Milling efficiency and technology

Permanent URI for this collectionhttp://elibrary2.sugarresearch.com.au/handle/11079/13845

Research outcomes: Optimised mill transport and logistics. Mill capacity and efficiency is optimised through improved processes, technology and value chain coordination and collaboration.

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A condensed report on cane deterioration trials : Fairymead, 1967 season
(BSES, 1968) Messrs, PG; Egan, BT; Kirby, LK
Following Discussion between the Australian Producers' Association and the Director of the Bureau of Sugar Experiment Stations it was decided to carry out a series of cane deterioration trials in the South Queensland district during the 1967 season. As management of Fairymead Mill offered to supply and harvest cane for these tests from their plantation, and to make available laboratory facilities for this work, it was decided to carry out the work at Fairymead.
A wedgewire support for screens in continuous centrifugals, Bingera mill - 1987 season
(BSES, 1988) Noble, AG
Discussions between Bundaberg Sugar Company, the Surescreen Group and BSES resulted in BSES sponsoring the installation of a wedgewire backing screen in a K1000 basket at Bingera Mill during 1987 season. This report presents the results of trials carried out to evaluate the performance of the machine fitted with the new wedgewire backing screen.
Advanced computer simulation of sugar factories - SysCAD : revised final report 2010/040
(Sugar Research Australia Limited, 2014) Broadfoot, R; McFeaters, J; Stephenson, R
This project aims to develop a highly adaptable 'whole of sugar factory' process model that includes the capability to incorporate a variety of adjunct processing options e.g. cogeneration, biofuel production from molasses, juice or fibre, biochemical production.
An experimental study of boiling in calandria tubes : SRDC final report JCU021
(SRDC, 2001) Schneider, P
Raw sugar processing relies heavily on process equipment employing calandria-based heating systems to concentrate highly viscous sugar solutions, such as evaporators or vacuum pans. The design of these unit operations is based largely on experience and lacks a rigorous basis. Due to the high capital cost of these components, this situation is highly undesirable. The main aim of this project is to develop an experimental apparatus that can be used to measure viscous boiling phenomena in a single calandria tube, boiling molasses and massecuites. Data gathered will be an invaluable resource to assist with the development of models that can be used to assist with the design of full-scale equipment.
An investigation of factors affecting ash in first expressed juice in the Rocky Point mill area
(BSES, 1981) Kingston, G
Because of a deep concern at the level of ash in Rocky Point sugars and the lack of information on inorganic composition of juices entering the factory the management of W H Heck and Sons requested BSES to undertake an investigation in 1979 which might assist in identification of factors which contribute to the ash problem at Rocky Point. Accordingly a project was planned to allow identification of the major factors contributing to the ash loading in first expressed juice and to determine whether the ash levels in juice could be related to yield parameters affecting cane growers in the mill area.
An on-line cane monitoring system to measure the extraneous matter present in billet sugar cane : final report CSU001
(Charles Sturt University, Sugar Research Institute, 2000) Moore, WE
Extraneous matter (EM) in cane billets consists of two major types of material; dirt and trash. Dirt consists of primarily inorganic, rock derived material, while trash consists of primarily organic, non-productive sugar cane derived material such as leaves, tops, and root balls, Trash can also contain other non sugar cane derived organic matter such as weeds and other items included during the harvesting process.
Biomass characterisation facility for extended stockpile model accuracy and capability: final report project 2011/049
(Sugar Research Australia Limited, 2015) Hobson, P; Plaza, F
Two issues critical to the design and operation of stockpiles are prevention of spontaneous combustion and minimisation of loss of heating value due to deterioration. There are currently few tools available to the industry to ensure optimum management of stockpiles. The project has delivered experimental means, data and model refinements necessary to advance the capabilities of an existing model towards being a practical stockpile design and management tool for the industry. The project has developed, from scratch, three sets of equipment to measure four important bagasse material behaviours relevant to bagasse degradation and spontaneous combustion. They are: 1. A permeability and diffusivity measuring test rig that reproduces the layered bagasse structure formed when a stockpile is built and compacted by the tracks of a bulldozer in a co-generation scenario. It has been shown that the permeability of the bagasse in the vertical direction is quite different to that along the horizontal direction. This is important since the ability of oxygen to move into the stockpile has a significant effect in the reactions occurring in the bagasse and its subsequent deterioration. 2. A large sample size calorimeter that is likely to be more representative of the behaviour of a bagasse stockpile compared to previously available equipment (many kg versus less than 20 g) to measure the heating behaviour of bagasse. 3. A degradation measuring rig was built in an incubator with the capability of measuring the behaviour of six bagasse samples simultaneously. By measuring for example the quantity of carbon dioxide given off, the percentage loss of combustible matter and fuel heating value were determined.
