INTERNSHIP REPORT Submitted To:

Engr. Sharif Sahib(Shakarganj mills limited jhang)

Submitted By: Muhammad Nasir Ihsan 06-ME-

100Muhammad shahid 06-ME-

120

DEPARTMENT OF MECHANICAL ENGINEERING

UNIVERSITY OF ENGINEERING AND

TECHNOLOGY,

TAXILA

A little about Shakarganj mills:

Shakarganj Mills Limited was incorporated on September 1967 as a public limited company and listed on Pakistan's bourses in June 1979. The first manufacturing plant was designed on 1,500 metric ton per day crushing capacity (TCD). Over the years the plant capacity was gradually increased and now the company operates from two locations. The current capacity is 12,000 TCD at principal location in Jhang, and 8,000 TCD extendable to 10,000 TCD at the satellite facility in Bhone. In addition a further capacity of 4,000 TCD is being added at Dargai Shah. As the sugarcane consumption increased from increase in capacity, the need for high quality raw material and improved yields at farm level became critical for a sustainable supply chain. Realizing that this is a critical factor for sustainable growth, Shakarganj made substantial investment in research and development. Shakarganj Sugar Research Institute was established by the company in 1983. This is the only private sector research facility in Pakistan working on development of high quality cane varieties. SSRI has introduced a number of new varieties of sugarcane in the country developed by its pioneering scientists. On September 20, 2007 Shakarganj has completed its fortieth year of existence.

The Cane Sugar IndustryThe sugar requirements of world are supplied from 2 main sources –the sugar cane and the sugar beet .the sugar cane has been known at least 2000 years, and crystal sugar has been manufactured from it for a simmila period as indicated by a Sanskrit word”sharkara” which denotes material in granular form and it is the origin of the term SUGAR in modern languages.There are five departments of the industry we will discuss:

1- mill house (study of juice flow diagram, cane unloading system)2- study of process house3- power house4- study of boiler house5- workshop

Mill HouseMill house is the backbone of sugar industry. In this Shakarganj mill there are two tandems.

Mill capacityThe capacity of a milling tandem is the amount of cane that can be economically crushed by the plant in the given time.Crushing capacity of tandem I is 7500 TCD (tone cane crushing per day)Crushing capacity of tandem II is 5500 TCD (tone cane crushing per day)

The main stages in this mill unit are:1-CANE2-CANE WEIGHING

3-CANE UNLOADING 4-CANE PREPARATION5-MILLING

Cane7 tons cane makes approx. 1 tone of sugar. The sugar cane requires high temperature and ample supply of water during the growing period. Hence ample rainfall or alternatively copious application of irrigation water is essential to successful cane growing.From the sugar manufacturer’s point of view the important consideration is to harvest the cane as close as possible to its peak of maturity. The harvesting and crushing season is therefore arranged accordingly. The duration of crushing season depends on the local climatic conditions.Sugar cane deteriorates rapidly after harvesting and t therefore delivered promptly to the factory to avoid losses of sugar.

Cane WeighingThere are two tandems both have there their own 3, 3 car tippers .the capacity of each is 50 tone. two car tippers are for gross weight and one is for the tare weight .Gross weight includes the weight of cane and the traller.

Net weight =gross weight –tare weight The net weight is measured in the control room.

Cane Unloading Systemcane is delivered by means of trucks .methods of unloading the cane varies accordingly .when unloaded, the empty truck is pushed clear of the carrier by the next oncoming full one and the trucks then coupled together and returned to field for further loads .

