CN103525887B - A kind of crystalline dextrose production method of energy-conserving and environment-protective - Google Patents
A kind of crystalline dextrose production method of energy-conserving and environment-protective Download PDFInfo
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- Separation Using Semi-Permeable Membranes (AREA)
- Preparation Of Compounds By Using Micro-Organisms (AREA)
Abstract
The invention belongs to food processing technology field, be specifically related to a kind of production method of crystalline dextrose of energy-conserving and environment-protective.A crystalline dextrose production method for energy-conserving and environment-protective, is characterized in that, described method comprises following step: starch milk → liquefaction → saccharification of sizing mixing → slagging-off decolorization filtering → ion-exchange → concentrated → Crystallization Separation → oven dry → crystalline dextrose.The filtering system that the present invention adopts is without the need to auxiliary agents such as extra diatomite, and no waste discharge, greatly reduces water consumption current consumption, improve product yield, safety and environmental protection.The optimization of heat recycling system reduces the energy consumption in production greatly.The present invention has positive meaning for the energy-saving and cost-reducing environmental protection of β-amylose manufacturing.
Description
Technical field
The invention belongs to food processing technology field, be specifically related to a kind of production method of crystalline dextrose of energy-conserving and environment-protective.
Background technology
Dextrose production process mainly comprise liquefaction, saccharification, filtration, from steps such as friendship, concentrated, crystallization, oven dry.
The production technique of current glucose can be divided three classes: acid system, acid-enzyme hydrolysis method and double-enzyme method.Acid technological process carries out liquefying-saccharifying using acid as amylatic catalyzer, starch is by the carbohydrate of multiple glucose molecule condensation, during acid hydrolysis, along with glycosidic link fracture in starch molecule, generate the glucose polymer that glucose, maltose and various relative molecular mass are lower gradually.This technological operation is simple, and saccharification speed is fast, and with short production cycle, facility investment is few.But acid technological process is wayward on hydrolysis degree, many factories use acid-enzyme hydrolysis method instead, i.e. acid system liquefaction, enzyme process saccharification.When acid system liquefies, controlled hydrolysis reacts, and makes DE value 20% ~ 25% time, stop hydrolysis, neutralizes rapidly.About adjust ph to 4.5, temperature is add glucoamylase after 55 ~ 60 DEG C to carry out saccharification, until required DE value, then heats up, go out enzyme.Though acid-enzyme hydrolysis method technique can control the final DE value of saccharified liquid preferably, the same with acid system, still there are some shortcomings, equipment corrosion is serious, and use raw material to be confined to starch, generate by product in reaction more, final syrup sweet taste is impure.
Liquefaction is divided into interval liquefaction process, semicontinuous liquefaction process and steam ejection liquefaction method with production technique difference.Interval liquefaction process liquefaction effect is poor, and after saccharification, the filterableness of material is poor, and the concentration of sugar is also low.Semicontinuous liquefaction process feed liquid spills easily scalds operator, poor stability; Steam consumption is large, multiplex vapour 15% compared with steam ejection liquefaction; Liquefaction effect is poor, and saccharified liquid strainability is also poor.
The object of filtering is the insoluble impurities in removing saccharified liquid, generally uses flame filter press at present, uses diatomite to be flocculating aids simultaneously, improves filtration velocity, extends filtration cycle, improves filtrate clarity.The way of general employing precoated layer, is not blocked by some tiny colloidal particles to protect the pore of filter cloth.Minority producer introduces vacuum drum and filters, mainly suspend in the middle of filtering hydrolyzed solution or the water-fast impurity of deposition, the rotary drum of continuous rotation and the super-cell coated in advance make the labour intensity of filter operation reduce to minimum level and obtain the highest filtration velocity.But Plate Filtration and vacuum drum filter the interpolation all needing the flocculating aidss such as diatomite, larger to the contaminative of environment.
The production line of existing glucose adopts double-enzyme method production technique, and liquefaction operation adopts second spraying liquefaction, and filter progress adopts Plate Filtration, and enrichment process adopts five effect falling-film evaporators, and baking operation adopts pneumatic conveying dryer.This production line is normal operation after coming into operation, and quality product meets relevant criterion requirement.Although this production line have employed production technique more advanced at present, by still having found to the investigation of this production line the part that much haves much room for improvement.Be mainly manifested in filter progress and adopt Plate Filtration, the low filtrate quality of filtering accuracy is poor, needs to add the flocculating aidss such as diatomite big for environment pollution in filtration procedure; In production, waste heat is not effectively recycled, and be discharged in the air with the form of waste gas, energy wastage is serious; The unrealized automatization of saccharification system, manual operation tolerance range is low, and raw material availability has much room for improvement.