Brix determination in first expressed juice by mass flow meter : SRDC final report SD97011
(BSES, 1997) Mackintosh, DL; Noble, AG; Sanders, DH
A series of trials have been carried out to evaluate the performance of a Micro Motion CMF025 mass flow meter in place of the standard hydrometer for brix measurement in cane pay analyses. Tests were conducted at ten sugar mills over 1994 and 1995 season. The evaluation has been painstaking and extensive in scope and has culminated in the proposal to include a Method 3A in the Laboratory Manual for Australian Sugar Mills, "Brix Determination in Juice by Vibrating Tube Density Measurement". The process has involved millers' and the growers' technical personnel.
Calibration of a density meter : final report PR92005
(BSES, 1992) Sanders, DH
The Australian Sugar Milling Council (ASMC), as part of its continuing investigation into precision density meters, purchased an EXAC Model 8300EX 12A mass flow meter with density measuring capabilities. This instrument will be tested in four sugar mill laboratories in the 1992 crushing season comparing results with those obtained by the conventional cane payment method ie brix hydrometer. Prior to conducting these trials ASMC requested BSES assistance in calibrating the instrument against the standard bix hydrometer using pure refined sugar solution.
Clean Cane Workshop 2000 : SRDC final report
(SRDC, 2000) Wilson, MF
The Corporation has identified clean cane as a strategic issue that transcends several of its programs of research.
Crack detection and durability assessment of low speed sugar mill gears : final report JCU2S
(BSES, 1995) Anderson, SI; Loughran, JG
Heavy low speed gearing used by the Australian Sugar Industry is manufactured according to code specifications. These gears fail in several ways with the most common failure modes being the gradual surface fatigue of the contacting teeth due to poor lubrication and sudden tooth fracture resulting from the presence of cracks. Over the last decade, sudden gear failures have cost .the industry millions of dollars. The problem is exacerbated by the unexpected lost production time and cost of gear replacements.
Data-base and data handling programs for Plant Data Record
(BSES, 1981) Dyne, GD
The information contained in the BSES Plant Data Record is stored in computer data-bases for reporting and reference. Data for both the 1979 and 1980 seasons is stored at Bundaberg and reports for each of these years were generated using the data-base software. Listings of the forms required for the collection of new information have also been produced with this system. The system offers many advantages over the previous manual techniques, including speed and accuracy of report preparation, and the ability to manipulate stored data and report is as required.
Determination of fracture properties of cast steels : final report JCU9S
(SRDC, 1998) Anderson, SI; Loughran, JG
Technology currently exists to estimate the structural durability of cracked sugar mill gears and mill roller shafts. Both SRDC projects JCU2S (Crack detection and durability assessment of low speed gears) and JCU6S (finite element and durability modelling of roller shells and shafts) involve the application of linear elastic fracture mechanics to assess cracked components in• Australian sugar factories. The benefits from these projects could not be fully realised due to the lack of fracture property data for Australian manufactured gear and shaft steels.
Determine the optimum tube dimensions for Robert evaporators through experimental investigations and CFD modelling: final report 2012/054
(Sugar Research Australia Limited, 2017) Broadfoot, R
Experimental investigations were undertaken in a single tube pilot evaporator for nine tubes of three different lengths and three different diameters to determine the optimum tube dimensions for Robert evaporators. Heat transfer performance was determined at operating conditions typically encountered in sugar factory evaporators. Juice of three brix levels were selected to mimic conditions for the 1st, 3rd and 5th effects in a quintuple evaporator set. For each brix, the heat transfer coefficient (HTC) was calculated at four juice levels, two headspace pressures and two pressure differences between the steam chest and the headspace. Of the four juice levels, one juice level was identified as the optimum juice level corresponding to the maximum HTC. In total, 432 tests were undertaken with nine tubes and a further 128 tests were replicated with four tubes. The maximum HTC and optimum juice level results, linked together with a capital cost analysis and sucrose loss considerations, determined the preferred tube dimensions for Robert evaporators in a quintuple evaporator set.