Dumping carrier (Shakarganj)

Cane conveyingCane is unloaded and conveyed by cane carrier. this is a large slat conveyor which conveys the cane from the unloading point to the milling plant. Tandem I There are three carriers

1) Dumping Carrier Length =60 ft length =60 ft length =60 ft

Width =18ft width =15ft width =17ft Linear speed =20ft/min each Angle of dumping carrier =18º

2) Main Cane CarrierLength =110 ftWidth =72 inElevated angle = 7.8 ºLinear speed = 30 ft/min

3) Fabrizer Cane Carrier Length=110 ftWidth = 72in Angle = 12 ºLinear speed = 45ft/minTandem-IIfour carriers are:1) Dumping cane carrier Length = 42ft

Width = 16.5ft Angle = 18 º 2)main cane carrier Length = 150ft Width = 90ftLength of elevated portion = 50 ft Angle of elevated portion = 7.7 ºLinear speed = 30ft/min 3)before shredder carrier Length = 66ft Width = 90inAngle = 15 ºLinear speed = 32ft/min

4) after shredder carrier Length = 60ft Width = 78inangle= 23 º

Arrangement of conveying

(Tandem I & tandem II)

Slats:The apron on which cane is carried is made up of steel slats bolted to the carrier

chains. The width of the slate is the pitch of the chain plus the overlap whilst the length is normally that of the mills rollers. Overlapping slates are used to prevent chips of cane from the knives falling between the slates as the passing around the driving sprocket and so causing damage when the carrier straightens again.Chains:

The chains are driven at the delivery end, or head of the carrier, by sprocket wheels. Thus only the loaded length of the chain is kept taut whilst the return portion remains slack. Wear increases the length of the chain, so a tightening arrangement should be attached to the sprocket shaft at the lower end of the carrier.

Drive:

Cane Levelers Tandem I

The levelers are used to level the coming cane on the cane carrier .it levels the bundles of cane on the conveyers.

Leveler(Shakarganj)There are 2 levelers in tandem one.Number of arms of leveler 1 = Number of arms of leveler 2 =No. of r.p.m =39Its arms are hard faced by means of electrode.

Tandem II

There is only one leveler in tandem II.Motor power = 80h.p

Number of arms = 38 Leveler r.p.m = 43Leveler arms are hard faced with electrode which increases its life.

Cane preparationPreparation of the cane has two main advantages:(a)to increase capacity by increase of bulk density of the feed.(b) To assist extraction at the mills by breaking down the structure of cane.

Tandem IPusher drum:-

It is a drum adjusted near the fabrizer and run by motor .it pushes the cane towards the fabrizer .on the outer end it has rectangles which are hard faced by special electrode as

shown in fig. its specifications are

Pusher drum(Shakarganj)

Diameter= 2240mmr.p.m= 2.78its motor specification are:type: SBN 630Power=485k.wn1/n2 = 750/335 r.p.mCane fabrizer:-Function of a cane fabrizer is to rupture the structure of cane and to open the cells of cane. It must be noted that fabrizer only open the cells of our cane and not squeeze it.it has a no. of hammers which strikes with the cane and rupture it. These hammers are attached on the SS bars. This fabrizer is run with the steam turbine and turbine’s r.p.m are reduced by a large gear. When fabrizer revolves its hammer opens and function .the hammers are also hard faced with a special electrode to avoid rust and chemical damage of material of hammer.

Cane fabrizer(Shakarganj)Its specifications are:No. of hammers=108No. of SS bars=06Weight of hammer=20 kgFabrizer r.p.m=1000Power of Steam turbine = 3000 K.WMagnet (iron separator)After this an electric magnet is placed for iron removal purposes to avoid any damage to the mill rollers. this is ANDRIN design.Tandem IIIn tandem II cutters and shredder is used instead of pusher drum and fabrizer.Cutters:-As the name indicates after leveling cutter is used to cut the cane into small pieces(chips) by knives. these knives are fixed radially on a shaft across the carrier as cane preprator by using a larger no. of knives with higher speed and deeper penetration of the cane layer on the carrier.staight blade knives aree used in our cutter however bent blades can also be used.

