TRAIN-LOAD OF CANE READY FOR THE MILL
A MODERN MILL
The carrier just referred to is a wide slat conveyor, running alongside the railroad tracks in the yards to a point directly over the first set of crushers. The cane is taken from the cars by a mechanical unloader, the arms of which reach out and with distended fingers pull the cane stalks off and land them on the slow-moving carrier, which takes them onward and upward to the crusher.
The crusher consists of two large rolls, with immense interlocking, corrugated teeth on the circumference of each. These rolls are set close together, and the cane passing through is broken into short pieces and matted to an even layer. The juice squeezed out by this preliminary crushing runs through a metal trough into a large receptacle known as the juice tank.
From the crusher the mat of cane passes to the mills proper. These mills consist of from nine to eighteen rolls, about thirty-four inches in diameter and seventy-eight inches long, arranged in groups of three, set in the form of an isosceles triangle, one above and two below, one set following the other in a direct line. The lower rolls are parted enough to allow the expressed juice to fall through them, while the half-crushed cane is carried over by means of an iron bar called the returner. The faces of the rolls are more or less roughened, or grooved, so as to draw the cane through and give a better crushing action. They are turned slowly by powerful engines, which transmit the power to each set of rolls through a system of gears. The rolls are forced together by hydraulic rams exerting a pressure of from four hundred to six hundred tons. It is this tremendous pressure that squeezes the sugar-bearing juice out of the cane.
From the crusher the matted cane passes through the first set of rolls, where a large percentage of the remaining juice is liberated. This is caught in a metal trough and, after passing over a fine screen to remove the small pieces of cane, runs to the juice tank. The cane passes through the second set of rolls, thence to the third set, and so on to the end of the mill. In front of the last set of rolls, hot water is sprayed on the cane to soften the fiber and dilute the remaining juice, thus aiding the final extraction. The adding of hot water is termed maceration. By the time the cane has passed through the last set of rolls, all the economically recoverable juice is out of it and delivered into the juice tank, with the exception of the juice and maceration water from the last set of rolls, which is always returned to the preceding set of rolls for maceration purposes. The juice or maceration water coming from the last set of rolls contains very little sugar, and the object is to secure greater concentration by using it for double maceration instead of adding that much additional water which would have to be evaporated later on in the process.
In well-designed, modern mills, with cane carrying not over twelve per cent of fiber, more than ninety-eight per cent of the sugar in the cane is extracted, the remainder being left in the fiber. This is almost perfection today. What it will be tomorrow no one can say.
The fibrous, woody part of the cane, or bagasse as it is called, is comparatively dry as it leaves the last rolls. It is conveyed from the mills to the boiler house on a wide slat conveyor, and fed directly into the furnaces under the boilers that generate the steam for power and boiling purposes. A modern raw-sugar mill requires practically no other fuel than that obtained as a by-product from the crushing of the cane.
The boiler plant is usually of large capacity, as a great deal of steam is required to drive the engines that run the crusher, the rolls, the electric lighting system, the pumps and other machinery. Besides, a large amount is needed to evaporate the water in the juice and to boil and dry the sugar. The ashes from the furnaces are returned to the fields as fertilizer, so that very little is lost.