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2. Old & Modern Continuous Centrifugals Operation / EvaluationBy
Muhammad Mahmood
(Process Manager)
Shakarganj Mills Limited, Jhang 2

3. Contents An overview of Continuous Centrifugal
Different models of Continuous Centrifugal machines
Selection of the type of Centrifugal machine
Effect of rpm & Basket Angle
Operational Parameters
Worldwide manufacturers of Continuous Centrifugal
Modern Continuous Centrifugal K 3300
An overview of Continuous Centrifugal K 3300 3 3

4. Contents Specifications of K 3300 Function of different angle basket
Comparison of crystal acceleration force of different basket
High capacity with less power consumption of K 3300
New two stage basket of K 3300
Standard Screen arrangement of K 3300
New rubber buffer design
“Turbo 3” Product distributor
Feeding Device of K 3300 4 4

5. Contents Split Spray nozzle lance of K 3300 Basic Automation
Operator Panel K 3300
Comparison of technical detail of different centrifugals
Technical Aspects
Economic Aspects
Conclusion 5 5

6. Introduction
Continuous centrifugals are in great demand in the sugar industry due to their smooth running and ease of operation. Recent development work and extensive factory trails of modern continuous centrifugals have shown particular advantages in separation of the massecuite into its constituents of shipment sugar & molasses. 6

7. An Overview of Continuous Centrifugal7

8. Different Models of Centrifugal Machines Installed in Sugar Mills
Konti -12 DC
Konti-1100
FCB- 1250
SK-1250 8

9. Selection of the type of Continuous Centrifugals Machine
Basic Parameters for selection of the machine
Curing Capacity Tons/hr with given condition of
Massecuite type and its :
i. Brix
ii. Purity
iii. Temperature
Sugar Quality
i. Purity

10. Selection of the type of Continuous Centrifugals Machine
Basket RPM
Basket Diameter and Angle
i. Basket diameter at top
ii. Basket angle with respect to the tangential at the centre of basket

11. Effect of rpm and Basket Angle
Rpm are selected with the massecuite type, normal recommended rpm and basket angle are as follow:
a / 30º at A Massecuite
b / 30 º at B Massecuite
c / 34 º at C Massecuite
High rpm beyond the recommended limit may cause:
a. Crystal damage
b. Reduce capacity curing
c. Decrease the V belts life
d. Decrease the bearing life
e- Ultimately risk operation of the Machine

12. Effect of rpm and Basket Angle
Low rpm against recommended limits may cause
Low quality sugar production
More molasses circulation in the system
Lesser degree basket against the recommended angle may cause/require :
Resistance to travel the massecuite and sugar over the basket screen.
More power demand for capacity run.

13. Effect of rpm and Basket Angle
Higher degree basket beyond the recommended angle may cause:
Low quality sugar production
More molasses circulation in the system

14. Start up Pre-cautions Bearings are fully greased
Basket is fully tightened with housing unit.
Nickel working screens are fully tightened and sides are overlapped according to the direction of rotation and screen holding clamps are tightened.
No foreign material is present in the basket and massecuite distributor.
Top cover is placed and no air entering point left open in the casing or top cover.
Rotation of the machine with motor run.
Machine is steam heated to +/- 60ºC
Feeding pipe contains no cooled massecuite.

15. Start up Pre-cautions
9. Steam up the feeding pipe of pugmill at both side of the massecuite control valve to reduce the viscosity of the feeding massecuite at the start up and prevent the massecuite from entering the machine, during massecuite removing from pugmill feeding pipe , temporarily blind the feeding pipe of the machine .
10. Stop the steam heating when feeding massecuite and machine gained good operation temperature and machine came in normal operation.
11. Close the feed control valve and open the main massecuite control valve.

16. Start up Pre-cautions
12. Start the machine, after Delta run, start feeding massecuite and notice the over all behavior of the machine at operating conditions, after satisfaction, regulate the massecuite feed control valve.
13. Always use hot water of C immediate after the auger control valve along with massecuite feed to lubricate the massecuite for ease of equal distribution with in the distributor.
14.Very Important to regulate operation of the machine for good quality sugar production at designed capacity at recommended Ampere of the Machine. If there is problem with operation at full load, check and rectify it do not leave it pending for next crop or compromise at reduced capacity operation.

17. Operational Parameters
Use nozzle water spray at basket to maintain Sugar quality with following conditions:
Distance not less than 50 mm
Water temperature C
Water pressure 2 kg/cm2
Good spray is observed with fish tail type nozzles spraying at two points at 180 degree to each other.

