APPLICATION REFERENCES

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ssSugar cane mill Drives and Biomass

Renewable energy solutions

for internal use only

Best of the month: JANUARY 2011

DESCRIPTION OF APPLICATIONSugar 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 en-ergy for processing use and for exportation. Ethanol fuel, pellets, thermal and electric energy are energies from a renew-able source: biomass of sugar cane.ALCOHOLERA DE ZAPOPAN, founded in 1920, is the leading company of drink-able, denatured, and non-smelling grain and sugar cane ethyl alcohol produc-tion 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 customi-zation 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 ma-chines driven by Bonfiglioli hydraulic gearmotors, hoist for track unloading, conveyors for cane feeding, roller conveyor for cane preparation (earth sepa-ration 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.

APPLICATION REFERENCE

for internal use only

GENERAL NEEDS OF THE APPLICATIONIn 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 distil-lation, 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 in-stalled gearmotors; product reliability; most simple and compact gearbox architecture with high-est torque rating.

BONFIGLIOLI SOLUTIONBonfiglioli gearboxes are installed in most of equipments of distillery plant:

cane feeder conveyor, cane chopper device, cane shredder device, rotat-ing 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. Bonfigl-ioli delivered (on time in September 2010) 2 foot-mounted reducers of new size 323 for 2 mills of 306 kW motor power each one. They have follow-ing 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 integrat-ed driven by Bonfiglioli AC motor, thermostats and oil pressure electro-valve. Full planetary solution is the most compact and costive-

ness 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 on-field-service by Mexican distributor Ecomssa and Bonfiglioli USA.

Bonfiglioli products

Description

Sugar canemill drives

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 S

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APPLICATION REFERENCE

for internal use only

author:Matteo Grossi: matteo.grossi@bonfiglioli.com

Bonfiglioli

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

Max output torque (Nm)

Motor displacement (cc/rev) and type

16÷19 0.20÷0.25 up to 20 up to 400 up to 230 1520 709 C2B 17000 75 (axial piston)

(fixed displacement)

Machine Data Gearbox Data

Weight (tons)

Tractive effort/weight

Travel speed (km/h)

Max pressure

(bar)

Max oil flow

(l/min)

SprocketPCD(mm)

Type Max output

torque (Nm)

Motor displacement (cc/rev) and type

16÷19 0.40÷0.50 up to 10 up to 400 up to 230 960 709 C2B 23000 Up to 90 (axial piston) (fixed displacement) S

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