roll, kW 200 - 200 250 – 250 315 – 315 355 – 355 400 – 400 600 - 600PF Top – Bottom Roll, kW 160 – 160 200 - 200 250 – 250 315 – 315 355 – 355 400 – 400UF Roll Drivenby Chain ATE 1245 ATE 635 ATE 635 ATE 1620-A ATE 1620-A ATE 6042** The above installed Power is general recommendation only, actual Power to be installed shall be consulted.

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Allied-Tek Cane Mill