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Agro Engineers
(ISO 9001:2008 Enterprise)
E-3, Industrial Estate,
Kota - 324007, Rajasthan, INDIA.
Tel/Fax:+91-744-2363799

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Sugar Crystalliser Drive

Selection for Sugar Crystallizer Drive

Sugar Crystalliser DriveAGNEE offers easy-to-fit, shaft mounted Crystalliser drives rated up to 10.0 HP, and for output speeds 1 to 0.25 RPM to cover standard range of horizontal type sugar crystallisers 30 T to 150 T capacities and up to 350 T capacity for vertical crystallisers. Developed after an in-depth study of typical crystalliser installations, AGNEE crystalliser drive employs high efficiency spur gearing instead of conventionally used worm gearing. The overall efficiency of AGNEE crystalliser drives is better than 90% and the installed motor rating is optimally used resulting in attractive savings in power consumption.

The drive arrangement consist of electric motor a multi-stage planetary gear reducer and a single stage spur gear transmission. The electric motor is flanged-mounted to the input of the planetary gear reducer, which in turn is flange-mounted to the input of spur gear transmission. The hollow input of the spur transmission can be keyed directly on to the crystalliser shaft. The drive unit can be aligned in a convenient direction with respect to the crystalliser axis and its torque arm structure is to be bolted at the convenient place. No other additional structure, such as base frames or any couplings are required. The drive unit is completely enclosed & oil-tight. All internals including bearings are oil-lubricated, oil change is recommended only once a season.

 

Comparison of Agnee Sugar Crystalliser Drive with open type Worm And Worm Wheel Arrangement for crystalliser application

Power Consumed  Generally motor rating will be from 10 to 40 HP Maximum motor rating will be within 10.0 HP
Efficiency

 

Highly inefficient and losses in the gear system are very high and efficiency is very poor and goes down to 25 / 30% Efficiency is very high-about 90% because of high efficiency planetary gearing.
Labour requirement for operation  All components are open type and hence one person is always required to attend the oil filling No need of frequent oil filling. Oil to be changed only once in a season.
Cleanliness

 

Surround area will be highly unclean due to oil overflowing As there is no oil over flow, surroundings will remain clean and free of oil spread
During power failure operation by hand Very difficult to rotate it by hand Very less power is required and one person can rotate the shaft
Installation Due to many components the alignments are to done property & the same are very critical. The phosphorous bronze bearing are used which have a restricted life and can damage other components due to microparticles generated because of wear & tear. It is mounted on crystalliser shaft directly. It is easy to install and as assembled with bearings has no tear to damage other parts.
Annual Maintenance Costlier No special annual maintenance is needed. Maintenance is limited to only changing the oil once in a season
Life of the gear unit Since the gears are open type and surrounding atmosphere is dirty due to overflowing of Massecute, gear unit life is very much affected. Totally enclosed construction and hence continuous lubrication is ensured & there is no scope for foreign material entry inside the gear unit leading to extended life of the gear.

ADVANTAGES OF AGNEE SUGAR CRYSTALLISER DRIVE:

1) Shaft Mounting Construction : Compact single unit, shaft mounted drive configuration goes directly on the crystalliser shaft. No couplings, bulky foundation, base frames etc.

2) Low Power Consumption : High efficiency Planetary transmission ensures at least 60% reduction in installed power as compared to the conventional worm gear system.

3) Reduced maintenance Cost : Routine maintenance is limited to re-lubrication, and that too once a season.

4) Longer Life : Enclosed construction ensures uniforms lubrication of rotating elements and result in longer life.

5) Handling : Easy to handle due to light weight and compactness.

6) Application : Can be used for all types of crystalliser. (i.e. Water-cooled, air-cooled and vacuumed. Also for horizontal and vertical types)

EXAMPLE OF ENERGY SAVING.

  • Size of sugar plant = 5000 TPD
  • Number of crystallisers used = 16
  • Power of each motor driving crystallisers with conventional method of worm wheel assembly 10 HP each       Hence total power consumed = 160 HP
  • Average power of each motor driving AGNEE DRIVE planetary drive 3.0 to 5.0 HP
  • Hence total power required 48 to 80 HP
  • Accordingly total power saved (actually it is higher than this value as we have considered 5 HP each for all drive Normally 5 HP, 3 HP are used in many drives 80 HP
  • Other indirect saving = due to lower horse power, we can use low capacity motor, feeder cable MCCs, starters switches etc. electrical and gear box maintenance cost
  • Consider 160 days of a season & rate of Rs. 4.00 per KWH. It adds to saving of
    a) No. Of crystalliser = 16
    b) Total No. Of Working Days = 170 Days
    c) Rate Per KWH Rs. 4.00
    d) Saving 80 HP / Day

    Therefore
    a b c d = saving of Rs. per Season
    16 170 4 80 = Rs. 8.70 lacs/ season
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