Cane cutter(Shakarganj)

.there are three cutter in tandem II.Cane cutter no.#01It is run by steam turbine.No. of knives=70Power of steam turbine=1200k.wCutter r.p.m=600Cane cutter no.#02It is also run by stam turbine of 1000k.w powerCane cutter no.#03It is run by motor.No. of knives=52Cutter r.p.m=600Power of motor=600 h.p

Shredder:- (BMA design)The Shredder, as the name implies, is designed to complete the preparation of the

cane by tearing or shredding it into finer pieces rather than by cutting. Several types of shredder have been used for this purpose, only one of which, the swing hammer type, is in widespread use at the present time in Shakarganj mill.it has a no. of hammers which strikes with the cane and rupture it. These hammers are attached on the SS bars. This fabrizer is run with the steam turbine and turbine’s r.p.m are reduced by a large gear. When fabrizer revolves its hammer opens and function.

Its function is same as that of fabrizer but its crushing capacity is greater. In this mill it is placed at the head of tandem II.

BMA design Shredder(shakarganj) A shredder hammerNo. of hammers=228No. of SS bars=08Weight of hammer=15.5 kgshredder r.p.m=1000Power of Steam turbine = 2000 K.WMagnet(iron seprator):ANDRIN designAfter this an electric magnet is placed for iron removal purposes same as that of tandem IRubbe rbelt conveyor is placed under the magnet to separate the iron particles from the cane. Its Power is17.5k.w.

Milling

it is the main unit in the milling tandem. in tandem I there are 5 mills and in tandemII there are 4 mills.Three roller mill:The three –roller mill consist of three horizontal rollers arranged as shown in fig.

The roller consist of cast iron shells mounted on heavy steel shafts and are arranged to rotate as shown by the arrows .the top roller is moving by prime mover through reduction gearing, and the two lower rollers by pinions meshing with the pinion gears mounted on each roller ,thus the top roller drives the other two.The cane is crushed twice ,first b/w the top and feed rollers then, with heavier pressure ,b/w top and delivery rollers, which are set closer together.

A Trash Plate supported on a trash bar is so placed as to guide the cane from the fee dopening to the delivery opening, maintaining it under some pressure and confining its path. Trash plate is laced b/w the feed and discharge roller. Nose Plate is placed in b/w the pressure feed top and pressure feed bottom roller. And Scrapper is placed on the top roller and discharge, used to remove the bagasse from the roller grooves.On the each mill roller, mills roller Beads are formed by some special electrode. They are also used for gripping of sugar cane.Rollers mill size:Mill Size of Tandem ILength of mill roller shell=72 india of mill roller shell=36 in

Mill Size of Tandem IILength of mill roller shell=78 inDia of mill roller shell=38 in

Roller speedThe juice has to escape against the direction of roller movement hence high roller speed will trend to give less affective drainage.Roller speed= 1673/4.5x62.5=5.9 approx.

Mill settingThe term “mill setting” reffered to the relative position of the three rollers and the trash plate as arranged in order to give the best results in terms of capacity and extraction.more specifically the setting refferes to the opening b/w top and feed and top and delivery rollers and also the clearance b/w the top roller and trash plate.the delivery roller is always set to a smaller then the feed roller thus the material is subjected to a higher pressure at the delivery and this is setting which determines the max. pressure and the extraction obtained by the mill ,the duty of the feed roller is essentially to give a partial compression and feed the bagasse to the delivry roller .however the feed roller achieves a considerable extraction and with suitable feeding arrangement exract the major portion of the juice extracted by mill as a hole.calculation of mill setting involves calculation calculation of the desirable feed and delivery openings as well as the arrangement of the trash plate.and several methods are used to calculate these setting.

Trash plate settingThe setting of the trash plate can affect the juice drainage at the delivery roller ,the plate is set to give adequate clearance b/w trash plate and delivery roller to enable the juice to escape freely down the face of roller. if this clearance too small excess juice pressure buids up .since the juice can not escape freelysh plate and delivery roller to enable the juice to escape freely down the face of roller. if this clearance too small excess juice pressure buids up ,since the juice can not escape freely.Grooving:The roller shell is provided with circumferential grooves of V section in order to improve the grip of the rollers on the cane and to give improved juice drainage. These grooves are called CHEVRON grooves. proper operation of grooves requires that they should not fill with biogases ,otherwise they do not provide ebagasse for escape of juice.

hence their dimensions should be determined according to the fitness of preparation and quantity of juice to be removed .the higher pressure at the delivery also requires a narrower groove to prevent bagasse being forced into the grooves. For the removal of such baggase scrapper is used.