Summary of the invention
In order to solve above-mentioned technical problem, the invention provides a kind of waste water and dregs that reduces and discharging, alleviating environmental pollution, the production method of the crystalline dextrose of saving heat energy.
A crystalline dextrose production method for energy-conserving and environment-protective, the method comprises following step:
Starch milk → liquefaction → saccharification of sizing mixing → slagging-off decolorization filtering → ion-exchange → concentrated → Crystallization Separation → oven dry → crystalline dextrose.
Concrete, a kind of crystalline dextrose production method of energy-conserving and environment-protective, the method comprises following step:
(1) in material-compound tank, starch concentration is adjusted to 16-20 ° of B é, pH value is regulated to be 5.5-5.9, add Thermostable α-Amylase, after feed liquid being stirred, powder stock pump is entered Jet liquefier, drop temperature controls at 108-115 DEG C, and from injector, feed liquid out enters laminar flow tank insulation 60-90min, makes its temperature remain on 95-100 DEG C; The add-on of described Thermostable α-Amylase is: starch dry matter per ton adds 300-500mL α-amylase;
(2) carry out second spraying again, temperature is to 135-145 DEG C, and high temperature maintains 3-5 minute, to Thermostable α-Amylase deactivation, adopts residual heat collection to utilize system to waste heat recovery after second spraying;
(3) feed liquid enters vacuum flashing cooling system and cools to 55-65 DEG C of insulation, pH value is dropped to 4.5-6.5 simultaneously, adds saccharifying enzyme, enter saccharifying tank and carry out saccharification, after saccharification to terminal, feed liquid is sprayed and heats and 70 DEG C of enzymes that go out of lowering the temperature; The add-on of described saccharifying enzyme is: starch dry matter per ton adds 300-500mL α-amylase;
(4) after saccharification, discharging enters filtration step, adopts membrane filtration system deslagging filtering, and after filtering, clear liquid enters storage tank, adds decolorizing with activated carbon 0.4-0.6h, filters, leach activated carbon after decolouring; The add-on of activated carbon is: material per ton adds 2-4kg activated carbon;
(5) to liquid glucose secondary decolourization, the condition of decolouring is, the amount adding activated carbon is: material per ton adds 1-4kg activated carbon, and bleaching time is 25-35min, filters after decolouring;
(6) liquid glucose after secondary decolourization is sent into ion-exchanger and carries out ion-exchange, the cation exchange resin column in the advanced first group of ion exchange column of liquid glucose, Zeo-karb with H
+metallic cation in ionic replacement liquid glucose, then enters resin anion(R.A) exchange column, anionite-exchange resin with OH
-acid radical anion in ionic replacement liquid glucose;
(7) liquid glucose after ion-exchange enters de-taste polymeric adsorbent and removes peculiar smell in liquid glucose, obtains liquid glucose for subsequent use, makes the colourity of liquid glucose lower than 10, specific conductivity is less than 30, pH value is 5-6.5, pure in smell free from extraneous odour;
(8) in five effect falling-film evaporators to above-mentioned steps in the liquid glucose that obtains concentrate, feed liquid after concentrated enters crystallizer, and the massecuite after crystallization, after whizzer is separated, enters pneumatic dryer, drying products is sieved by trommel screen, carries out finished product packing to qualified product; The condition of above-mentioned steps is respectively: in enrichment step, be concentrated into 72%, the rotating speed of centrifugation is 1500 rpm, and centrifugation time is 15min; Be dried to moisture in pneumatic dryer and be less than 9%, the requirement of screening is that 40 mesh sieve percent of pass reach 95%.
In step (1), in material-compound tank, starch concentration is adjusted to 18 ° of B é, pH value is regulated to be 5.7, add Thermostable α-Amylase, after feed liquid being stirred, powder stock pump is entered Jet liquefier, drop temperature controls at 110 DEG C, from injector, feed liquid out enters laminar flow tank insulation 80min, makes its temperature remain on 97-98 DEG C; The add-on of described Thermostable α-Amylase is: dry-matter per ton add Thermostable α-Amylase 400mL.
Material in last process enters storage tank, then enters fresh feed pump, is filtered by film device, concentrated solution enters storage tank, then enters fresh feed pump and filtered by film device, and iterative cycles carries out, film device is cleaned by scavenging pump, filters the penetrating fluid obtained enter next procedure by film device; Film device in have ceramic membrane, the acid fastness of ceramic membrane: >=95 % fastness to alkalies: >=92 % void content: 30-45%, ultimate compression strength: 11 Mpa, bending strength: 5.7 ± 0.1 Mpa, thermostability: 250 DEG C, density: 1.45 ~ 1.52Kg/m3, treatment media temperature: 5 ~ 800 DEG C.
