APPLICATION REFERENCE
Sugar cane and Biomass
Best of the month: JANUARY 2011
Sugar cane mill Drives and Biomass
Renewable energy solutions
DESCRIPTION OF APPLICATION
Sugar cane is a raw material that can be transformed in several end products:
sugar, alcohol for alcoholic beverages, ethanol fuel, alcohol for industrial or
antiseptic uses, paper from the pulp, pellets for domestic stoves from the solid
residues, organic fertilizer (compost) for agriculture, thermal and electric energy for processing use and for exportation.
Ethanol fuel, pellets, thermal and electric energy are energies from a renewable source: biomass of sugar cane.
ALCOHOLERA DE ZAPOPAN, founded in 1920, is the leading company of drinkable, denatured, and non-smelling grain and sugar cane ethyl alcohol production and commercialization in Mexico. It is located in Zapopan city in Jalisco
State (Pacific Coast). One of its several distillery plants, with latest generation
technology, is located close to Córdoba city; at Veracruz State (Golf of México).
ALCOHOLERA DE ZAPOPAN has chosen Bonfiglioli Group because of its wide
range of products in terms of transmissible torque (from 1kNm to 1195 kNm),
different kinds of gearmotors (helical, bevel helical, planetary and helical worm
reducers driven by AC electric motors) and Bonfiglioli ability in product customization to solve specific needs of these applications.
By new 323 size for sugar cane mill drives of 306 kW power, Bonfiglioli Group
has been now able to supply gearmotors for entire process: agricultural machines driven by Bonfiglioli hydraulic gearmotors, hoist for track unloading,
conveyors for cane feeding, roller conveyor for cane preparation (earth separation and washing, and drying by compressed air flow), devices to chop and
shred the cane, sugar cane mills to extract the juice and dry the solid residues
(bagasse), belt conveyors of solid residues, belt conveyors for ash of burned
residues and sugar crystallizer mixer drives.
for internal use only
Sugar cane and Biomass
APPLICATION REFERENCE
GENERAL NEEDS OF THE APPLICATION
In distillery plant close to Córdoba city, there are 2 big sugar cane mills, each with 4 cane rolls.
Each sugar cane mill is driven by a Bonfiglioli gearbox connected by a torque limiter to an electric
motor of 306 kW power, with 1190 rpm rated speed, vector controlled by frequency inverter.
The sugar cane mills receive the bagasse after the sugar cane has been mashed to extract the
juice (sucrose) in order to dry them between 48% and 50% of humidity. t’s very important to dry
bagasse as much as possible in order to get the better efficiency in thermal and electric energy
generation. These new sugar cane mills are able to dry the bagasse up to average moisture of
49% instead of 52% of other traditional sugar cane mills in Mexico and they have the capacity
to receive the bagasse corresponding to a rate of 100.0 tons of cane per hour.
Other machines of preparation and extraction are sized to reach this high production. The boiler
will burn bagasse up to average moisture of 49% producing steam that will be sent to the distillation, cane diffuser and concentration equipment. Part of steam is expanded inside a turbine
that produces 8 MW of electric energy from renewable source that will be used in the plant and
exported to the Mexican government enterprise (CFE).
Crucial needs are: punctuality (start up ought to be completed before the harvest); reduced
number of reliable suppliers able to perform excellent service for the entire wide range of installed gearmotors; product reliability; most simple and compact gearbox architecture with highest torque rating.
BONFIGLIOLI SOLUTION
Bonfiglioli gearboxes are installed in most of equipments of distillery plant:
cane feeder conveyor, cane chopper device, cane shredder device, rotating cutter that levels off the cane, sugar cane mills drives, belt
conveyors of solid residues, belt conveyors for ash of burned
residues, sugar crystallizer mixer drives. Bonfiglioli delivered (on time in September 2010) 2 footmounted reducers of new size 323 for 2 mills of
306 kW motor power each one. They have following special features: torque limiter on input shaft,
special 1st planetary stage for high speed, squared
output shaft to be coupled with special elastic joint on
output, water/oil heat exchanger with double filter (no
down time for filter change) and lubricant pump integrated driven by Bonfiglioli AC motor, thermostats and oil
pressure electro-valve.
Full planetary solution is the most compact and costiveness architecture for high torque reducers. For mill with 306 kW of installed
motor power at n1=1190 rpm, bearings life time > 36 000 h and unlimited life of gears at
full motor power, max peak torque =1.2 MNm. Reliability and credibility in delivery and onfield-service by Mexican distributor Ecomssa and Bonfiglioli USA.
Bonfiglioli products
Description
Sugar cane
mill drives
for internal use only
2 x X_3 23 L 3 203 FP V120 A G0A each one includes
BN 90LA 4 230/400-50 IP55 CLF B35 CUS in oil pump of water/oil heat exchanger
Sugar cane and Biomass
APPLICATION REFERENCE
Agricultural machines:
Sugar cane harvesters. Main customers: CNH and John Deere.
Main markets: Brazil (4000 gearmotors/year, sizes: 709C2, 606W-607W-609W), USA (400
gearmotors/year sizes: 709C2, 606W-607W-609W), India (sizes: 606W-607W-609W),
China (sizes: 606W-607W-609W).
Distillery owners usually own also plantations and sugar cane harvesters.
Machine Data
Gearbox Data
Weight
(tons)
Tractive
effort/
weight
Travel
speed
(km/h)
Max
pressure
(bar)
Max oil
flow
(l/min)
Wheel
diameter
(mm)
Type
16÷19
0.20÷0.25
up to 20
up to 400
up to 230
1520
709 C2B
Machine Data
Max output Motor displacement
torque
(cc/rev)
(Nm)
and type
17000
75 (axial piston)
(fixed displacement)
Gearbox Data
Weight
(tons)
Tractive
effort/
weight
Travel
speed
(km/h)
Max
pressure
(bar)
Max oil
flow
(l/min)
Sprocket
PCD
(mm)
Type
16÷19
0.40÷0.50
up to 10
up to 400
up to 230
960
709 C2B
for internal use only
Max output Motor displacement
torque
(cc/rev)
(Nm)
and type
23000
Up to 90 (axial piston)
(fixed displacement)
author:
Matteo Grossi: [email protected]
Bonfiglioli