SUGAR TECHNOLOGY

& INNOVATION

R-5 28/11/2011

RR TASKS

Cane juice extraction is the most power demanding step in the sugar process.

Reggiana Ridutto has developped an innovative mill rollers drive system, succeeding in following tasks:

-INCREASE IN MECHANICAL EFFICIENCY

-INVESTMENTS REDUCTION (CONSTRUCTION and MAINTENANCE)

- EXTRACTION CONTROL

-CONVENTIONAL MILLS UPGRADING

Let’s see HOW

INCREASE IN MECHANICAL EFFICIENCY

CONVENTIONAL MILL DRIVEfoot-mounted reduction gearings with tail bar, crown pinions and rope couplings

does it easier with its INNOVATIVE PINIONLESS MILL DRIVE consisting of

SHAFT MOUNTED GEARBOXES DIRECTLY ON THE ROLLER SHAFT

EQUIPMENTS PINIONLESS DRIVE

CONVENTIONAL MILL

AC Motor 96% 96%

REDUCTION GEARS 95% 92%

Low speed OPEN GEAR 60%

Tail Bar 97%

CROWN PINION 92%

TOTAL EFFICIENCY 47%

INCREASE IN MECHANICAL EFFICIENCY

VFD Electric motor96%

High speed reducer90%

Crown pinion92%

Tail bar97%

WIN 200% MORE EFFICIENCY WITH

PINIONLESS DRIVE

CONVENTIONAL DRIVE

91%

INCREASE IN MECHANICAL EFFICIENCY

EQUIPMENTS PINIONLESS DRIVE

ROPE COUPLING MILL

AC Motor 96% 96%

REDUCTION GEARS 95% 92%

Rope coupling 97%

CROWN PINION 92%

TOTAL EFFICIENCY 91% 79%

ROPE COUPLING DRIVE

15% MORE EFFICIENT THAN COMMONLY USED PLANETARY

DRIVE

RR EXPERIENCE:

INCREASE IN MECHANICAL EFFICIENCY

4 MILLS 40” x 80”, 6000 TCD.

MILLING SPEED: 4,5 rpm

INSTALLED POWER: 840 kW/mill.2 X 250 kW TOP ROLLER (RR55000)1 X 250 kW BOTTOM ROLLER (RR55000)1 X 90 kW TRF (RR25000)

POWER SAVING WITH PINIONLESS DRIVE: 100 kW/mill

100 kW/mill

400 kW/day

72 MW/Season(6 months)

SHAFT MOUNT

ED GEARBOXES

NO NEED

OF FOUNDATIONS

COMPACT

FACTORY

DESIGN

INVESTMENTS REDUCTION

SPLITTED POWER

SMALLER GEARBOXES and MOTORS

SIZE

BETTER AVAILABILITY and LOWER SPARE PART

PRICES

SHORTER

POWER TRASMISSION CHAIN

LESS MAINTENANCE

REDUCED

SPARE PARTS STOCK

INVESTMENTS REDUCTION

INDIPENDENTLY DRIVEN ROLLERS

FLEXIBLE ROLLERS RELATIVE SPEED SET UP

BETTER CANE FIBERS SHREAD and COMPRESSION CONTROL

ROLLER SPEED RATIOS can be RELATED TO CANE QUANTITY, QUALITY and DENSITY

SMARTER MILL SET UP

BETTER EXTRACTION CONTROL

EXTRACTION CONTROL

WITH PINIONLESS DRIVE

UNIFORM CANE BLANCKET COMPRESSIONLONGER COMPONENTS LIFETIME

LESS MAINTENANCE

EXTRACTION CONTROL

TORQUE TRASMISSION BETWEEN CROWN PINIONS CAUSES a LOCAL REACTION and HIGH STRESS LEVELS at MILL ROLLERS END

UNSYMMETRICAL ROLL LIFT

NOT UNIFORM CANE BLANCKET COMPRESSION

LOWER EXTRACTION EFFICIENCY

HIGH STRESS LEVEL at MILL ROLLER SHAFT END

FREQUENT FAILURE and WEAR OUT of:CROWN PINIONSBRASSESBEARINGS

EXTRACTION CONTROL

INDIVIDUAL PINIONLESS ROLL DRIVE

POWER ABSORPTION AND ROLL SPEED CONTROL

DRIVE FOLLOWS THE ROLL MOVEMENT

UNIFORM ROLL LIFT and LOWER STRESS LEVEL (no pinion reaction)