In second spraying step, temperature to 140 DEG C, high temperature maintains 4 minutes, to Thermostable α-Amylase deactivation, adopts residual heat collection to utilize system to waste heat recovery after second spraying.
In step (3), feed liquid enters vacuum flashing cooling system and cools to 55-65 DEG C of insulation, pH value is dropped to 4.5-6.5 simultaneously, adds saccharifying enzyme, enter saccharifying tank and carry out saccharification, after saccharification to terminal, feed liquid is sprayed and heats and 70 DEG C of enzymes that go out of lowering the temperature; The add-on of described saccharifying enzyme is: starch dry matter per ton adds 400mL/T α-amylase.
After saccharification, discharging enters filtration step, adopts membrane filtration system deslagging filtering, and after filtering, clear liquid enters storage tank, adds decolorizing with activated carbon 0.5h, filters, leach activated carbon after decolouring; The add-on of activated carbon is: material per ton adds 3kg activated carbon.
In step (5), the amount adding activated carbon is: material per ton adds 2kg activated carbon, and bleaching time is 30min, filters after decolouring.
The present invention carries out research and development transformation on the basis of original production line: use membrane filtration to replace flame filter press, greatly reduce the discharge of waste water and dregs, reduce the pollution to environment; Increase energy-recuperation system, recycled by heat circulation, saving heat energy, adopt closed-type steam condensing hot air furnace, reduce further energy expenditure; Realize the automatization of saccharification system, simple to operate, reduce human factor, effectively improve raw material availability and quality product, and save a large amount of manpower.Production line after transformation efficient energy-saving more, reduces production cost and the pollution to environment.
Liquefaction is divided into interval liquefaction process, semicontinuous liquefaction process and steam ejection liquefaction method with production technique difference.Interval liquefaction process liquefaction effect is poor, and after saccharification, the filterableness of material is poor, and the concentration of sugar is also low.Semicontinuous liquefaction process feed liquid spills easily scalds operator, poor stability; Steam consumption is large, multiplex vapour 15% compared with steam ejection liquefaction; Liquefaction effect is poor, and saccharified liquid strainability is also poor.Generally adopt steam ejection liquefaction method in β-amylose industry at present, the advantage of this method is that liquefaction effect is good, and well, the filtering property of saccharified liquid is good, and equipment is few, is also suitable for operate continuously in the condensation of protein-based impurity.
Filtering is exactly remove the insoluble impurities in saccharified liquid, generally uses flame filter press at present, uses diatomite to be flocculating aids simultaneously, improve filtration velocity, extend filtration cycle, improve filtrate clarity.The way of general employing precoated layer, is not blocked by some tiny colloidal particles to protect the pore of filter cloth.Minority producer introduces vacuum drum and filters, mainly suspend in the middle of filtering hydrolyzed solution or the water-fast impurity of deposition, the rotary drum of continuous rotation and the super-cell coated in advance make the labour intensity of filter operation reduce to minimum level and obtain the highest filtration velocity.But Plate Filtration and vacuum drum filter the interpolation all needing the flocculating aidss such as diatomite, larger to the contaminative of environment.
The object of ion-exchange removes water miscible inorganic impurity exactly, the positively charged ion in liquid glucose and the H on Zeo-karb
+exchange, the negatively charged ion in liquid glucose and the OH on anionite-exchange resin
-exchange, finally exchange the H in liquid glucose
+and OH
-be combined into water, the water that the inorganic impurity in liquid glucose all becomes respective amount is removed.Ion exchange resin is divided into Zeo-karb and two kinds, anionite-exchange resin, and the technique generally applied at present is sun-4, male-female-the moon filter bed, and namely 2 pairs of cationic, anionic exchange resin filter bed series connection use.
The circulating evaporation of concentrated general employing can make a part of concentrated solution Returning evaporimeter, and material heated time is shorter than intermittent type, and concentration is also more easy to control, is applicable to the concentrated of liquid glucose.Capital cost in evaporation operation is steam consumption, in order to steam saving, adopts multiple-effect evaporation, both makes full use of secondary steam, and saved again a large amount of cooling waters.
Main innovation part of the present invention is:
Ceramic membrane is adopted to improve filter progress.Original filter plant is Plate Filtration, and the filtrate transmittance of Plate Filtration is low, and water consumption current consumption is large.And in filtration procedure, need constantly to add the auxiliary agents such as diatomite carry out precoating, waste discharge amount is large, severe contamination environment.Adopt ceramic membrane filter, improve separation accuracy and product yield, do not need to add auxiliary agent, without waste sludge discharge, reach reduction wastewater discharge, reduce the object of maintenance cost.