Develop a blueprint for the introduction of new processing technologies for Australian factories: final report 2015/043
(Sugar Research Australia Limited, 2018) Broadfoot, R; Rackemann, DW; Moller, DJ
Several overseas factories are using technologies that reduce their process steam consumptions to very low levels, e.g. lower than 32% on cane, which are much lower than achieved by the most steam efficient Australian factories (~40% on cane). The steam efficient technologies that are not currently being used in Australian factories include:- Falling film tube evaporators and Kestner evaporators; In-line juice heaters on vapour from the final evaporator; Barriquand juice heaters; Use of vapour from the 3rd evaporator for pan boiling; Direct contact pan feed conditioning systems; and Vapour recovery systems such as in condensate cigars.
Developing a framework for advancing road transportation of sugarcane : SRDC final report SD98013
(BSES, 1998) Robotham, BG; Norris, CP
An objective of this project was to initiate a research program for the road transportation of sugarcane. Future research projects will be undertaken with the knowledge and cooperation of key parties and therefore have realistic and achievable goals. This project has encouraged communication between road regulators, manufacturers of haulout equipment, suppliers of tyres and suspension systems, users of haulout equipment, researchers and cane growers and thus created a cooperative environment for future research in this area. In addition to the initially specified objectives, this project has addressed the current issue of legislation not adequately covering the newer types of haulouts and the non-conformity of many haulouts to current regulations.
Developing a new methodology for competency based training courses for shift supervisors in sugar factories : revised final report QUT032
(Sugar Research Australia Limited, 2014) Broadfoot, R
The provision of effective training of supervisors and operators is essential if sugar factories are to operate profitably and in an environmentally sustainable and safe manner. The benefits of having supervisor and operator staff with a high level of operational skills are reduced stoppages, increased recovery, improved sugar quality, reduced damage to equipment, and reduced OH&S and environmental impacts.
Evaluate the performance of the falling film tube evaporator at Bingera Mill : final report 2019/201
(Sugar Research Australia Limited, 2020) Sichter, N; Zahn, R; Kumar, S; Broadfoot; Adbi, I
For the 2018 season Bundaberg Sugar installed a 4000 m2 falling film tube evaporator (FFTE) of the BMA design at No 1 evaporator position at Bingera Mill. This was the first installation of a FFTE into the Australian industry. An evaluation program was undertaken during the 2019 season to assess the performance with respect to heat transfer efficiency, effect of scaling rates on heat transfer, deentrainment efficiency of the juice droplets from the vapour outflow stream and the general operational performance. As well tracer studies were undertaken to determine the distribution of residence times for juice in the evaporator. Measurements were also undertaken to determine the extent of sucrose degradation occurring within the evaporator. Overall the evaporator has performed well with respect to the above list of test parameters. However, the effect of scaling on heat transfer efficiency was only able to be evaluated for typically 120 hours of operation as the mill was restricted to 5 day crushing operations each week due to the small drought affected crop. A chemical clean of the evaporator was undertaken on shutdown each week.
Evaluate the suitability of the fixed element crystalliser for widespread adoption in Australian sugar factories : final report 2019/202
(Sugar Research Australia Limited, 2020) Gregg, M; Lowrey, M; Broadfoot, R; Abdi, I
The fixed-element design of a horizontal cooling crystalliser is relatively new to the Australian industry and the installation at Broadwater Mill for the 2017 season proved to be an economical solution to refurbish the mill’s first unit in a continuous-flow station of three crystallisers. The crystalliser consists of 12 fixed cooling elements and 14 rotating paddles. A variable-speed drive was installed to allow a rotational speed of the paddles up to 1.45 r/min, depending on the massecuite viscosity and imposed torque. Apart from fabrication of the fixed elements, the mill’s staff undertook the complete installation. During the 2019 season, trials were undertaken which demonstrated good overall performance with respect to heat transfer, residence time distribution and molasses exhaustion. The good performance is attributed to the paddles providing strong flow of massecuite transversely and also longitudinally to generate flow across the cooling surface. Torque control of the variable speed drive is recommended as this allows rotation of the paddles at maximum speed for the prevailing viscosity of the massecuite, while limiting the stresses on the drive components.
Evaluation of high open area screens
(BSES, 1987) BSES Staff
Following the offer from ANI-Sargeants of several sets of high open area screens for testing, trials were arranged at Fairymead and Millaquin Mills, as it has been the contention that higher open areas would allow higher fugalling rates for the same purging efficiency and purity rise.