Crystal Sugar Engineering Services Pvt. Ltd.

Shivaji Nagar, Pune, Maharashtra

Cane Handling and Feeding System is the most important part of sugar mill. We are one of the fastest growing organizations in providing a total customized solution for Cane Handling and Feeding System. With Technical expertise and high quality standards; we provide a comprehensive range of Devices with customized design for turnkey operation. CANE UPLOADER Crystal Sugar Engineering Services Pvt. Ltd. is leading manufacturer of special purpose crane commonly known as Cane Unloaders which are used to unload the Sugar Cane from Trucks/ Trolleys/ Carts to the Main Cane Carrier / Feeder Table. Our Cane Unloaders can be operated in both the ways mechanically or hydraulically. Our Cane Unloaders comes with either Mechanical/Hydraulic operated Grab or Sling Bar System. Hydraulic Grab System Crystal’s HYDRAULIC GRAB SYSTEM is all steel construction. It has 2 sets of grabbing fingers mounted on either side of body. It is meticulously designed to accommodate in the inside width of a standard truck/ trolley. Our Hydraulic Grabs are designed up to 5 M.T. cane handling capacity per cycle. Opening and closing action of grab is actuated by hydraulic cylinders. Positive and swift action enhances the cane unloading capacity by more than 50% over mechanical grab. Hydraulic Grab System Sling Bar System gives an advantage of bulk unloading up to 20 T of cane in a single grip. Cane unloading with sling bar system requires systematic loading of cane in the vehicles with slings. Sling bar unloads the cane directly on the Feeder Table. Cane feeding in the main conveyor is easily controllable by Feeder Table with variable speed. FEEDER TABLES Salient Features Loading capacity up to 20 Tonnes. Robust Steel Construction. Special high strength Feeder Table conveyor chain. Gun Metal/ Anti Fiction ball bearings for journals. Dyno Drive/ A.C. Variable Frequency Drive for precise speed control. Standard inclination from 3-50 towards head shaft. Inclination up to 450 as per specific requirement. Cane Carrier It can be designed and supplied as per the client’s requirements.

Cane Chopper To overcome the drawbacks of Cane Kicker and Cane Cutter this Swing Type Cane Chopper is introduced. It is running successfully with best performance at various sugar mills in India. Main advantage of the Chopper is to avoid the jamming & to feed equally to Fibrizor. Cane Chopper favour the capacity of Mill. It assists the extraction of the mills by breaking the rind of the cane and so facilitating its disintegration and the extraction of its juice. Swing Type Cane Fibrizer Fibrizers are used for shredding of sugarcane into fibres and open cells to enable prepared cane to be crushed in between the rollers of the mills to extract juice. Features Hammers with replaceable tips. Three / Four arm type integral, specially designed discs to eliminate failure against shocks. Rotor is supported in well-designed heavy duty bearings in solid cast steel bearing housing blocks with water cooling jacket. Provided Anvil of Pocketed construction which is hard faced to 500 BHN for improved and uniform cane preparation. Swing Hammers are hinged on axles with bush bearings. Hammers are staggered to cover entire rotor width. Easy installation on existing Cane Carrier. Rake Carriers / Rake Elevators Rake Carriers/Rake Elevators cane be designed to transfer the crushed cane from 1st to last Mill for continuous feeding at Mills. TRPF – Toothed Roller Pressure Feeder Conversion of existing 3 roller mill to 5 roller mill is made easy by Crystal’s TRPF System Our TRPF are designed for increased Juice extraction and reduced bagasse moisture. Features Easily adaptable on conventional three roller mills Hinged housing for easy maintenance without disturbing the original alignment Common static collar with mill, with stainless steel linings, providing efficient side juice drainage Pressure chute in heavy construction with stainless steel lining, specially designed for smooth flow Toothed roller hard-faced all over for better gripping and longer life Drive from the main rollers / separate drive as per the power requirement Advantages Increase in capacity by 25 to 30 percent over conventional mill with no loss of extraction Higher crushing rates achieved at lower mill speeds, improving the gripping and reducing the re-absorption GRPF – Grooved Roller Pressure Feeder Conversion of existing 3 roller mill to 6 roller mill is made easy by Crystal’s GRPF System. In our GRPF System existing 3 Conventional Rollers plus Two Grooved Pressure Feeders and One Underfeed Roller is used. Features Easily adaptable on conventional three roller mills Lotus type roller in addition to static collars for optimum juice drainage Adjustable type pressure chute in fabricated construction with stainless steel lining, specially designed for smooth flow Hinged housing for easy maintenance without disturbing the original alignment Separate drive as per the power requirement Advantages Increase in capacity by 20 to 25 percent over conventional mill with no loss of extraction 8 to 10 unit rise in primary extraction, therefore more gain in RME The ultimate capacity and performance achieved by four mills only, which shall be more than the conventional six mills of three roller type Rotary Juice Screen Solid / liquid separation is effected on a welded wedge bar screen drum mounted in horizontal position with appropriate slope towards non-drive end. The diameter, the length of the screen, the speed of the rotating screen and its inclination are well designed to facilitate complete drainage of juice. Maximum juice is separated in feed section of the screen. Special design feature also includes cleaning the screen periodically by automatic application of hot water through flat cone nozzles which ensures clean screen surface throughout the operation period. Features Less space requirement on the mills. On-line and automatic cleaning of the screen at preset interval is possible. Less maintenance and no on-line adjustments, supervision is required. No chocking of screens. Lower power requirements. Can work at reduced crush rate with same efficiency. Eliminates the requirement of stationery screens. Rotary Juice Screen also elements screw conveyer. Mill House Cranes Double Girder Overhead cranes in SWLs ranging from 5 MT to more than 30 MT. These cranes can either incorporate standard ABUS crabs up to a SWL of 30 MT or fully customized open winch type crabs. Crystal can supply fully customised Double Girder Cranes as your requirements for different duty cycles and a diverse range of applications. Double Girder Cranes can be offered for a very large range of spans, heights of lift as well as customizable speeds depending on your application. They can also be provided with multiple hoisting trolleys running on the same bridge or auxiliary hoisting mechanisms on the main trolley. Precise control of all motions is achieved through Variable Frequency Drives. We also offer Double Girder Overhead Cranes for the steel industry, built according to IS 4137 norms. These cranes are built to be capable of withstanding extreme requirements of operating speeds and operating conditions.