Waste heat in producing is recycled.Waste heat waste in production process is serious, and the rate of recovery of mainly liquefy feed liquid flash distillation waste heat and condensation water residual heat is lower.Recycle network to liquefaction feed liquid flash distillation waste heat steam sparging device, improves the rate of recovery of secondary waste heat; In addition improve original steam condensate recovery system, adopt closed-type steam condensate recovery system, successfully solve the turbid problem of vapour, greatly improve waste heat recovery rate.
The filtering system that the present invention adopts is without the need to auxiliary agents such as extra diatomite, and no waste discharge, greatly reduces water consumption current consumption, improve product yield, safety and environmental protection.The optimization of heat recycling system reduces the energy consumption in production greatly.The present invention has positive meaning for the energy-saving and cost-reducing environmental protection of β-amylose manufacturing.
Accompanying drawing explanation
Fig. 1 is the artwork of filtration step in technical process of the present invention;
Fig. 2 is the structural representation of waste heat recycling system in the present invention;
In figure: the raw steam-in of 1-, 2-secondary steam entrance, 3-nozzle, 4-trunnion, 5-diffuser tube, 6-insulating cotton.
Embodiment
Below in conjunction with the drawings and specific embodiments, the present invention is further described, so that those skilled in the art more understands the present invention, but does not limit the present invention with this.
Embodiment 1
A crystalline dextrose production method for energy-conserving and environment-protective, the method comprises following step:
Starch milk → liquefaction → saccharification of sizing mixing → slagging-off decolorization filtering → ion-exchange → concentrated → Crystallization Separation → oven dry → crystalline dextrose.
Concrete, the crystalline dextrose production method of energy-conserving and environment-protective, comprises following step:
(1) in material-compound tank, starch concentration is adjusted to 18 ° of B é, pH value is regulated to be 5.7, add Thermostable α-Amylase, after feed liquid being stirred, powder stock pump is entered Jet liquefier, drop temperature controls at 110 DEG C, and from injector, feed liquid out enters laminar flow tank insulation 80min, makes its temperature remain on 97-98 DEG C; The add-on of described Thermostable α-Amylase is: starch dry matter per ton adds 400mL α-amylase;
(2) carry out second spraying again, temperature to 140 DEG C, high temperature maintains 4 minutes, to Thermostable α-Amylase deactivation, adopts residual heat collection to utilize system to waste heat recovery after second spraying;
(3) feed liquid enters vacuum flashing cooling system and cools to 60 DEG C of insulations, pH value is dropped to 5 simultaneously, adds saccharifying enzyme, enter saccharifying tank and carry out saccharification, after saccharification to terminal, feed liquid is sprayed and heats and 70 DEG C of enzymes that go out of lowering the temperature; The add-on of described saccharifying enzyme is: starch dry matter per ton adds 400mL α-amylase;
(4) after saccharification, discharging enters filtration step, adopts membrane filtration system deslagging filtering, and after filtering, clear liquid enters storage tank, adds decolorizing with activated carbon 0.5h, filters, leach activated carbon after decolouring; The add-on of activated carbon is: material per ton adds 3kg activated carbon;
Filtration step is specially: the material in last process enters storage tank, enter fresh feed pump again, filtered by film device, concentrated solution enters storage tank, enter fresh feed pump again to be filtered by film device, iterative cycles carries out, and film device is cleaned by scavenging pump, filters the penetrating fluid obtained enter next procedure by film device; Film device in have ceramic membrane, the acid fastness of ceramic membrane: >=95 % fastness to alkalies: >=92 % void content: 30-45%, ultimate compression strength: 11 Mpa, bending strength: 5.7 ± 0.1 Mpa, thermostability: 250 DEG C, density: 1.45 ~ 1.52Kg/m3, treatment media temperature: 5 ~ 800 DEG C;
(5) to liquid glucose secondary decolourization, the condition of decolouring is, the amount adding activated carbon is: material per ton adds 2kg activated carbon, and bleaching time is 30min, filters after decolouring;
(6) liquid glucose after secondary decolourization is sent into ion-exchanger and carries out ion-exchange, the cation exchange resin column in the advanced first group of ion exchange column of liquid glucose, Zeo-karb with H
+metallic cation in ionic replacement liquid glucose, then enters resin anion(R.A) exchange column, anionite-exchange resin with OH
-acid radical anion in ionic replacement liquid glucose;
(7) liquid glucose after ion-exchange enters de-taste polymeric adsorbent and removes peculiar smell in liquid glucose, obtains liquid glucose for subsequent use, makes the colourity of liquid glucose lower than 10, specific conductivity is less than 30, pH value is 6, pure in smell free from extraneous odour;
(8) in five effect falling-film evaporators to above-mentioned steps in the liquid glucose that obtains concentrate, feed liquid after concentrated enters crystallizer, and the massecuite after crystallization, after whizzer is separated, enters pneumatic dryer, drying products is sieved by trommel screen, carries out finished product packing to qualified product; The condition of above-mentioned steps is respectively: in enrichment step, be concentrated into 72%, the rotating speed of centrifugation is 1500 rpm, and centrifugation time is 15min; Be dried to moisture in pneumatic dryer and be less than 9%, the requirement of screening is that 40 mesh sieve percent of pass reach 95%.
