Cane preparation unit and method of operation

1. A method for operating a cane preparation unit with an energy optimizing unit, wherein the cane preparation unit includes a plurality of carriers coupled to each other for receiving cane from a cane loading section, cutting the received cane into a desired size, shredding the desired size cane into shredded cane pieces and conveying the shredded pieces to a chute of a first mill, wherein each of the carriers is associated with a carrier motor, the method comprising:

receiving, by the energy optimizing unit, a working range for at least one operating variable for the plurality of carriers of the cane preparation unit;

estimating, by the energy optimizing unit, energy consumed by the cane preparation unit when operated with a first plurality of set points in the received working range for the at least one operating variable;

selecting, by the energy optimizing unit, one or more first set points as use set points for the at least one operating variable based on the estimation of energy consumed by the cane preparation unit, obtained with an objective function to reduce energy consumed for the at least one operating variable, wherein the objective function includes terms to reduce deviations in a first mill chute level for maintaining uniform feed and to reduce the speed of at least one of the carrier motors, and wherein the use set points correspond to reduced energy consumed in the operation of the cane preparation unit; and

operating the cane preparation unit at the use set points for the at least one operating variable.

2. The method of claim 1 , wherein the at least one operating variable is selected from a group consisting of: a cutter level indicator, a cutter speed indicator, a cutter output size indicator, a shredder level indicator, a shredder speed indicator, a shredder output indicator, a transporter level indicator, a transporter speed indicator, and a final output level indicator, and combinations thereof.

3. The method of claim 1 , comprising:

monitoring the at least one operating variable for energy consumed at the use set points at distinct time intervals;

re-estimating energy consumed for a second plurality of set points;

generating one or more second set points with the objective function, wherein the objective function includes a first term to reduce deviations in a first mill chute level for maintaining uniform feed and a second term to reduce the speed of at least one of the carrier motors, corresponding to a reduced energy consumed at the one or more first set points or the second plurality of set points as new use set points; and

operating the cane preparation unit at the new use set points.

4. The method of claim 3 , wherein the one or more second set points are same as the one or more first set points.

5. The method of claim 1 , wherein the plurality of first set points are generated using a model for the cane preparation unit.

6. The method of claim 3 , comprising:

generating the plurality of second set points by a model for the cane preparation unit.

7. A cane preparation unit for a sugarcane processing plant, the cane preparation unit comprising:

a plurality of carriers coupled to each other and configured for carrying out a predetermined function based on at least one operating variable, wherein each of the plurality of carriers is associated with a carrier motor; and

an energy optimizing unit for:

receiving a working range for the at least one operating variable for the plurality of carriers of the cane preparation unit,

estimating energy consumed by the cane preparation unit when operated with a first plurality of set points in the received working range for the at least one operating variable,

selecting one or more first set points as use set points for the at least one operating variable for each of the plurality of carriers based on the estimation of energy consumed by the cane preparation unit, the first set points obtained with an objective function for reducing energy consumed for the at least one operating variable, wherein the objective function includes terms to reduce deviations in a first mill chute level for maintaining uniform feed and to reduce the speed of at least one of the carrier motors, and wherein the use set points correspond to reduced energy consumed in the operation of the cane preparation unit, and

operating the cane preparation unit at the use set points for the at least one operating variable.