FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
As amended by the Patents (Amendment) Act, 2005
5 &
The Patents Rules, 2003
As amended by the Patents (Amendment) Rules, 2006
COMPLETE SPECIFICATION
(See section 10 and rule 13)
10
TITLE OF THE INVENTION
Prepared cane equalizer for improvement in cane preparation, crushing and results in cane
sugar industry
15 APPLICANTS
Pruthviraj Rajendra Patil and Rajendra Baburao Patil, both Indian nationals of Flat No. S-10,
Kings Court Apt., Shivaji Park, Kolhapur- 4116001
INVENTORS
20 Pruthviraj Rajendra Patil and Rajendra Baburao Patil, both Indian nationals of Flat No. S-10,
Kings Court Apt., Shivaji Park, Kolhapur
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the nature of this invention and the manner
25 in which it is to be performed.
2
Prepared cane equalizer for improvement in cane preparation, crushing and results in cane
sugar industry
TECHNICAL FIELD
5
This invention relates to “prepared cane equalizer for improvement in cane
preparation, crushing & results in cane sugar industry “type sugar cane mill & more
particularly to system for cane crushing mill having several mill units in one milling tandem.
10 BACKGROUND
In sugar plant, the extraction of juice from the cane is done at milling station. The
cane bundles in the truck are lifted by cane unloader and kept on feeder tables &dropped by
its drag type chain into cane carrier. These feeder tables are located on either side of cane
15 carrier. Generally length of cane carrier is around 65 Mtrs. the preparative devices such as
chopper, Leveller & fiberizer are mounted on top side of cane carrier, after ending straight
cane carrier length about 45 Mtrs.
The cane is conveyed by cane carrier to the milling station by making it as prepared
cane by cane preparatory devices like chopper, Leveller & fiberizer. The function of these
20 devices is to cut cane in pieces & make them as fibrous keeping its PI (Preparative Index)
above 85 but not to drain the juice in these devices. Juice is extracted in milling station only.
Cane sugar industry is facing financial crises due to FRP (Cane Price given to
Farmers) & comparatively reducing prices of sugar day by day, increasing production cost,
draught condition resulting in unavailability of sufficient cane, changing government policies.
25 There are also several technical problems and losses in sugar industries due to manufacturing
defects, lack of proven technology at some station. Loop holes resulting in less efficiency
during modification, expansion & addition of plant and machinery. Collectively these
problems led to the huge losses to sugar industry & nation due to reduced crushing capacities,
less efficiencies, long duration repeated stoppages, break downs & failures collectively
30 resulting in high total sugar losses resulting in low sugar recovery.
There is a serious problem of uneven feeding to all preparative devices & milling
tandem in the sugar industry. Uneven blanket height of prepared cane are passed from
chopper and leveller from the top side, this uneven blanket i.e. up & down blanket passing
3
towards cane fiberizer has vary irregular and poor density of around 275 to 350Kg/m³. There
are so many problems due to irregular, uneven feeding resulting in the cut cane blanket height
and quantity is always up & down. All of these problems, results in less crushing rate,
irregular milling performance, irregular bagasse quality & boiler efficiency resulting to
reduce export of 5 co-gen frequently.
EXISTING SETUP & PROBLEMS IN THE SUGAR INDUSTRY
For cane preparation there are three machines installed, one after another in series on
10 cane carrier. The cane chopper/Kicker, Leveller or cutter & fiberizer or shredders to achieve
continuous working & achieve high cane preparation for cane milling tandem. The expected
preparatory index is in the range of 85 to 88. The cane preparation is expected of shred of
long hairy fiber type & not in the powder form.