MILL DRIVESIndividual steam turbine

In each mill a separate turbine is used .it possess most of the advantages of electric derive, including good starting torque, absence of oil contamination from the exhaust steam, reduction in space required, and facility of remote push-button control from a convenient point.it avoids the double transformation of energy required by electric derive, with consequent losses of energy.however,specifis steam consumption increases considerably when the turbine is operated at other than its designed speed. the turbine is a very flexible machine, supplementary nozzles are provided which can be opened when higher power output is required .thus by regulating the no. of nozzles ,efficient operation is obtained .since the initial speed of these turbines is in the range of 5000 r.p.m.so four stages of speed reduction are required.the speed is further decreased by using high and low speed gears. these gears are made of WALKER company.Secondary speed of steam turbine used=1800-----2000.

Tail bar bux couplingWith the normal arrangement of final derive to the top roller which lifts against the pressure during operation, the derive must allow for such movement ,hence the tail bar connecting the final stage of the gearing to the top roller is fitted with the coupling at each end to provide the necessary range of movement b/w the top roller and the line of the final gear shaft.

Intermediate CarrierIntermediate carriers are essentially conveyors moving the bagasse from the delivery of one mill to the feed of next.they are designed for the proper mixing of bagasse with the imbibition fluid .The carrier used in this mill is Rack or Scrapper conveyours.

Rack conveyorWith the rack or scrapper conveyor the lower run of the conveyor is the active. The racks attached by angle irons to the chain on which they are supported ,drag the bagasse along the inclined plate from the top of which it falls down the slopping feed plate to the following mill.Since the bottom tray is a steel plate this type of conveyor overcomes the main disadvantage of the slat conveyor in that it does not allow fine bagasse to be drop. the

Y-links are used as a conveyor in this carrier as shown in fig.

Rack bar carrier(shakarganj) y-type link

ImbibitionIt is not possible to remove all the juice from bagasse by pressure ,even after repeated application of heavy pressure ,the bagasse retinas a quantity of juice approximately equal to the weight of fiber .in order to obtain a satisfactory extraction of sugar therefore it is necessary to dilute th e juice remaining in the bagasse thus procedure is known as imbibition.in SHAKARGANG mill compound imbibition is used , where the juice from the final mill is used as imbibition before the second last mill water is added only before the final mill and this is called compound imbibition.

Optimum quantity of imbibitionThe optimum imbibition is determined by two main factors

1) the increase in extraction obtained2) the cost of evaporating the added water

Method of applying imbibitionImbibition water is generally applied by a perforated pipe which adds the water in the form of jets at considerable velocity and gives the reasonable penetration of the bagasse blanket

It must be remember that 70% of the juice exraction must be attain for best result.and so approx. 96% juice will be obtain at the end of final mill .this juice is calculated in seprate tanks.so,at the end bagasse of both tandems is sent to the boiler house for burning by belt conveyor. And juice is then sent to the process house for clarification by pumps.

Process HouseSummary of process:- The purpose of clarification is to remove impurities from the juice as early as possible in the process. the juice contains considerable colloidal and fine suspended matter ,and it is mainly these constituents which are removed in clarification .some soluble constituents are also removed .the process , as for as suspended matter is concerned ,is closely analogous to the treatment of water supplies , the fine suspensoids are coagulated giving particles which will settle at a reasonable rate, and the juice is then pumped to settling vessels to allow the coagulated matter to settle .the mud is then treated to recover the considerable proportion of sugar which it contain.Water from the mill house comes to the process house by means of a pump in green pipes at 25—30° temp.Tandem I juice pipe dia = 8 inTandem II juice pipe dia=10 in