18. Operational Parameters
Avoid over washing the sugar crystals, better check is to maintain molasses brix, If at recommended molasses brix sugar quality is not achieved then check other parameters like:
Machine rpm
Number of V belts and tightening condition
Massecuite quality
Nickel working screen condition
Internal cleaning of the machine casing & distributor

19. Operational Parameters
Check and maintain:
Cleaning the machine casing at defined interval
Inspection of the sugar quality
Hourly record the data for;
Feeding massecuite temperature
Water spray temperature
Running Ampere of the machine
Bearing temperature
Sugar and molasses quality

20. Worldwide Manufacturer of Continuous Centrifugals
BMA - Germany
FCB – France
Broadbent – England
Silverweibull – Sweden
Hein Lehman - Germany
Western States – U.S.A
Guangxi Su Group – China
Patange- India
Five Cail KCP-India 20

21. Modern Continuous Centrifugal
K 3300
Newly designed K 3300 series Continuous Centrifugal is highly sophisticated machine with modern characteristics and efficient safe operation.
Reduction in installation height and small space requirement of the new design easy to install and easy to assemble. 21

22. An overview of K 3300 Continuous Centrifugal22

23. Specifications of K 3300 Basket Diameter 1,300 mm Basket Angle
280 / 350
Screen Area
19,500 cm2
Max. gravity factor
2,906
Max. Speed
2000 rpm
Capacity for A-massecuite
35 – 45 t/h
Capacity for B-massecuite
22 – 35 t/h
Capacity for C-massecuite
15 – 19 t/h
Capacity for C-affination
22 – 30 t/h 23

24. Function of different Angle Basket
Centrifugal basket angle determines at what proportion of the centrifugal acceleration is available to move the crystals up the screens and out of the basket.
280 basket
300 basket 24

25. Comparison of Crystal acceleration force of different basket angle
Basket Speed, RPM
Ratio of transport force, F
280
2000
7.3
300
1800
6.5
Steeper basket at high rpm have high crystal acceleration force as where 300 basket has less crystal acceleration force 25

26. Salient Features of New Continuous Centrifugals
K 3300 26

27. High Capacity with Less Power Consumption of K 3300
25% Less power consumption as compared to old
continuous centrifugals.
15% Less wash water quantity.
Better molasses brix which resulted less time on
pan boiling.
Efficient massecuite processing with new turbo 3
distributor. 27

28. Main elements of new design
K 3300
New two stage basket
Upper diameter 1300 mm
Pre - separation of syrup
with high throughput
Harmonized sugar layer in main separation step
Basket of K 3300 28

29. Standard Screen Arrangement
K 3300
Wedge-wire screen at the pre step
Better sugar quality
Reduce 25% energy consumption subject to massecuite quality 29

30. New rubber Buffer design K 3300
Rubber buffers outside of heat affected zone
Easy replacement of rubber buffer
New Motor arrangement
V-Belt tension monitoring 30

31. “Turbo 3” – Product Distributor K 3300
Process Features
- Efficient heating for reduction of massecuite
viscosity
- Increase throughput
- Higher sugar quality
- Better massecuite distribution
- Easy assembling & easy accessible 31

32. “Turbo 3” – Product Distributor K 330032

33. Feeding Device K 3300 Pneumatically operated control valve
Centering facility
Compensator
Sight glass (Temperature
resistant plastic)
Double walled feeding
and heating pipe 33

34. Basic Automation K 3300 Pneumatic acting valve - for massecuite and
- mixing / melting medium
Magnetic inductive flow meter
- for wash water and 34

35. Local Operator Panel K 3300
Two controller for mixing or melting version
Flashing light for less v-belt tension
Flashing light for to high vibration
Display for wash water consumption 35

36. Comparison of Technical Details Of Centrifugals
Description
Konti 12-DC
K-1100
K 3300
Throughput, t/h
For A-mass
B-mass
C-mass
17 – 18
12 – 14
14 – 16
10 – 12
06 – 08
35 – 45
22 – 35
15 – 19
Basket diameter, mm
1265
1100
1300
Basket Angle
300 / 340
300
280 / 350
Maximum Speed, RPM
1800
2000
Power consumption, Kw 75 90
Maintenance / Complexity
High / High
Low / High
Low / Low

37. Technical Aspects
K 3300 37

38. Technical Aspects K 3300 Small space requirements and low installation
height allow a simple replacement of old
centrifugals
High processing rate and best technological
results
Optimum massecuite treatment prior to separation
to close filling system and large Turbo3 product
distributor 38

39. Technical Aspects K 3300 Excellent separation effects to quick syrup
discharge and shifting of the crystals within the
basket
Optimum running smoothness of the centrifugal to
newly designed overall structure
Fewer malfunctions to high degree of automation
with automatic feed control and monitoring of
important functions
High operational safety 39

40. Economic Aspects
K 3300 40

41. Economic Aspects K 3300 Excellent value for money
High Processing rates
Improve process flow
Low operating cost
Long service life to use of stainless steel for parts
in contact with product and syrup
Minimized maintenance costs to reduction of
wearing parts and improved access possibilities 41

42. Conclusion Improved and modern design of centrifugal requires less
application of water which results lower molasses purity.
Enhancement in massecuite curing capacity with less
power consumption.
Save loss in molasses by 1 to 1.5 degrees with
modernization which include:
- Better design of centrifugal
- Better design of centrifugal screens
- Better centrifugal operation
- Measuring operating parameters 42

43. Thanks 43

44. Topic is open for discussion…44