AUTO FEED CONTROL IRIS VALVE FOR CONTINUOUS CENTRIFUGE.

In traditional manual feeding system, due to different viscosities and varying

line pressures result in uneven massecuite feed. The lubrication water remains
unchanged for different feed rate to the centrifuge. This causes reduced
capacity and higher molasses purity/ dilution of molasses.

Automatic massecuite feed control with iris valve for continuous centrifugal
machine To improve the capacity of continuous centrifugal machine, it
requires automation of massecuite feed and water wash. The IRIS flow control
valve (centrally opening as camera aperture) can easily control the massecuite
feed. The automatic massecuite feeding system controls loading of the
centrifugal (motor load) by adjusting the opening of IRIS valve. The Iris
valve provided is operated by an electro pneumatic actuator. For a high control
precision, the pneumatic actuator is designed for a high number of operations.
To control the desired quantity of water wash needle valves are to be adjusted
manually.
OBSERVATIONS:

A continuous centrifugal machine with a manually operated feeding system will

typically average 70% to 80% of the capacity to the capacity of the same
centrifuge using an automatic feeding system. This is because the operator will
normally set the unit to run with lighter load to allow the variation in
massecuite feed rate caused by changing massecuite viscosity and head
pressure.

Even though the machine is capable to cure the massecuite at 80 Amp load, to
avoid overloading, tripping and over flowing the operator will set the machine at
70 Amp on a safer side. That means machine will work at average 6.5 Tons per
hr.

The Centrifuge with an auto feed in it can set to its maximum capacity as it is
continuously monitoring and controlling the preset current value. The machine
never gets over loaded or overflows. Hence the Machine will work at constant 8
Ton per hr. rate.
ADVANTAGES:

1. Optimized sugar yield; wash water and steam quantity are set for optimum
performance; the quantity of massecuite is corrected.
2. Due to IRIS valve massecuite flow is concentric and finely controlled.
3. Optimized centrifugal throughput. (Higher than 10% to 20% of manual
control).
4. Gentle centrifugal operation for a longer service life.
5. No overflow of massecuite in motor trip condition as valve closes
automatically in motor off/ trip condition.
6. Reduced dilution of molasses and direct sugar losses
7. Saves electricity and steam
8. Very user friendly and robust design
9. Easy to install and commission
10. Can be retrofitted easily with the existing panel
11. Maintain Constant Load on the Centrifugal Drives
12. Increase Productivity with Quality
13. Increase Throughput thus Maximum Equipment Utilization
14. Save Energy and Water
15. Increase Work Efficiency
16. Reduce Human Errors
17. Reduce Production Costs
18. Power, Steam and Water Saving due to continuous and controlled intake.
19. Molasses Intake Regulated W.R.T Machine Load.
20. Eliminate Overflow in all stages thus avoid Material Wastage.
21. Facilitate Optimum Capacity Utilization.
22. Control Wash Water in accordance with Feed
23. More Production with the same Equipment.

IN ADDITION TO THIS THERE ARE OTHER INDIRECT LOSSES CAN BE

RECOVERED AS FOLLOWS

1. Due to concentric and constant feed rate mechanical vibration and jerks
reduces. Hence low mechanical maintenance
2. No over flow of massecuite as the valve closes immediately as in case main
motor trip or off condition
3. Solid massecuite rope. There is no air trapped inside the rope. Hence rope
diameter reduces and it helps to distribute the massecuite evenly on the
screen causes increase in curing capacity of machine.
CONTROL PANEL OPERATING FACILITY:

1. The Centrifuge motor on / off controls

2. Centrifuge Load Indication
3. Local and DCS operating Facility
4. Auto/Manual operating Facility through Control Panel
5. Auto/Manual operating Facility through Solenoid valve manual lever

SPECIFICATION WITH SCOPE OF SUPPLY

IRIS Control Valve Specifications

Qty. 01 set
IRIS Valve Centrally opening aperture
valve
Size 8" suitable for basket size
1100mm/1500mm
Body material MS Fabricated
Valve Internals SS 410
1 Body Material Cast Steel
Actuation Pneumatic Linear
Actuator Stroke 150 mm
Positioner Microprocessor based
Electronic
Position Feedback Hall effect
Solenoid Valve ½" for Steam/ water
connection for valve
cleaning
 Matching Flange 1 No.
Iris valve SolenoidSolenoid valve gang with
necessary pneumatic
fittings
Air filter Air filter and valve for inlet
air line
2 Load Sensing of Centrifugal Machine Load
Motor Load
Sensing
Qty. 1 No.
Make AE / L & T / Equivalent
2.1 Sensor Type Current Transformer (CT)
Range Each Motor
Cable Termination 2 - Core Cable
Output 0 - 1 / 5 Amp AC.
Centrifugal Machine Load Transmitter
Qty. 1 No.
2.2
Enclosure DIN Rail mounted.
Input 0 - 5 AC Amp
Power Supply 24 VDC
Isolation 2500 VRMS Barrier for
Signal and Power supply.
Output 4 - 20 mA
Microprocessor based PID controller
Qty. 01 No
Make Honeywell control
Power Supply 24 VDC
Input 4-20mA
3 Output Linear - Time Proportionate
Control Action PID
Relay Output For Solenoid Valve for
steam washing.
Output No.1 4 - 20mA
Output No.2 High & Low Relay output