VAPOUR CELLS / EVAPORATORS Concept of Vapour Cell Evaporators Earlier the common Evaporation Systems were straight Quad or Triple or sometimes Quintuple. With passage of time bagasse use was diversified for paper Industry and Cogeneration. In between high pressure boilers and more efficient Evaporator Systems like Semikestener and Falling Film Evaporator entered the Industry and this development changed the whole scenario. The new inventions created immerse possibilities of vapor bleeding and subsequent steam economy. The concept of Vapour Cell and then Double Effect Vapour Cell was gradually accepted with advent of low retention time Semikestener /Falling Film Evaporator. Factories even installed reducing pressure Evaporators which could not be thought about earlier due to inversions and sugar destruction chances in case of old Robert Type Evaporators. With proper de super heating arrangement of exhaust steam and auto controls, the chances of sugar/reducing sugar loss have receded to quite considerable extent. With modern arrangement as explained above people have achieved steam consumption figure even upto 42-43% as average during season and recorded figure even below upto below 40% cane. Even with low pressure boilers of 18 kg/cm2 and exhaust steam at 0.76 to 0.78 kg/cm2 the steam consumption could be brought down to a record low figure of 46-47% cane with DEVC and Quad by adopting maximum possible vapour bleeding available vessels.

RAKE TYPE LIME CLASSIFIER Advantages Reciprocating rake grit washing mechanism provided is capable of removing more than 95% of all fine and coarse grits of plus 100 mesh range. These lime classifiers produce a substantially grit-free of lime solution and a cleansed, well washed and drained grit from the milk of lime prepared from drum slackers. This helps better process control in downstream, process Equipments. These features fully balanced harmonic motion mechanically, which increase the life of machine completed to other types of classification units. Grits separation efficiency is superior. The dry deck length provided with grits wash spray arrangement aids further to minimize chemical losses through the grits. Low power consumption.