15
PRINCIPLE & WORKING OF EXISTING CANE PREPARATIVE DEVICES
The cane bundles from the truck are lifted by cane unloader & kept on feeder tables &
dropped by its drag type chain in to cane carrier. The cane is conveyed by cane carrier
20 through preparative devices like chopper, leveler & fiberizer. This prepared cane is dropped
in to rake carrier going to the mill stations. The function of these preparative devices is to cut
cane in pieces & make them in to long hairy fiber type. Cane bundles dropped from all feeder
tables are not equal by width, depth, length & density. When same cane bundles passes
through chopper & leveler the cut cane blankets going to fiberizer are always up & down.
25 This results in frequent load variation i.e. up & down load on fiberizer.
As fiberizer load is sensed in A.C.F.C. (Auto feed control carrier device) it reduces &
fluctuates cane carrier speed frequently affecting on crushing rate minimum by 50 ton/Shift.
This results in always unequal quantity of prepared cane going to mill & boiler.
As mill setting & mill RPM are constant it results in wet bagasse & also on mill
30 extraction when less bagasse quantity passes through same mill opening. These variations can
be observed in every minute on mill load i.e. current of mill driving motor (prime mover).
4
This more & less quantity & simultaneously wet & dry bagasse going to boiler effects
on variations in load, pressure & temperature of steam & ultimately resulting to reduce
generation & export of co-gen turbo-alternator minimum 5-6 time in one hour.
Hence expected uniform & equal feeding of prepared cane to milling station with uniform
cane preparation 5 is not achieved.
DESCRIPTION
10 In the “Prepared Cane Equalizer” the cut cane blankets coming from preparative
devices chopper & leveller has always up & down blanket height. Also there is variation in
the density & quantity of prepared cane going to fiberizer. The prepared cane Equalizer is
situated between leveller & fiberizer at top level of cane carrier. Thus when excess height
cane blanket comes to Equalizer it is thrown back by the knives towards leveller& fills the
15 gaps & voids to correct level of blanket. Fix height blanket of prepared cane is allowed to go
to fiberizer. Also the density of approaching cane is enhanced to 400 to 425 kg/m3. The
compact density properly levelled and stabilized flow of prepared cane is allowed to pass
towards the fiberizer.
The power & speed of equipment are as minimum as possible. Thus excess height
20 prepared cane blanket approaching to the equipment is immediately & efficiently thrown
back towards cane leveller to fill up empty voids & gaps already existing due to batch type
cane feeding, by this equipment is never allowed to pass to the fiberizer from bottom as well
as top side of equipment. Simultaneously prepared cane density proceeding to fiberizer is
increased to the higher level 425 to 475 kg/m3 to help to improve uniform cane preparation &
25 total preparatory index. Thus the total performance of fiberizer & milling tandem is improved
due to equal & uniform feeding.
DESCRIPTION OF WORKING OF “PREPARED CANE EQUALIZER”
30
Sugar cane coming to the sugar factory in the bundle or loose form by bullock carts,
tractors trailers & trucks. They are lifted & kept on feeder table & then dropped in to cane
carrier & conveyed by it. The cane bundles in the cane carrier are in different shapes, length,
5
height & width. It has many gaps & voids in between bundles creating non continuous less
density flow of sugar cane passing through the preparative devices this inlet cane density is in
the range of 150 to 175 kg/m3.The same uneven height & quantity cane is passed through
chopper & leveller where its density is increased in the range of 300 to 350 kg/m3. The
prepared cane Equalizer has specially knives having sharp edge if necessary 5 to cut & throw
back the excess height blanket of prepared cane. This prepared cane Equalizer designed to
rotate in reverse direction as compared to the travel of incoming cane on the cane carrier. The
prepared cane Equalizer rotates with the speed in the range of 40 to 60 rpm.
