Modeling the performance of two experimental high-capacity roller gin reclaimers to assess the impact of carryover to seed ratio and saw speed

Authors: Tumuluru, Jaya Shankar; Armijo, Carlos; Whitelock, Derek; Funk, Paul

Submitted to: National Cotton Council Beltwide Cotton Conference
Publication Type: Abstract Only
Publication Acceptance Date: 2/22/2023
Publication Date: 5/15/2023
Citation: Tumuluru, J., Armijo, C.B., Whitelock, D.P., Funk, P.A. 2023. Modeling the performance of two experimental high-capacity roller gin reclaimers to assess the impact of carryover to seed ratio and saw speed. National Cotton Council Beltwide Cotton Conference, January 10-12, 2023, New Orleans, Louisiana. p. 161.

Interpretive Summary:

Technical Abstract: During roller ginning, a small percentage of partially-ginned seed cotton called “carryover” is removed along with the fully ginned seed. A reclaimer is a specialized machine that returns carryover to the gin stand for ginning and avoids lint and seed loss. The study focused on understanding the seed and lint loss (lb/bale) by the seed cotton reclaimer during the roller ginning process. The present study utilizes empirical data from previous experiments comparing a conventional roller gin reclaimer to two experimental, high-capacity reclaimers based on a 3-saw stick machine seed cotton cleaner and a model 700 gin stand feeder (Lummus Ag Technology, Savannah, GA). The data reflect Pima and Upland cotton processing to understand seed and lint loss during reclaiming. In all the tests, the reclaimer feed rate was kept constant (69 kg/min for Upland and 95 kg/min for Pima). The material that was produced after roller ginning was measured for carryover and seed weights. The material produced while roller ginning both cotton varieties was further used for the reclaimer tests where the speed of processing cylinders within both reclaimers was varied between half- to full-normal operating speed using a variable frequency drive (30, 45, and 60 Hz). Even though the roller ginning process was carried out at a constant rate, the percent carryover to seed ratio measured changed marginally. For Upland cotton, the percent carryover to seed ratio was 30-38%, and for Pima, it was between 4.2-6.0%. The reclaimer cylinder speed (Hz) and carryover to seed ratio (%) was used to develop the non-regression models to describe the seed and lint loss during the reclaiming process. The models developed have adequately described the process based on coefficient of determination values of >0.9 except the 3-saw lint loss model which was about 0.84. These models were further used to draw surface plots to understand how the carryover-to-seed ratio and reclaimer cylinder speed impact the seed and lint loss. Even though the carryover/seed ratio tested was narrow, it did impact lint and seed loss during the reclaiming process. The reclaimer cylinder speed also impacted the seed and lint loss, where lower reclaimer cylinder speeds reduced lint loss, and higher reclaimer cylinder speeds reduced seed loss. These models were further optimized using a hybrid genetic algorithm to precisely identify the reclaimer speed and carryover to seed ratio which minimizes seed and lint loss (lb/bale). The optimized conditions indicated that 700 feeder resulted in lower lint and seed loss compared to the 3-saw stick machine for Upland (0.508 lb/bale of lint and 31 lb/bale of seed compared to 0.86 lb/bale of lint and 44.45 lb/bale of seed, respectively). At the optimum operating conditions, the 700 feeder had 46% lower lint loss and 30% lower seed loss than the 3-saw stick machine. In the case of Pima, the 3-saw stick machine had 38% lower lint loss and 24% higher seed loss compared to 700 feeder at optimum operating conditions. Both the 3-saw stick machine and 700 feeder performed better for Upland cotton than the conventional reclaimer. The conventional reclaimer resulted in about 12.39 lb/bale of lint loss, whereas the 3-saw stick machine and 700 feeder resulted in about 0.86 and 0.508 lb/bale of lint loss. In the case of Pima, the 3-saw stick machine resulted in a lower lint loss of about 0.206 lb/bale, whereas the conventional reclaimer resulted in a lower seed loss of about 9.53 lb/bale. Optimization of the reclaimers in series and parallel indicated that parallel arrangement results in lower total (seed+lint) loss than series alignment.