VRL AUTOMATION ENGINEERING AND PROJECTS PVT LTD Peenya, Bangalore, Karnataka

  It consists of vaporiser with thermic fluid and transient heater to heat the massecuite by low temperature vapour of thermic fluid at about 80°C before feeding to Continuous Centrifugals.The vapors from vaporiser will pass through the tubes of Heat Exchanger to exchange the heat to the Massecuite passing through the Transient Heater. After dissipating the heat to the Massecuite, the vapors will condense & return back to the Vaporiser, in the form of thermic fluid.This type of exchanger operates at low temperature and at a faster rate of heat transfer to avoid dissolution of crystals.

  Sugar Melter Designed & Manufactured by VRL utilizes Non Condensable gases/ Vapors from the calendria of last body of the evaporators under vacuum for heating and syrup as melting media.It avoids utilization of direct steam, otherwise required in the conventional type sugar melter. In additional to its contribution towards steam saving, considering the fact that the material to be handled in the melter is of high purity and as the heating media we are using is 80°C temperature vapor, it helps in reducing sugar loss and caramalisation of sugar, on account of avoiding of localized heating with high temperature steam.High brix, high temperature crystal free melt generated in the sugar melter helps in greatly improving both steam economy as well as pan floor capacity with improved boiling.

  Automation ensures in meeting the product quality & capacity Monitoring the kiln tempratures, load, speed, bunker levels etc. Interlocks between conveyors. Auto sequence of motors for different circuits like Kiln, Cooler, Injection, Coal, Product seperation, Lime stone, Iron ore, Coal and loading operation etc. Being a in-house Automation & Electrical manufacturing company, VRL can customize the requirement to cater total Sponge iron plant.

  Non Compartmentalized type for uncomplicated sequence Operation & Maintenance Compact Size Sequence of Feeder Operation controlled by Sequence timers /PLC/DCS.

  Full functionality, protection and monitoring availability by means of configurable control In remote control through network In local control when bus system fail Safe design and high degree of applicability Integrated Power & Control up to high ratings Main Protections & Control functions in one device Accurate measurement Solid - state full motor protection ensuring long term stability of tripping characteristics Numerous alarms & trip thresholds Basic overload & the more demanding protections based on temperature sensor, earth leakage & voltage Sharp analysis of motor operating conditions Monitoring and operation statistics NETWORK COMMUNICATION MODBUS PROFIBUS PROFINET ETHRNET TCP/IP

  Motor Control Centre is designed, engineered and manufactured for switching and protecting Electric motors, resistive and capacitive loads connected to a low voltage circuit Employing an economical multitier, constructions and modular design. This MCC houses in a self contained module, a Main SFU, MCCB, Contactors, Bimetallic O/L Relays, Other Control devices and Circuit Elements. The MCC is designed to meet as per IS, IEC & BS.

  Mono Vertical Crystallizers from VRL are very effective in cooling low grade massecuite to the desired temperature. It is provided with well designed massecuite feed distribution on the top and stationery coils in Cooling & Re-Heating zones.Agitator with arms in between cooling coils helps in enhancing heat transfer, resulting in required rate of massecuite cooling & best exhaustion of Molasses. The agitator assembly is very sturdy with planetary gear drive and well supported bearings offering less friction.The bottom set of coils are with hot water circulation facility, to reheat the massecuite if required.Four number Raisers of sufficient cross-sectional area are provided at the periphery of crystallizer to convey the treated massecuite to over-head discharge pipeline.

  The Molasses conditioners from VRL is a unique design working under Vacuum utilizing NCG or penultimate body vapor, eliminates use of medium pressure steam or exhaust steam normally used for this application.It is a static conditioner with no moving parts, contributing to steam economy, along with effective molasses conditioning for crystal free molasses ADVANTAGES Normal Molasses Conditioners utilize medium pressure steam for heating molasses in a tank. This results in localized heating, effecting both sugar recovery and color. VRL molasses conditioners are Direct Contact type with very minimum contact time; hence no localized heating, as heating vapor is at a temperature of about 80°C. Saving of steam, which otherwise required in the conventional molasses conditioners. No drives and stirrers, as a result maintenance and power requirement is avoided, in addition to steam saving. Improvement of evaporation rate in evaporators, on account of sweeping effect of non-condensable gases in the last effect calendria. .