Juice HeatersHere juice heaters are of simple shell and tube design there are primary and secondary heaters. Juice is pumped through the tubes. While return ends or headers at each end guide the juice leaving one pass into the tubes .while return ends are headers at each end guide the juice leaving one pass into the tubes of the next .here in this mill vertical heaters are used .these juice heaters are also given insulation to minimize the loss of heat as for as possible.two heaters are used at a time and one is kept standby.heaters specificationSSP tubes dia= 35 mm SSP tubes length= 4.5 mTemperature= 70----75°

Lime dozerIn lime dozer milk of lime is added to increase the p.h of juice.

Calcium phosphate precipitationFormation of calcium phosphate precipitates is the most important reaction in the clarification process as it is this precipitates absorbs and takes with it much of the colloidal and other fine suspended material .most of the phosphors in the cane juice is apparently in form of soluble phosphates .as 80 to 90 percent is removed by ppt with lime. Reaction

Milk of lime +phos. Acid → calcium phosphate (ppt)

Ca (OH) 2 + H3PO4 → Ca3 (PO4)2

this reaction is very slow and we know that solubility of calcium phosphate in cane used is much higher then in H2O.Retention tankthen water is sent to retention tank in which we also add some amount of lime.there is a stirrer to mix the solution ,so that ppt not settle down. Reaction tankMixture is then sent to the reaction tanks.there are four reaction tanks where mixing occour .

After this juice is sent to the defecation tank. this juice is called defecated juice.this juice is further pumped to the flush tank where extra gases are removed and polyelectrolyte solution is mixed in it to increase its stickiness.the volume of the flush tank is 250m3

.

Clarification process(To clarify the juice)

Objects of clarification:-1) Maximum possible elimination of impurities ---suspended, colloidal and soluble.2) adjustment of PH to minimize decomposition of sugar in clarification and

subsequent boiling house temperature PH CONTROL OF LIME ADDITION

Number fixed value can be prescribed however for optimum clarification; its figure change with the nature of impurities .now in this clarification we keep its PH 6.7---7.1.

Two types of clarification are 1) Deification, some time called lime deification, where lime is the only material

added.2) Sulphetation where in addition to lime SO2 gas is added to juice giving a

precipitate of calcium carbonate.in this SHAKARGANJ mill, both process are used .in clarifier temperature changes from 90—95° to 104 --107°

Vacuum filters

They are used for the filtration of the cane mud’s the essential of such filter for cane mud is the use of a screen of perforated stainless steel sheet.The filtering surface or screen are arranged on the periphery of the drum

.Vacuum filter(shakarganj)

Evaporation and sugar boilingThe clarified juices from the subsiders contain about 15-20 % of solids depending on the concentration of the original juice in the cane and the maceration practice employed. This has to be concentrated eventually to raw sugar and molasses the water has to be removed almost entirely. This evaporation duty is divided into two portions.

1) The evaporation so called which concentrates the juice to heavy syrup, taking care to stop short of saturation.

2) the sugar boiling in which concentration is carried further so that crystals from and are grown under conditions to the desired size .the sugar boiling processes carried out in stages ,the final product being raw sugar and final molasses .

The first step (evaporation) is carried out in multiple effect evaporators of conventional design the second (the sugar boiling ) involves boiling a viscous liquid containing crystals in suspension and evaporators of a special design , known as vacuum pans are used in single effect.From the fuel economy point of view it is advantageous to carry the multiple effect evaporation as for as possible with out reaching saturation; hence a concentration of approximately 70 brix is generally in the syrup leaving the evaporators.In this mill there are three quards .in each of quard in 1&2 evaporator there is pressure boiling and in 3&4 there is vaccume boiling.