Precision Linear DC Signal Isolators

4
Qty. 1 No.
 Enclosure Din Rail Mounted
Power Supply 24 VDC
Isolation Barrier 1500 Vrms
Isolation type Galvanic
Input 4 – 20 mA / 0 – 10 VDC
Isolated Output 4 – 20 mA / 0 – 10 VDC
Maximum Non- +/- 0.05%
linearity
Supply of Remote control panel with, motor
on / off controls and indicators with Local
and DCS operating Facility
Qty. 1 No.
Enclosure MS Panel Dual Tone
Siemens Gray and Black
Colour
Power Supply 230 VAC
SMPS 24VDC
Microprocessor 1 No.
based Valve
5 Positioner
Wiring All internal Instruments,
cabling through FRC.
Colour Coded wiring with
Ferrules and Din Rail
Mounted Connectors
(Wago Make) for all
Incoming and Outgoing
Cables / Cables for
Isolators.
Protection MCB Class C for Phase and
Neutral, Make Siemens
Mounting Panel will have Cut-outs
Arrangement for Display. All Displays
strategically mounted on
the Door.
Ventilation Fan/s. Pressurized Panel
with Air Filter.
Internal Lighting Panel Shall have 1 ft 20W
Tube Light.
Location/s Panel to be kept in control Room or Wall
5.1
mounted near machine
IRIS VALVE PHOTOS
COST BENEFITS OF AUTO FEEDING SYSTEM FOR CONTINUOUS
CENTRIFUGE

Consideration:
Plant crushing capacity: 2500 tons per day
Total C Massecuite: 200 Tons per day
No. Of NK 1100 machine installed: 2Nos.
100 Tons per machine
Machine manufactures claim:
Size: 1100
Capacity for C fore worker: 6-8 tons/ hr
Electrical power required: 55 KW

Observations:
Machine NO LOAD current: 30 Amp
Machine full load current: 110 Amp
Maximum curing current for C Massecuite: 80 Amp
with minimum water addition
Maximum Machine capacity: 8 tons per hr.
That means 50 Amps motor loading will give 8 ton per hr. capacity
through put.
It also defined as 1Ton per hr. will require 6Amp motor current.
It is also observed that due changes in viscosity and line head of
massecuite the load current does not remain constant. The motor
current oscillates +/- 10 Amp to set value.
A continuous centrifugal machine with a manually operated feeding
system will typically average 70% to 80% of the capacity to the
capacity of the same centrifuge using an automatic feeding system.
This is because the operator will normally set the unit to run with
lighter load to allow the variation in massecuite feed rate caused
by changing massecuite viscosity and head pressure.
Even though the machine is capable to cure the massecuite at 80 Amp
load, to avoid overloading, tripping and over flowing the operator
will set the machine at 70 Amp on a safer side. That means machine
will work at average 6.5 Tons per hr.
The Centrifuge with an auto feed init can set to its maximum
capacity as it is continuously monitoring and controlling the preset
current value. The machine never gets over loaded or overflows.
Hence the Machine will work at constant 8 Ton per hr. rate.

Saving after using auto feed system for continuous

centrifuge

ELECTRICAL POWER SAVING CALCULATION:

Centrifuge with manual feeding will require: 100/ 6.5=15.4 hrs.
To cure 100 tons for a day
Centrifuge with auto feeding will require: 100/8 = 12.5 hrs.
To cure 100 tons for a day
Hence (15.4-12.5)=2.9 hrs saving of 55 KW per day
That means 55 x 2.9 = 159.5 KWH per day
159.5 x 150 = 23,925.00 KWH per season.
Considering the electrical energy average rate $0.10 per KWH
The Total electrical power saving for one machine for one crushing
season is 23,925.00 x $0.1 = $ 2392

Evaporation losses:
To cure 100 t C massecuite the operator require to add water 2% of
massecuite flow to centrifuge.
That is 8 ton per hr x 2%= 160 liter per hr
The manual feed centrifuge require 1.3 hr extra to cure 100 Ton per
day than the auto feed centrifuge
Hence additional water added to molasses is 1.3 x 160 liter= 208
liter per day per centrifuge
That is 208 x 150 days= 31200 liter of water per crushing season.
To evaporate 31200 liter of water will require 31 Ton Steam per
crushing season.
0.5 Kg bagaees will produce 1 KG of steam.
That means 15.75 Tons of bagasse will save per crushing season
One ton bagasse will cost @ $30
Hence total saving will cost $ 30 x 15.75 = $473

Sugar losses in molasses:

As the manual feed machine add more water for lubrication causes to
increase in molasses purity.
The observation is 1- 2unit of molasses purity was found in manual
feed unit. For the calculation we will consider 0.5 rise in final
molasses.
The sugar recovery will increase by 0.04% of sugar cane if we can
reduce the final molasses purity by 1 unit.
That means Extra sugar can recovered per machine per season
1250x 0.04% x 0.5= 0.25 tons of sugar
Considering the sugar price $0.50 per Kg
Sugar loss per day 250 x $0.5 = $ 125
Sugar loss per season $125 x 150 days=$18750

.
Total Direct losses:
Electrical loss per season: $2392.00
Evaporation loss per season: $473.00
Sugar loss per season: $18750.00

Total $ 21615
In addition to this there are other indirect losses can be recovered as follows
• Due to concentric and constant feed rate mechanical vibration and jerks
reduces. Hence low mechanical maintenance
• No over flow of massecuite as the valve closes immediately as in case main
motor trip or off condition
• Solid massecuite rope. There is no air trapped in side the rope. Hence rope
diameter reduces and it helps to distribute the massecuite evenly on the
screen causes increase in curing capacity of machine.

Conclusion:
The Cost of automation system will be recovered in few months.