  Flash recovery system from VRL is the heart of steam economy scheme, which contributes directly towards reduced steam consumption at process house.In this well-designed centralized flash recovery unit, the condensate received from each of the Evaporator bodies, tubular juice heaters and pans are systematically flashed out in different stages. The flash vapours generated are systematically connected to downstream side Evaporator bodies, helping in reducing the steam consumption at evaporator station. There will be considerable reduction in process steam demand at Evaporators. Considerable power saving, as there is no need of condensate pumps at individual bodies, Pans and Juice Heaters. Elimination of condensate pumps, help in reducing the maintenance and store inventory

  Falling Film Evaporators from VRL are compact and occupy very less ground space, requiring no heavy structures and platforms. Unique feature involves effective vapor distribution across the calendria and efficient withdrawal of condensate and non-condensable gases from Calendria.These Evaporators operate with very low temperature gradient between heating vapor and body temperature. As the Juice is travelling down the tube, there is no influence of hydro static head on heat transfer.The Juice distributors at the top of the Falling Film Evaporators are unique in design and ensure assured flow of juice through each tube. PLC-SCADA Automation is provided to maintain required rate of juice recirculation, wetting entire inner surface of tubes, eliminating sugar losses due to overheating of juice. Inorder to ensure wetting of inner surface of tubes even at lower position at bottom of the tube, the tube height is limited to 8meters.   Effective flashing of vapor from the juice falling down from calendria tubes as well as juice entering from previous body contributes towards higher rate of evaporation. Poly baffle type entrainment catchers provided between vapor flashing zone & vapor outlet from the body are very effective in arresting carry-over of juice particles along with vapor.

  More than 300 Direct Contact Juice Heaters from VRL are in operation with no complaints of any nature. They play major role in the success story of VRL towards Steam Economy.These Direct Contact Juice Heaters work with very low approach temperature of about 1°C between heating and heated media. This feature allows utilization of low temperature vapors for better use in juice heating. ADVANTAGES Operates with very low approach temperature Contributes towards steam economy, because of low temperature vapour utilization from later vessels of evaporators. Considerable power saving as there is no pressure drop across the heaters for pumping the juice. Considerable power saving as there is no condensate pumps for these heaters. It helps in reducing maintenance and store inventory related to these pumps. Zero maintenance at Juice heaters, as there is no opening/closing of Juice heaters, No tube cleaning, No maintenance & No worry of tube leakages. In short it is a fit and forget type of Juice Heater It helps in reducing maintenance and store inventory related to these pumps.

  These Condensate Heaters once again are unique design from VRL. The Juice and water are in perfect counter current pattern, contributing to high heat transfer co-efficient and with low approach temperature between heating and heated media.The modular design makes it user friendly with ease of operation. These heaters once again are purely heat recovery equipment, as the Vapor Condensate from Flash Recovery System is used for Juice Heating. This apart from Temperature gain in Juice also helps us in reducing the Temperature of Vapor Condensate.

  Type : Standard / Interleaved Enclosure : IP 54 / I55 for Outdoor Construction : CRCA / Aluminum Body SC level : 50KA for 1sec Busbar Supports : FRP/ SMC in Ribbed construction Interval of Support: 400mm Max. Conductor : Aluminum E91E Grade of Fasteners : 8.8Grade Type of Joints : Cu. Flexible braided at Transformer end& Al. Flexible strips joints at Panels end. Design : As per customer plant requirement.

  Application : Sugar Plant Centrifugal Motors -250KW, AC Motor A paradigm of our adaptation- current trends of technology in industries