Process in pansThe sugar boiling process can be considered only in terms of the total work of the pans and the centrifugals; in fact, the tem pan station is often used to include vacuum pans and centrifugals. Sucrose is crystallize from the syrup in 3 stages; the process is shown by the simplified flow sheet as below

In the diagram one pan is shown for each stage or strike; this does not mean that one pan is reversed for a particular grade of massecuite as a pan may be used in turn for first and second massecuite, or more then one pan may be boiling similar massecuite at a given time. the first or A massecuite consist eventually of of syrup from the effects ; this is concentrated eventually to the maximum crystals content practicable , and forms first or A massecuite .this is dropped to a mixer , and then passes to centrifugals ,in which the mother liquor is separated while the sugar goes out as finished raw sugar designated a sugar . The separated mother liquor is first or A molasses and forms the basis for the second or B massecuite. This in turn goes to the centrifugals giving a further crop of finished raw sugar, together with second or B molasses. This forms the basis for the third or c massecuite. this the final massecuite and on discharge from the pan goes to a crystallizer to complete the crystallization as for as possible by cooling .the massecuite is then centrifuged, the molasses in this case being the final molasses, which is a waste product as for as the raw sugar process is concerned the c sugar or low grade sugar carries it with a considerable film of low purity final molasses. At one tine such sugar was sold to the syrup to form a magma, which then is used in the A and B pans as seed or footing for the high grade strikes. The C sugar is boiled to a small grain size (approximately 0.3 mm) and so forms a convenient footing for the high grade strikes,

which are finished at a grain size, approaching 1.0 mm .this usage of C sugar as footing for the high grades is known as the magma system. Flow diagram (raw juice to a melt)

A melt is obtained from A grain by melting it by steam.Design of vacuum pansThe main requirement of vacuum pan design is seen as the ability to maintain effective calculation and mixing with massecuite of high viscosity and crystal content. Desirable features are minimum resistance to flow over the heating surface, minimum hydrostatic head and means of ensuring ready escape of vapor bubbles from the surface of the boiling massecuite.

Centrifugal M/CThe machine is variously termed a centrifugal drier, basket, centrifugal or simply centrifugal, often abbreviated to “fugal”. The operation of separating the molasses with these machines is known as purging, centruiifuging, centrifugling are fugal ling. A machine consists essentially of a cylindrical basket designed to receive the massecuite, and the pierced with numbrerous holes to allow the molasses to escape: the basket is aligned with the perforated or slotted sheet metal. The fine perforation of the screen retains the sugar crystals while allowing the molasses to pass through; backing screens allow free flow the molasses between the inner screen and the wall of the basket

Process on A MELTFrom the centrifugal a melt is sent to the buffer tank and then to the supply tank.these are storage tanks.from these tanks the liquor is sent to the heaters where the liquor is heated 80—85 temp.then it is futher sent to the reaction tank where talofloc ,phosphoric acid,talo flot and lime scrate are mixed and this liquor is droped to the taloclarifier from which mud is sent to the surplus tank(for again treatment)and clear juice is reched to the talo tank.

then SO2 is passed to the juice in sulphitation tank.SO2 function:1)to decolourize the juice2)to remove impurities3)as a bleaching agentThen it is sent to the sulphated melt tank.from here it is transferred to the smare tank.it comes to the pressure filters by gravity.pressure filter is used to remove mud.there are 06 pressure filters (04 large and 02 small).in pressure filter plates are used as shown in fig.

Pressure filter plates (shakarganj)Clear filtrate is sent to the polish melt tank.from where it is sent to the deep bed supply tank and then it enters the deep bed filter to clear the juice nearly 100%.it contains one layer of one foot each material as:Carbon media Sand Crush (3,6,12 mm)Gravel (18 mm).After passing these materials juice clears up to max stage.then comes storage tanks.it is further passed from the refine pans.and the same process repeat until sugar is obtain in crystals form.it is passed through the centrifugal ,by passing through we obtain crystals and run off molasses.run off molasses further goes to the refine pans ,in which further addition of seed is done.and here we get R1 crystals and similarly R2 and R3 crytals are obtained. Generally speaking the moisture content of the sugar leaving the centrifugals is too high for convent handling and storage .the main consideration is to reduce the moisture content of the sugar to a value low enough to prevent growth of micro-organisms which would cause deterioration and loss of sugar on storage.these crystals are sent to the drier by means of wet elevator.it is further send to to the grader by means of dry elevator.here we can obtain sugar of different grades according to requirement.then final sugar is packed in bags..