The prepared cane Equalizer assembly is connected to electric motor through the
10 speed reduction gear box these motor, gear box & Equalizer assembly along with the pedestal
can be erected on fabricated staging structure & without requiring civil foundation. The total
round disc on the main shaft are in the range of 10 to 15 depending upon crushing capacity &
carrier width. Thus this prepared cane Equalizer keeps constant height & quantity of prepared
cane simultaneously increasing the density of prepared cane going to fiberizer. The excess
15 height blanket are thrown back & fill up between voids & gaps between the uneven prepared
cane & the flow stabilized & become uniform. The precisely controlled quantity of densely
prepared sugar cane is allowed to pass through fiberizer. The density of incoming prepared
cane in the range of 300 to 350 kg/m3 is increased up to 425 to 475 kg/m3 due to press &
vertical force of the knives on the prepared cane blanket. Thus the equalizer helps to provide
20 uniform feeding & improve cane preparation, avoiding cut cane going to the mills. Also the
cane preparative index is observed uniform & thus the milling efficiency improved due to
regular, equal prepared cane feeding.
We have observed following advantages & benefits of prepared cane Equalizer due to
feeding equal, uniform quantity & height of prepared cane blanket whose density is increased
25 remarkably, which effects on working of fiberizer, uniform PI, increased crushing rate,
milling & boiler efficiency & co-gen export.
ADVANTAGES, FEATURES, BENEFITS OF PREPARED CANE EQUALIZER
1) Keeps equal load on cane fiberizer.
30 2) Reduces cane carrier load, speed fluctuations & increase density of bagasse going
to fiberizer.
3) Gives constant & equal bagasse flow to fiberizer, mill & Boilers.
6
4) Keeps cane preparation uniform due to equal and uniform feeding of cane to
fiberizer it also avoid to pass uncut cane from fiberizer.
5) Removes out foreign material going to fiberizer and mill.
6) Reduces mill Donnelly chute jamming problem.
7) Reduces wear & tear of mill components due to equal, constant 5 feeding and loads
on all mills.
8) Reduces oil & lubricants required for milling station & plant due to equal,
constant feeding & smooth operation of mills.
9) Maintain juice tank level above 60% constantly.
10 10) Reduces wet bagasse (during gap & fluctuations) going to boilers.
11) Reduces fluctuations in boiler load, pressure, temperature & efficiency.
12) Reduces fluctuations in Co-gen plant, electricity generation, export & efficiency.
13) Optimize mill extraction & boiler thermal efficiency due to constant level of dry
bagasse.
15 14) Optimizes & keep constant temperature & pressure of boiler resulting in Optimize
enthalpy of steam.
15) Optimizes specific steam consumption of turbines.
16) Increases bagasse saving by minimum 15 to 25 M.T. per day.
17) Increases crushing rate by 100 to 150 ton per day.
20 18) Increases export of power by 3000 to 5000 unit per day.
19) Stabilize capacity & efficiencies of whole mill, boiler, turbine, co-gen & boiling
house i.e. whole plant.
CONSTRUCTION & OPERATION OF “PREPARED CANE EQUALIZER”
1) The overall tip diameter is in the range of 1250 to 1390mm.
25 2) Speed of the Equalizer rotor is 30 to 72 rpm.
3) The installed power is only 20 to 35 HP i.e. 0.075 to 0.095 bhp/tch crushing rate at
15% fiber on cane.
4) The disk diameter is 700 to 900 mm.
5) Speed reduction gear box is used of suitable ratio.
30 6) The tip speed of knives is 3.25 to 4 m/s.
7) The direction of rotation of rotor is in reverse direction with respect to cane
travelling to the sugar cane through cane carrier.
7
8) The pitch of the knives is 110 to 170mm horizontally.
9) The knives are located axially at peripheral pitch of 900.
10) The clearance below tip of knives up to the bottom level of cane carrier slat is
about 4 to 4.27 times the clearance, below the cane leveller.
11) The ratio of clearance below fiberizer 5 remains unchanged.
12) There is one working sharp edge to throw excess cane blanket back towards the
leveller this knives are made up of IS : 2062, 1999 GR.A the length of cutting
knives is 400 to 450mm & thickness 50mm.
13) The no. of knives in the rotor is arranged in four equal rows. Total no. of knives
10 are 48.
