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Sugar Crystalliser
Drive
Selection for
Sugar Crystallizer Drive
 AGNEE 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
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Power Consumed |
Generally motor
rating will be from 10 to 40 HP |
Maximum motor
rating will be within 10.0 HP |
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Efficiency
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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. |
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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. |
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Cleanliness
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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 |
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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 |
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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. |
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Annual Maintenance |
Costlier |
No special annual
maintenance is needed. Maintenance is limited to only changing the
oil once in a season |
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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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