Flow diagram(A melt to final sugar)

Properties of SugarOther desirable conditions are that the sugar should be

1) Comparatively free from insoluble matter2) It should be hard ,uniform and fair sized ,grain and free from conglomerates3) An unwashed sugar i.e. the molasses film must not be diluted by washing 4) It should be manufactured under sanitary conditions to minimize access of micro-

organisms.

Boiler house. The sugar industry is probably unique among the major industries in obtaining all its fuel requirements from its raw material bagasse.Boiler feed water:The water fed to the boiler in the SHAKARGANG industry is mostly condensed steam. The stem works in a closed system forming condensate in these items of plant, which is returned the boiler for re_evaporation.First of all water is pumped to the water demineralization plant by means of water pumps.Water Storage tankWater is brought to the storage tanks by water pumps and stored in it.Water treatment plantsdemineralization plantwater is filtered here.it has three portions.one is anion ther is cation and third is anion cation.there are two water demineralization plant .the ph of water is controlled in this plant.impurities are removed from it.the ph is kept near 7.8.capacity1-15 tone/hr2-30 tone/hrIt is shown in fig.

Demineralization plant(shakarganj)

Reverse osmosis plant:-This is another plant to pure the water from the impurities.its capacity is 30 tone/hr.it is also called RO plant.its efficiency is greater than demineralization plant.it is shown as below.

Make up pumps These are used to trsnsfer the water from water treatment plant to the hader .these are run by moters ,as well as by turbines.Most of these pumps are KSB design. there impellers are shown as below.

Deairation Tanks In these tanks extra gases are removed from the surface of water.there are three Deairation tanks .air is removed from the water also in these tanks .water is then sent to the boiler to prepare steam.

Boiler

any boiler unit consists of 2 main parts The heat generator:Here the fuel is burnt to generate the heat. This comprises the furnace and combustion chamber which are generally separate but may be combined.

The heat absorber:Here the the heat generated is transmitted to the water in the boiler so generating steam. The absorber equipment also includes auxiliary heating surfaces such as steam super heater, air preheater and economizer. The object of heat generator is to burn the fuel completely with the minimum quantity of air necessary for complete combustion. This gives the maximum temperature of the resulting gases, which facilitates the efficient transfer of heat to the water in boiler .Combustion of fuel:In practice complete combustion is not obtained with the theoretical quantity of air and some excess air above theoretical is necessary for complete combustion.Combustion is supported by supplying part of air as secondary air i.e. supplying portion of air above fuel bed.Three types of fans are used in boiler

1) ID Fan (Induced draught fan)2) FD Fan (force draught fan)3) Secondary fan (For combustion )

Function of FD fanIt supplies access of air from the bottom of dumping grid for efficient combustion of fuel(bagasse).by this fan positive pressure is given.

Function of ID fanIt is used for exhaust purposes. it is used with the chimney of boiler. negative pressure is given by this fan

Function of Secondary fan:- It is used for combustion purpose. it spreads the bagasse all around the boiler. it provides the preheated air to the bagasse which reduces the percentage of moisture in bagasse, for efficient combustion.

Mud drumIt lies at the inner portion of the furnace .this tank is full of water. From the Mud Drum various tubes generate, these tubes are called generation Tubes. Generation Lies in the area pf furnace. Where water is heated to the specified value.

Steam DrumSteam drum Lies at the top of the furnace. The generation tubes coming from the mud drum ends at the steam Drum .This drum is somewhat full of water but not completely filled with water. In this portion steam lies at the top surface of water.

SteamWater Super HeaterThen water is further heated to the superheated value. this super heater increases the temperature to the value of 350C° .this super heated water is Further sent to the header ,from where it is distributed uniformly in the turbines and in the place of requirement.