There is following many defects in original Plate Filtration equipment: the impurity such as soluble proteins, colloid, impurity polysaccharide, submicron particle existed a large amount of in syrup cannot be carried out high efficiency separation; The transmittance of filtered solution is lower, generally lower than 85%; Residuals has a certain impact to the extraction of post-order process, the finished product quality, yield tool tool; Need the auxiliary agents such as diatomite to carry out precoating, flocculation, the quantity discharged of waste residue is large, contaminate environment.The shortcomings such as simultaneously to there is step many for original technique, and water loss current consumption is large, and labour intensity is large, and the large and concentration of wastewater discharge is high.
Vacuum drum filters and be better than Plate Filtration in use properties, can improve filtration velocity, reduce labour intensity, but vacuum drum filtration still needs adding of flocculating aids, has certain pollution to environment.
Membrane filtration is a kind of screening process relevant to membrane pore size size, with the pressure difference of film both sides for motivating force, take film as filtration medium, under pressure, when stoste flows through film surface, the many tiny micropore gathered in film surface only allows water and small-molecule substance pass through and become permeate, and the material that in stoste, volume is greater than film surface micropore footpath is then trapped within the liquid feeding side of film, become concentrated solution, thus realize the object of the isolation and identification to stoste.
In the selection of mould material, because glucose is easier to go bad when temperature is lower, viscosity strengthens greatly simultaneously, is unfavorable for filtering, so have employed high temperature service and high temperature resistance diaphragm--ceramic membrane.Ceramic membrane is coated with in wide-aperture supporting body surface the very thin dense micro-hole rete being covered with 4 ~ 6 micron thickness to be composited, unique rete formula and strict high-sintering process, make the pore size distribution of ceramic film very narrow, absolute precision is very high, ensure that impurity substances big and small in liquid glucose cannot permeation ceramic membrane layer easily, more than 99% is reached to the rejection of insoluble suspended substance, impurity etc.Ceramic membrane can reduce liquid glucose from high temperature to the cooling time of low temperature, reduces rotten probability, membrane flux can be made again to be improved to some extent, reduce the treatment time.Meanwhile, because the albumen in membrane filtration liquid and impurity are sufficiently removed, the pollution that the resin of subsequent technique is subject to will greatly reduce, and effectively improve the processing power of resin, and extend the work-ing life of resin, crystallization yield and final product quality all will improve.
For sugar soln, even if when transparence 100%, generally still containing the starch do not transformed completely, the micro-point of insoluble protein colloid and various microorganism.In the liquid glucose of different material, the size of the materials such as contained protein, enzyme, colloid, soluble dextrins, oligose, disaccharide, monose, organic acid, mineral salts is also different.Therefore, adopt the film of different pore size, liquid glucose is done to the separation step by step of micro-filtration, ultrafiltration, nanofiltration.
Its advantage of membrane filtration system of the present invention is adopted to be,
(1) separation accuracy is high, and filtrate transmittance is high.The transmittance of the filtration liquid glucose after ceramic membrane filter improves greatly, can up to 97%, the starch existed in liquid glucose, high molecular weight protein, colloid, fiber, bacterium etc. are by the basic filtering of ceramic membrane, so just greatly reduce the pollution of subsequent ion exchange resin, add the work-ing life of resin, extend the regeneration period of resin; Simultaneously due to the reduction of colourity impurity in filtrate, also reduce the add-on even eliminating follow-up decoloration active carbon.
(2) without the need to adding auxiliary agent, no waste discharge, safety and environmental protection.Because membrane filtration processes is absolute filtration process, only by high-precision membrane pore size, material component is separated, carry out precoating, flocculation without the need to auxiliary agents such as extra diatomite, filter the filter residue after terminating due to pollution-free, can to return containing high protein process sleeve with or reclaim as feed manufacturing or organic fertilizer.And some hygienic safety hidden danger may be there are due to diatomite, general not recommendation diatomite filtration in foodstuffs industry enterprise abroad.
(3) membrane element having selected brand-new film formulation to produce, acid-proof alkaline is splendid, film long service life.Compared with the domestic organic polymer filter membrane generally adopted, the ceramic membrane of high temperature sintering is rigid porous structure, and be inertia when contacting with soda acid, avoid the easy compression set of fenestra, the cleaning and regeneration difficulty existed when using macromolecular filter membrane, the fatal defects such as that clean-out system is expensive, diaphragm is not wear-resistant is fragile, reliability is not high, the not high yield of cycles of concentration is not high, work-ing life is short, film replacement charge is high.
