MILL SETTING
JEGADEESH.M
ENGINEER
INDIAN CANE POWER LIMITED
DEFINITIONS :
Mean effective diameter of Top Roller D
= (Outside diameter of roller - Depth of grooving)
Work Opening : Actual opening between any two points on the
surface of the two rollers in their common
axial plane when the mills are in operation.
Mill Setting opening : Actual opening between PCD to PCD of concerned
opening rollers, when mills are at rest and empty.
DATA REQUIRED FOR MILL SETTING
C = Crush rate desired in tons (Metric)/hr.
f = fibre % cane
D = Mean effective diameter of Top Roller (mm)
L = Length of the roller (mm)
n = Speed of rotation (rpm) {To be determined based on
No. of rollers in mill tandem, crush rate, preparatory
index, specific fibre loading, power availability at setting
speed etc.}
PROCEDURE FOR CALCULATION OF MILL SETTING
V = Mill Roller surface speed
xDxn
V = ------------- m/min.
1000
Calculate fibre rate 'F' as per formula given below:
F = C x f x 0.166 Kg / min.
Calculate the discharge work opening as
per formula given below:
F x 63429.6
Discharge work opening = ---------------------- mm.
SxVxL
Where ‘S’ denotes the Fibre Index to be read from Table – 1.
Actual Discharge Work Opening = (Discharge work opening – Roller
Rise) mm.
The 'Roller Rise' considered for the mills shall be taken as per Table 2.
TABLE – 1
Values of Fibre Index ‘S’
Mills 12 Roller Tandem 15 Roller Tandem
2nd of `B’ Tandem 38 40
3rd of `B’ Tandem 45 46
4th of `I’ Tandem 52 52
TABLE – 2
ROLLER RISE
Mill No. 12 Roller Tandem 15 Roller Tandem
Roller Trash Roller Trash
2nd of `B’ 7 8 7 8
Tandem
3rd of `B’ Tandem 6 7 6 7
4th of `I’ Tandem 5 6 6 6
Calculate the Feed work opening as per formula given below:
Feed work opening = Discharge work opening X (Ratio of feed
to discharge opening) mm.
The Ratio of Feed to Discharge opening for the mills shall be taken as per
Table 3.
Actual Feed Work Opening = (Feed work opening – Roller Rise) mm.
TABLE – 3
Ratio of Feed to Discharge Opening presumed for calculations
Mills 12 Roller Tandem 15 Roller Tandem
2nd of `B’ Tandem 2.00 2.05
3rd of `B’ Tandem 2.15 2.10
4th of `I’ Tandem 2.20 2.15
Calculate the Trash plate work opening as per formula given
below:
Trash Plate work opening = Feed work opening X (Ratio of trash
plate to
feed opening ) mm.
The Ratio of Trash Plate to Feed opening for the mills shall be taken as
per
Table 4.
Actual Trash Plate Work Opening = (Trash Plate work opening – Roller
Rise)mm.
TABLE – 4
Ratios of trash plate to feed opening presumed for calculations
Mill No. 12 Roller Tandem 15 Roller Tandem
2nd of `B’ Tandem 1.70 1.75
3rd of `B’ Tandem 1.80 1.80
4th of `I’ Tandem 1.80 1.85
SPECIMEN CALCULATIONS
DATA
Crushing Rate (c) : 250 Tons (Metric) of Cane per hour (TCH)
Fibre % Cane (f) : 13%
Roller Length (L) : 78 1/8 inches
Mill Size (D x L) : 39 inches O.D. x 78 1/8 inches
Speed selected (n) : 5.5 r.p.m.
Now calculate the factor 'F' for the above conditions
xDxn 3.1416 x 915 x 5.5
V = --------------- m/min. = ------------------------
1000 1000
= 15.81 m / min.
Calculate factor 'F' as per formula given below:
F = C x f x 0.3733 lb / min.
= 250 x 13 x 0.166
= 539.5 Kg / min.
Calculation of Discharge work opening
F x 63429.6
Discharge work opening = -----------------mm.
S x V xL
For value of ‘S’ see table - 1
539.5 x 63429.6
= ------------------------
40 x 15.81 x 1980
= 27.3 mm
Calculation of Feed work opening
Feed work opening = Discharge work opening X
(Ratio of feed to discharge
Opening)
For value of ‘Ratio’ see TABLE-3
= 27.32 x 2.05
= 56 mm
Calculation of Trash plate work opening
Trash Plate work opening= Feed work opening X
(Ratio of trash plate
to Feed Opening)
For value of ‘Ratio’ see TABLE-3
= 56 x 1.75
= 98 mm.
The discharge, feed and trash plate openings for all the four mills are
tabulated below.
Mill No. Feed Side Opening Discharge Side Opening Trash Plate
(mm) (mm) Opening
(mm)
2nd of `B’
56 27.3 98
Tandem
3rd of `B’ Tandem 50 23.8 89.8
4th of `I’ Tandem 45 21 83.7
The ‘Mill Settings’ for all four mills can be calculated as given
below:
Mill Settings in mm
Mill No. Feed Setting = Discharge Opening = Trash Plate Setting =
Actual opening- roller Actual opening- roller Actual opening- roller
rise rise rise
2nd of
`B’ 56 – 7 = 49 27.3 – 7 = 20.3 98 – 8 = 90
Tandem
3rd of `B’
50 – 6 = 44 23.8 – 6 = 17.8 89.8 – 7 = 82.8
Tandem
4th of `I’
45 – 6 = 39 21 – 6 = 15 83.7 – 6 = 77.7
Tandem
The mill settings calculated should be rounded off for practical adjustment
purpose.