Economizer:Economizer consists of vertical tubes arranged in the main boiler flue in Shakarganj economizer is installed later it is placed in the last pass of gasses leaving the boiler.

Recovery of sensible heat:When complete combustion of fuel with a practical minimum of excess air has been obtained, the furnace gasses will be at a maximum temperature and the sensible heat is recovered as far as practicable. The temperature of fuel gasses leaving the boiler however is still well above the boiling point of water at the boiler pressure.The temperature difference b/w the outgoing gasses and water temperature being greater with the higher rates of evaporation in order to further reduce the temperature of fuel gasses it is necessary to utilize them to heat some fluid at a temperature lower then heat of the boiler water .The obvious fluids are the fluids are the air for combustion and the feed water entering the boiler and air pre_heaters and economizers (feed water heaters)Comprises the equipment used for this purpose. the heat so transferred to the combustion air or to the feed water is thus heat which would otherwise be lost ,and which replaces an equivalent quantity of heat which otherwise would have to be supplied by the fuel .with a fuel of high water content such as bagasse the fuel gases has a correspondingly high content of water vapor ,means a substantial increase in the sensible heat lost in fuel gases compressed with that of dry fuel and renders sensible heat recovery more important.

Power HouseCondensing Turbine 1

Inlet Pressure=2.4MPa

Extraction pressure=.392 MPaExhaust pressure=.0072 MPaExtraction Rated power=6MWInlet temperature=350C °Extraction flow=15t/hRated speed=3000r.p.m QINDAO JIENENG STEAM TURBINE LTD

Turbo generatorRated power=6 mwRated voltage=11000 vRated current=3936 vRated speed=3000rpmFrequency=50 hz Phase no=3 Rated power factor=08 Rated extraction voltage =117Rated extraction current= 251 ampereStator Connection =YInsulation Grade=FTotal weight of unit=23.05 tonSICHVAN DONGFENGELECTRICAL MICHINERY WORKS. LTDSMALL Turbine Back Pressure Power=2210KWSpeed=5269/1500Gear Ratio=3.5Oil Guage Pressure=2 BarWeight=3000kgGenerator BBC3 phase generatorY 440volt2680KVAExtraction 59 volt

Steam turbineInlet pressure=2.35MPaExhaust Pressre=.245MPaRated Power=6MWInlet Temperature=325 C °Rated Speed=3000rpm

Workshop

(1-6) Lathes(7, 8) Planner(9, 10) Drill machine11 Lathe(12, 13) Shaper14 Balance Machine15 Power hacksaw16 Header17 Office18 Table19 Saw Machine20 Grinding Arbor

Centre Lathe Machine

The Centre Lathe is used to manufacture cylindrical shapes from a range of materials including; steels and plastics. Many of the components that go together to make an engine work have been manufactured using lathes. These may be lathes operated directly by people (manual lathes) or computer controlled lathes (CNC machines) that have been programmed to carry out a particular task. A basic manual centre lathe is shown below. This type of lathe is controlled by a person turning the various handles on the top slide and cross slide in order to make a product The headstock of a centre lathe can be opened, revealing an arrangement of gears. These gears are sometimes replaced to alter the speed of rotation of the chuck. The lathe must be switched off before opening, although the motor should automatically cut off if the door is opened while the machine is running

. The speed of rotation of the chuck is usually set by using the gear levers. These are usually on top of the headstock or along the front and allow for a wide range of speeds/ part. However, sometimes the only way to set the lathe to a particular speed is to change the gear arrangement inside the headstock. Most machines will have a number of alterative gear wheels for this purpose.

Quality policy

Our quality policy stems from our vision and is to maintain industry leadership and customer satisfaction through production ofhigh quality sugar, yarn and allied products at lowest cost, using environment friendly technology and safe working conditions.

We run our business with integrity and professionalism and believe in continual improvement and a fair deal for our investors, customers, suppliers and employees