14) The knives are fitted on each consecutive row are staggered to cover complete
width of cane carrier. The knives are fitted on each rows& opposite to each other.
Also knives on each row are in equal number & weight for static & dynamic
balancing.
15 15) The disk hubs are made up of Abrasion resistance Mild Steel Material IS-2062,
GR.A.
16) There are 4 nut bolts of sufficient cross section for each knife holding firmly with
the disk hub.
17) No necessity of flywheel on N.D.E to reduce the peak load.
20 18) There are spacers fitted horizontally to support & keep intact the disk hub at equal
pitch.
19) The M.S plate hood is provided at the top to safeguard workers & workmanship to
avoid injury to the worker.
20) The single fold hinged flaps are provided immediate at top after ending leveller
25 hood. The height & weight of flap is kept so as to level some excess cane blanket
& settle in cane carrier voids.
21) All the problems caused by feeder table, chopper & leveller are corrected in this
new designed equalizer named “PREPARED CANE EQUALIZER FOR
IMPROVEMENT IN CANE PREPARATION, CRUSHING & RESULTS IN
30 CANE SUGAR INDUSTRY”
8
DESCRIPTION OF DRAWING
Referring Fig 1. Is somewhat diagrammatic overview location of “PREPARED
CANE EQUALIZER FOR IMPROVEMENT IN CANE PREPARATION, CRUSHING &
RESULTS IN CANE SUGAR INDUSTRY”
Fig 2.Is details of shaft, disk hub & knife of “PREPARED 5 CANE EQUALIZER FOR
IMPROVEMENT IN CANE PREPARATION, CRUSHING & RESULTS IN CANE
SUGAR INDUSTRY”
Fig 3. Is details of assembly of knives on disk & assembly of disk with knives on
shaft, of “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
10 PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY”
DETAILED DESCRIPTION
Referring fig 1. In the PREPARED CANE EQUALIZER FOR
IMPROVEMENT IN CANE PREPARATION, CRUSHING & RESULTS IN CANE
15 SUGAR INDUSTRY “sugar cane conveyed through the cane carrier passing through
chopper, leveler & travels further on the cane carrier the flow is of irregular height & width
density. This irregular height, width & density of chopped sugar cane is passing to the
prepared cane equalizer. The direction of rotation of equalizer rotor is in reverse direction as
compared to the travel of incoming cane on the cane carrier.
20 Thus the edge of knives levels the excess height of cut cane coming to the
equalizer; it throws back the excess level of chopped cane towards the leveler to fill up the
voids & gaps in the blanket of cane to maintain the constant (equal) height of blanket.
As fig 1. Shows the uneven height & density of cut cane blanket is leveled or
maintained by the knives of the prepared cane equalizer. The density of cut cane blanket is
enhanced up to 425 to 475 Kg/m325 & higher preparatory index of 85% suitable for milling
tandem. Thus the prepared cane equalizer is very innovative concept useful for sugar tandem.
The crushing capacity is increased with P.I & milling tandem performance is improved to
great extent with the help of prepared cane equalizer.
9
As in Fig 2. The “PREPARED CANE EQUALIZER FOR IMPROVEMENT
IN CANE PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY
“there are knives having single sharp edge. Also the arrangement of knives on disk are shown
total number of knives are 48, each disk have four knives fitted equiaspaced.
As in Fig 3. The “PREPARED CANE EQUALIZER 5 FOR IMPROVEMENT IN
CANE PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY “there
is arrangement of disk on shaft the knives are fitted on each consecutive row are staggered to
cover complete width of cane carrier. The knives are fitted on opposite rows are in equal no
& weight for static & dynamic balancing.
