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