(4) improve product yield.Membrane filtration processes is dynamic cross flow filter process, therefore can not as Plate Filtration, centrifugal filtration process filter residue solid content very high, but the effective constituent can collected to greatest extent by the mode of " cross flow filter+dialysis " in filter residue, improve the yield of product, for different products and the dialysis technique that adds water, the yield of product can be controlled in 95% ~ 99%.
(5) wastewater discharge reduces greatly, alleviates environmental protection pressure.By the optimization of film operation process, the wastewater flow rate produced in membranous system operational process is reduced greatly; Simultaneously because the high-accuracy filtration of mineral membrane reduces the impurity of filtrate, thus the wastewater flow rate of generation when subsequent ion exchange resin regenerate and COD/BOD reduce greatly.
The Collection utilization of liquefaction feed liquid flash distillation waste heat
Twice steam ejection liquefaction technique is the processing method generally adopted during current β-amylose is produced.This liquefaction process can abundant amylatic insoluble particle, improves the yield of product, and can make the abundant sex change of protein, to improve the infusion temperature of filtration velocity and product.But twice steam ejection liquefaction process stream can release a large amount of steam during flash distillation after pressurize, also discharge a large amount of heats simultaneously, if this part heat can be recycled, not only can reduce the burden of boiler, the production cost of product can also be reduced.
The energy expenditure that the flash distillation of liquefaction feed liquid relates to is analyzed as follows:
(1) uperize consumption:
Vapor pressure 0.6Mpa, r=2091.1kj/kg.k; Starch milk specific heat is Cp=3.38kj/kg.k; Starch milk is 55 DEG C in temperature, and (evaporation condensed water of deionized water and 45 DEG C is through Large Plate Heat Exchangers heat exchange and enter after evaporating preheating become sugar water after friendship system, and water temperature controls at 62 DEG C; And in tank of sizing mixing, the effective 62 DEG C of hot water circulation insulation of setting dish, controls starch milk temperature more than 55 DEG C)
In order to improve Dx value, starch concentration before injection is adjusted to 17 Baumes: density 1.133, mass percent concentration 30.21%, concentration of volume percent 34.16%):
Q=MsCpΔt=302.9/30.21%×103×3.38×（108－55）
=18×10
7（Kj）
Therefore need steam 18 × 10
7/ 2091.1=86.1t/d
Once spray and use vapour intensity: 86.1/20=4.3t/h
(2) one times vacuum dodges chilling but:
Q=MsCpΔt=（1002.6+86.1）×103×3.38×（95－108）
=-4.8×10
7（Kj）
This sudden strain of a muscle chilling but amount of anhydrating is: 3.9 × 10
7/ 2091.1=22.9t/d
Liquefaction system once sprays the secondary steam of generation: 22.9/20=1.14t/h
A liquefaction flash produces secondary steam and is: 22.9/240=0.095t/t (relationship commodity one water crystallization glucose)
(3) second spraying steam consumption:
Vapor pressure 0.6Mpa r=2091.1kj/kg.k
Q=MsCpΔt=（1002.6+86.1-22.9）×103×3.38×（135－95）
=14.4×10
7（Kj）
Therefore need steam 14.4 × 107/2091.1=68.9t/d
Second spraying vapour intensity: 68.9/20=3.45t/h
Therefore second spraying liquefaction portion vapour unit consumption is: 68.9/240=0.29t/t (relationship commodity one water crystallization glucose)
Liquefaction by vapour unit consumption is always: 0.36+0.29=0.65t/t (relationship commodity one water crystallization glucose)
Liquefaction always uses vapour intensity: 4.3+3.45=7.75t/h
(4) secondary vacuum dodges chilling but:
Q=MsCpΔt=（1002.6+86.1-22.9+68.9）×103×3.38×（95－135）
=-15.3×10
7（Kj）
This sudden strain of a muscle chilling but amount of anhydrating is: 15.3 × 107/2091.1=73.4t/d
73.4/20=3.7t/h
It is 73.4/240=0.31t/t (relationship commodity one water crystallization glucose) that second spraying liquefaction flash produces secondary steam
The recyclable secondary steam intensity that whole liquefaction, saccharification system produce altogether: 1.14+3.7=4.84t/h
The recyclable secondary steam unit consumption that liquefaction, saccharification always produce is: 0.095+0.31=0.41t/t (relationship commodity one water crystallization glucose)
The present invention adopts steam sparging device to recycle secondary steam, and the structure of jet apparatus is as follows:
Jet apparatus comprises diffuser tube, trunnion, raw steam-in, secondary steam entrance, nozzle, insulating cotton; Its structure is specific as follows: the nozzle 3 of this device is connected with raw steam-in 1 by flange, secondary steam entrance 2 is provided with above nozzle 3, trunnion 4 one end is linked together by flange and nozzle 3, the other end of trunnion 4 is connected with diffuser tube 5, and the outer wall of trunnion 4 and diffuser tube 5 is enclosed with insulating cotton 6.This device is connected directly between on steam-pipe, after raw steam sprays via nozzle 3, the high velocity air of formation forms certain negative pressure around, drives the secondary steam of secondary steam entrance 2, enter trunnion 4 and raw vapor mixing, make vapour pressure balanced in the diffusion through diffuser tube 5.This steam directly enters an effect heating chamber of five effect falling-film evaporators of evaporization process after exporting, as the thermal source of quintuple effect evaporator.