10 Our new invention & device named as Prepared Cane Equalizer is first time
moderately designed & located at new position i.e. in between leveller & fiberizer. These
equalizer keeps equal blanket height & quantity of prepared cane going to fiberizer, mill &
boiler. When more height of blanket of cut cane passes through leveller and comes to
equalizer. The excess blanket is thrown back & dropped in voids & gaps, which makes equal
15 level of blanket. Also the density of prepared cane going from equalizer to fiberizer is
increased. This uniform & equal quantity, density of bagasse due to new equalizer, goes to
fiberizer, mill & boiler resulting in ultimately increasing crushing rate, bagasse saving, export
of power, as mill & boiler thermal efficiency are optimized and also stabilized.
In short: - Due to uniform feeding of cane to fiberizer, cane preparation is uniform &
20 no uncut cane is passed. Uniform feeding has resulted in minimum variations in auto cane
feed control system & also juice flow fluctuation are observed minimum. This uniform
preparation has led to uniform bagasse generation & also fiber size is uniform.
Hence equal & dry bagasse from mills goes to boiler. This has improved boiler
operation to optimized level & designed parameter of pressure & temperature are achieved.
25 Fluctuation in steam pressure & temperature are observed very less. This also has
made turbine to operate at designed load & efficiency parameters & hence export is
increased. Also steam going to process is observed uniform.
30
10
We claim:
1) In the “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY”
Sugar Cane dropped from feeder tables on the cane carrier is conveyed by it &
that travels in different shapes bundles width, height, length 5 & density in the
entangled from & it has many gaps & voids in between bundles, creating non
continuous less density flow of Sugar cane passing through the first two
preparatory devices chopper & leveler, where sugar cane is cut in to pieces but
prepared cane blankets remain up & down horizontally & also widthwise. Also
10 there is variation in quantity & density of prepared cane going to fiberizer.
The new “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN
CANE PREPARATION, CRUSHING & RESULTS IN CANE SUGAR
INDUSTRY” Is situated after leveler & fiberizer. This is the first time new
location & it is moderately designed & fitted at selected position where its
15 purpose & aim is achieved with result. The incoming uneven blanket height of
prepared cane towards this new equalizer is well leveled, densed & excess
prepared cane is thrown back which is dropped in gaps & voids, where level of
blanket is automatically corrected & also maintained, hence equal height, quantity
& density of prepared cane goes to fiberizer. Hence we get uniform cane
20 preparation& P.I. Also no uncut cane is passed & load on fiberizer remains
uniform resulting to reduce fluctuation in cane carrier. Thus crushing rate is
improved satisfactorily. This uniform, equal quantity of prepared cane goes to mill
tandem for juice extraction.
2) The “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
25 PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY” as
claimed in claim 1 where in the location & position of the equalizer are shown &
are in between leveler &fiberizer.
3) “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY” as
30 claimed in claim 1 where in the speed of rotor of equalizer is 30 to 72 rpm. The
drive hp of motor is in the range of 20 to 40 hp.
11
4) The “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY” as
claimed in 2 & 3 where in the tip diameter is in the range of 1250 to 1390 mm.
5) The “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
PREPARATION, CRUSHING & RESULTS IN CANE 5 SUGAR INDUSTRY” as
claimed in claim 2 & 3 where in the disk hub diameter is 700 to 900 mm.
6) The “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY” as
claimed in claim 2 & 3 where in the length of cutting knives is 300 to 450 mm. &
10 horizontal pitch of knives is in the range of 110 to 170mm.
7) The “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY” as
claimed in claim 2& 3 where in the knives of equalizer are made up of IS 2062,
1999 GR.A & working edges of knives are hard-faced by best possible abrasion,
15 wear & chemical resistant properties.
8) The “PREPARED CANE EQUALIZER FOR IMPROVEMENT IN CANE
PREPARATION, CRUSHING & RESULTS IN CANE SUGAR INDUSTRY” as
claimed in claim where in the no. of knives on the rotor are arranged in from equal
rows with 24 to 25 /MT width of cane carrier. The knives fitted or opposite row
20 are in equal number &weight, for static & dynamic balancing.