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SUGARTECHNOLOGY&INNOVATION R-5 28/11/2011. RR TASKS Cane juice extraction is the most power demanding step in the sugar process. Reggiana Ridutto has.

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Presentation on theme: "SUGARTECHNOLOGY&INNOVATION R-5 28/11/2011. RR TASKS Cane juice extraction is the most power demanding step in the sugar process. Reggiana Ridutto has."— Presentation transcript:

1 SUGARTECHNOLOGY&INNOVATION R-5 28/11/2011

2 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 Lets see HOW

3 INCREASE IN MECHANICAL EFFICIENCY CONVENTIONAL MILL DRIVE foot-mounted reduction gearings with tail bar, crown pinions and rope couplings does it easier with its INNOVATIVE PINIONLESS MILL DRIVE INNOVATIVE PINIONLESS MILL DRIVE consisting of consisting of SHAFT MOUNTED GEARBOXES DIRECTLY ON THE ROLLER SHAFT

4 EQUIPMENTSPINIONLESS DRIVE CONVENTIONAL MILL AC Motor96% REDUCTION GEARS95%92% Low speed OPEN GEAR60% Tail Bar97% CROWN PINION92% TOTAL EFFICIENCY 47% INCREASE IN MECHANICAL EFFICIENCY VFD Electric motor 96% High speed reducer 90% Crown pinion 92% Tail bar 97% WIN 200% MORE EFFICIENCY WITH PINIONLESS DRIVE WIN 200% MORE EFFICIENCY WITH PINIONLESS DRIVE CONVENTIONAL DRIVE 91%

5 INCREASE IN MECHANICAL EFFICIENCY EQUIPMENTSPINIONLESS DRIVE ROPE COUPLING MILL AC Motor96% REDUCTION GEARS95%92% Rope coupling97% CROWN PINION92% TOTAL EFFICIENCY 91%79% ROPE COUPLING DRIVE 15% MORE EFFICIENT THAN COMMONLY USED PLANETARY DRIVE

6 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)

7 SHAFT MOUNTED GEARBOXES NO NEED OF FOUNDATIONS COMPACT FACTORY DESIGN INVESTMENTS REDUCTION

8 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

9 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

10 WITH PINIONLESS DRIVE UNIFORM CANE BLANCKET COMPRESSION LONGER 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 PINIONS BRASSESBEARINGS

11 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 EXTRACTION REDUCED WEAR LESS MAINTENANCE

12 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

13 SIZET 2max [Nm] RR651200 RR1051800 RR1102000 RR2102500 RR3105500 RR5107000 RR7108500 RR81014500 RR101017500 RR170026500 SIZES FOR SIZET 2max [Nm] RR250037000 RR320058000 RR400075000 RR520092000 RR6500125000 RR8000160000 RR10000190000 RANGE AND SOLUTIONS 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 !

14 MILL CAPACITY over 6000 TCD MILL CAPACITY up to 6000 TCD SIZES FOR RANGE AND SOLUTIONS RANGE AND SOLUTIONS SIZET 2max [Nm] RR15000275000 RR20000395000 RR25000580000 RR30000680000 RR40000790000 RR55000950000 RR700001000000 RR850001100000 RR1100001500000 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

15 RANGE AND SOLUTIONS 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

16 RANGE AND SOLUTIONS 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

17 RR thinks global and acts local RR GROUP WORLD READY TO ASSIST YOU WORLDWIDE!

18 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.


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