Water of condensation contains 20 ~ 30% of steam total heat, and best in quality, is appreciable residual heat resources.If condensing hot air furnace rate is low, then can cause the huge waste of heat energy and water resources.The major cause that condensing hot air furnace rate is low has two aspects: on the one hand, due to steam trap type selecting, installs the problems such as wrong and the quality of drain valve own, causes indirect gas utilization unit cannot be normally hydrophobic, or impact heating, or serious steam leakage; On the other hand, owing to not solving the pumping problem of cavitation of high-temperature condensation water well, the many employings of recovery method are open, and the loss of flash distillation cooling is very serious.
Want efficiency utilization water of condensation, improve fractional energy savings, first should reduce the leakage vapour of gas utilization unit as far as possible, secondly water of condensation should be delivered in time the occasion being applicable to utilizing as far as possible.And these needs solve from system and equipment two aspect, i.e. through performance good equipment composition hermetic condensed water recovery system, makes water of condensation be utilized in the less situation of cooling loss.
Existing steam condensate recovery system is open recovery, namely in condensing hot air furnace process to atmosphere opening, to discharge leaked steam and flash steam, reach reduce pressure and reduce temperature so that conveying object.This method is the feedback of level difference type for the principle that water of condensation feeds back, and namely gas utilization unit position is the highest, and the recovery tank of condensed water is then built in vault, and the bottommost that condensated water recovering pump is arranged on water tank is to ensure an applicable malleation.
The advantage of open recovery is that adaptability is wide, reduced investment.Defect is that thermal waste is large, and waste heat recovery rate is low.Succeeding in developing of closed steam condensate recovery system, well overcomes this shortcoming.
The transformation key of condensate recovery system is how when ensureing normal production, eliminates cavitation phenomenons.Cavitation phenomenons refers to that high temperature saturation water can separate out steam when step-down, and the steam produced, when entering high pressure area, liquefies suddenly again and condenses into water and make steam bubble explosion.As this process is carried out repeatedly, destruction, in addition all kinds of associated erosion effect will be produced to the piece surface in this region, finally cause spongy or cellular cavitation damage.The consequence that cavitation occurs destroys the continuity of vapor transmission process, increases resistance, blocks runner, and the efficiency having a strong impact on water pump is produced with normal.In the past in order to eliminate cavitation phenomenons, reclaimed water of condensation often through step-down, to discharge a large amount of flash steam to reduce cavitation source.But this way can cause energy dissipation undoubtedly.Therefore will solve pump cavitation phenomenon, the best approach is the pressure making the pressure entering water pump exceed cavitation, thus is fundamentally avoiding the generation of cavitation.The main operational principle of closed condensate water recovery technology is exactly the supercharging principle utilizing squirt pump, and set up the anti-cavitation being applicable to the conveying of high temperature saturation water theoretical, final appropriate design squirt pump solves the problem of cavitation of water pump.In addition, this system to the type selecting of drain valve with the most unfavorable processing condition parameter for foundation, thus avoid the energy dissipation phenomenon originally caused by contradiction between drain valve type selecting and actual motion.
This system utilizes heat pump type condensed water recovery device by custom-designed steam jet heat pump, is extracted out by flash steam, and boosting recycling, can solve the emptying problem of flash steam preferably.Flash steam is extracted out, the pressure in water collect tank can be made to reduce, condensation water temperature drop.Pressure drop in water collect tank, can make condensate-water polishing unimpeded, be conducive to the work of interchanger.Flash steam pressurization local use, decreases than liquefaction back boiler the energy that conveying consumes, decreases heat radiation and the flue gas loss of boiler, achieve closed circulation.Replace original drain valve with orifice-plate type drain valve, decrease maintenance load and the replacement cycle of drain valve, save substantial contribution than with common drain valve.Utilize steam jet heat pump, the flash steam of condensed water is boosted, recycle, accomplish that carbonated drink is reclaimed simultaneously, make used vapour amount be greater than the evaporation capacity for engine of boiler.And condensed water temperature when flash steam is sucked away can be made to reduce, return with anti-cavitation pump and use again.