Continuous Juice Sulphitor Sulphitation of juice is the key to the entire process of a Sugar plant, be it for better quality of sugar or reduced viscosity in molasses and masscuite. In our Continuous Juice Sulphitor we have incorporated pre and shock liming as well as, made the equipment capable to deal with refractory juices also. Our Juice Sulphitor has been designed with unmatched innovative features to take care of all the requirements of a good sulphitation. Main Advantages The pH of juice is observed at three places during the process and the addition of lime and SO2 gas is adjusted accordingly, thus the process control is better. Optimum quantity of lime is added to the juice first and then SO2 is added for desired sulphitation PH. Pre-liming or Pre-sulphitation and shock liming and sulphitation is carried out as per the process requirement and juice quality. Complete absorption of SO2 gas takes place due to gas and juice contact time over 10 seconds provided due to 3.5 M level of juice above gas outlet sparger. The flow of gas and juice is streamlined for maximum circulation & then ensuring proper mixing with 15 fold circulation without stirrer on air lift principle. Design is flexible to adopt different processes, i.e. Pre-liming or pre-sulphitation or simultaneous liming and sulphitation etc. No moving parts and hence very low maintenance. No power requirement. Compact design. Less scaling in evaporators due to less rise in CaO content from mixed juice to clear juice. Continuous Syrup Sulphitor Syrup sulphitation plays an important roll in sugar manufacturing process and to a great extent the process decides the quality of syrup to Feed Pan. Considering the facts, designing of syrup sulphitor comes under category of Chemical Reaction Vessel. Special Feature Constant retention time at various crushing rate. In- built absorption tower. Special designed syrup spray Nozzle. Efficient Gas sparger. Advantages Easy operation Higher mixing efficiency Even pH at any point of sulphitor. Almost complete absorption of SO2gas Negligible maintenance. Sulphur Burners Suphitation is the heart of sugar manufacturing process. Addition of adequate quantity of lime is prime importance and this can be achieved only when there is continuous supply of so2 gas to juice sulphitor. At the same time to reduce the sulphur consumption it is necessary to sulphur burner at different burning capacity as per fluctuation is crushing rate. Crystal Manufactures two types of Sulphur Burners A) Auto Continuous Sulphur Burner B) Film Type Sulphur Burners A) Auto Continuous Sulphur Burner Sufficient heating surface for sulphur melting and proper space for cleaning removes the problem of melting the sulphur and choking of the melt valves. The bigger volumetric capacity of melter and receiver gives sufficient breathing period, to the operators for sulphur charging. Properly located melt feeder pipe maintains constant tray area and hence the gas production. The sublimation will never be there due to correct application and mixing of Air. Special design consideration while deciding the tray area and cooling surface of Main Furnace Chamber ensures the optimum burning capacity. Better spraying arrangement of water on the cooling pipes will avoid the flashing of water all around. Salient Features Continuous working with steady flow of SO2 gas. Complete combustion of Sulphur. Variable burning rate as per change in crushing rate. Digital monitoring controls over main working parameters. B) Film Type Sulphur Burner Sulphur Furnace plays crucial role in the clarification process in sugar plant. This new FILM TYPE SULPHUR BURNER overcome following problems of regular Batch Type Burners: Salient Features The problems of improper melting of solid sulphur Cleaning of melter and receiver Choking of melt valves Leakage of melt valves Frequent charging Varying combustion Sublimation Corrosion of main furnace Flashing of water all over the Burner station Leakage of gas Melter Raw sulphur is melted with Sufficient heating surface and the impurities are separated with overflow (to separate solid impurities) and underflow (to separate floating particles) arrangement. Separate compartment provides clean and clear melt of sulphur to melt feeding pump & valves and ensures smooth feed to the furnace. The bigger volumetric capacity of melter gives sufficient period, for sulphur charging and pumping. Melt Feed Arrangement Melt Feed Pump provided with stroke variation arrangement for adjusting the desired feed. It maintains constant & accurate feed of melt to combustion chamber and maintains constant gas production. Preheating arrangement The oil-fired preheater is provided for preheating of main furnace if required at the beginning. The Main Furnace chamber The hi-tech design of combustion chamber (refractory lined) where the oxidation of sulphur and dilution by air is completed and uniform gas is delivered to the sulphitors. Special design consideration while deciding the volumetric capacity and cooling surface of Main Furnace Chamber ensures the optimum burning capacity. Internally special arrangement of refractory bricks lining is provided to obtain desired air flow passage and enhanced burning area for sulphur burning and vapourisation. The capacity of burner can be adjusted from 50 to 250 kg/hr by adjusting the stroke of feed pump. The Cooling Arrangement Vertical water jacketed primary cooler and secondary cooler (i.e cooler and scrubber combined unit) to obtain desired outlet temp. of SO2 and avoid the flashing of water all around. Instrumentation 1) Sulphur Feed adjustment coarse by stroke adjustment and fine by vfd (AC drive unit). 2) Four point temperature indication at various stages from sulphur melt to final gas. 3) Over Current protection for pump motor Advantages over Conventional Sulphur Furnaces Variable capacity from 50 to 250 Kg/hr Complete combustion of Sulphur Auto Sulphur feed by melt feed pump Quick startup Easy for immediate stoppage Optimum sulphur consumption No sublimation No possibility of SO3 formation Control over pollution Practically negligible maintenance