BETTER EXTRACTIONREDUCED WEARLESS MAINTENANCE

CONVENTIONAL MILLS UPGRADING

PINIONLESS DESIGN CAN CONVERT CONVENTIONAL

MILLS INTO MODERN PINIONLESS MILLS AND TAKE ADVANTAGE OF MOST TECHNICAL ADVANTAGES

FLANGE TO FLANGE ASSEMBLY CAN UPGRADE THE TRADITIONAL ROLL DRIVES

INTO SHAFT MOUNTED GEARBOXES.

YOU CAN IMPROVE EXISTING SUGAR PLANTS ENERGY LEVEL TO THE MOST MODERN STANDARDS end GAIN BETTER EXTRACTION

SIZE T2max [Nm]

RR65 1200

RR105 1800

RR110 2000

RR210 2500

RR310 5500

RR510 7000

RR710 8500

RR810 14500

RR1010 17500

RR1700 26500

SIZES FOR

SIZE T2max [Nm]

RR2500 37000

RR3200 58000

RR4000 75000

RR5200 92000

RR6500 125000

RR8000 160000

RR10000 190000

RANGE AND SOLUTIONS

- Cane carrier- Cane elevator- Cane leveller- Cane feeder- Bagasse elevator- Bagasse Stacker- Juice clarifiers- Scraper- Crystallisers- Agitator- Conveyor

WE CAN DO THEM ALL !

MILL CAPACITY over 6000 TCD

MILL CAPACITY up to 6000 TCD

SIZES FOR

RANGE AND SOLUTIONS

SIZE T2max [Nm]

RR15000 275000

RR20000 395000

RR25000 580000

RR30000 680000

RR40000 790000

RR55000 950000

RR70000 1000000

RR85000 1100000

RR110000 1500000

TRF up to 100 KW each

TRF over t 100 KW each TOP and BOTTOM rollers up to 300 kW each

TOP and BOTTOM rollers over 300 kW each

OUTPUT SPEED UP TO 12 rpm

RANGE AND SOLUTIONS

CONVENTIONAL HOLLOW SHAFT

WITH SHRINK DISC

SPLINED OUTPUT SHAFT WITH

- CLAMPING RING- DOUBLE CENTERING

EASY ASSEMBLY and DISASSEMBLY

SAFER (better stress distribution)

NO RUST

SHAFT OPTIONS

LINEAR OR ANGULAR

CONFIGURATIONS

WITH HELICAL OR BEVEL HELICAL INPUT

HIGHER THERMAL RATINGS

HIGHER INPUT SPEEDS

RANGE AND SOLUTIONS

AND . . . WE DO IT CONVENTIONAL TOO!

FOOT MOUNTED PLANETARY GEARBOXES with :

SQUARE OUTPUT SHAFT FOR ROPE COUPLING/CROWN PINION

COOLING SYSTEM

all over RANGE

RR thinks global and acts local

RR GROUP WORLD

READY TO ASSIST YOU WORLDWIDE!

Sugar cane projects

- JAY MAHESH SUGAR IND.LTD. (NSL Sugars Ltd.) (INDIA).

- MUKTESHWAR SUGAR MILLS LTD (INDIA).

-GANGAKHED SUGAR & ENERGY LIMITED (INDIA).

-QUANG NGAI SUGAR (VIETNAM).

-UTTAM (INDIA).

-SADA (BRASIL).

-MT SUGAR (THAOLAND).

… and many other worldwide.