From technique, hermetic condensed water recovery system is made up of recovery pipe network and condensate pumps two portions generally.Pipe network part mainly comprises steam trap and recovery channel; Pump station part mainly comprises the monitoring valve and instrument etc. of water collect tank, pressure regulator valve, retrieving arrangement, Self force valve and necessity.The Main Function of pipe network part is under guarantee does not affect the prerequisite of the heating process of gas utilization unit, stop the steam of uncooled heat release directly to be discharged, and dredged out in time by water of condensation wherein, and conveying is collected to a distance; The Main Function of pump station part is then that the water of condensation concentrated is delivered to suitable utilization place in time further, controls simultaneously and process flash steam.
Closed condensing hot air furnace controls to adopt PLC technology type electrical control system automatically, housing is set the simulating signal of differential pressure transmitter is delivered to starting or stoping of Controlled by Programmable Controller water pump, too high/the too low and water collect tank hypertonia warning of water collect tank water level etc.
The simulating signal that housing can accept to be brought by differential pressure transmitter, the switch signal of liquid level relay sensed water level electrode, the too high and too low guard signal of water collect tank water level, water collect tank hypertonia signal, warning audition, silence switch signal; The the starting or stoping of Controlled by Programmable Controller water pump, control to be vented warning light.
Closed reclamation of condensate water technology has suitability widely, and can be applied to steam is the various industries of indirect heating medium.Owing to eliminating the evaporating, emitting, dripping or leaking of liquid or gas of steam, the recycling of condensed water and heat thereof is fully timely, not only can fuel economy and softening water in a large number, makes boiler operatiopn steadily, can also reduce pollution emissions, improve plant environment.Energy saving of system rate after application improves 20 ~ 30%, and the payback period is 5 ~ 8 months.Energy-saving effect is remarkable, creates huge economic benefit and social benefit.
The Economic and Efficiency Analysis that the present invention produces is as follows:
Membrane filtration system cost compared with original Plate Filtration system increases and decreases situation:
Product per ton saves 6kg diatomite, and diatomite calculates by 3000 yuan/t, saves 18 yuan/t product.Annual 100000 tons of products, save 1 44 ten thousand yuan;
Electricity reduces 6KWh, and often degree is by 0.6 yuan of calculating, can reduce by 3.6 yuan/t, reduces 28.8 ten thousand yuan every year.
The sugared mud of membrane filtration, the nearly 0.32t dry basis of recoverable per hour, annual recyclable 2304t, calculates by net value 400 yuan/t, can increase benefit 92.16 ten thousand yuan every year.
Upkeep cost saves 50,000 yuan.
To sum up, calculate by annual 100000 tons of products, membrane filter plant can create beneficial result be 269.96 ten thousand yuan every year.
The Collection utilization of flash distillation waste heat is actual save that primary steam is theoretical value 80%, namely often produce one ton of DEXTROSE MONOHYDRATE BP and save primary steam 40,000 tons, energy 2.5 x 10
4, save standard raw coal amount (with 5000 kcal/kg, boiler efficiency calculates with 0.7 raw coal calorific value) M=2.5x10
4/ 5000/0.7x24=171.4kg/d.Raw coal is reduced expenses (raw coal unit price per ton is with 280 yuan of calculating): 0.17x280 unit=47.6 yuan.Can cut down expenses every year 4760000 yuan.
Embodiment 2
The crystalline dextrose production method of energy-conserving and environment-protective, comprises following step:
(1) in material-compound tank, starch concentration is adjusted to 16 ° of B é, pH value is regulated to be 5.5, add Thermostable α-Amylase, after feed liquid being stirred, powder stock pump is entered Jet liquefier, drop temperature controls at 108 DEG C, and from injector, feed liquid out enters laminar flow tank insulation 60min, makes its temperature remain on 95 DEG C; The add-on of described Thermostable α-Amylase is: starch dry matter per ton adds 300mL α-amylase;
(2) carry out second spraying again, temperature to 135 DEG C, high temperature maintains 3 minutes, to Thermostable α-Amylase deactivation, adopts residual heat collection to utilize system to waste heat recovery after second spraying;
(3) feed liquid enters vacuum flashing cooling system and cools to 55 DEG C of insulations, pH value is dropped to 4.5 simultaneously, adds saccharifying enzyme, enter saccharifying tank and carry out saccharification, after saccharification to terminal, feed liquid is sprayed and heats and 70 DEG C of enzymes that go out of lowering the temperature; The add-on of described saccharifying enzyme is: starch dry matter per ton adds 300mL α-amylase;
(4) after saccharification, discharging enters filtration step, adopts membrane filtration system deslagging filtering, and after filtering, clear liquid enters storage tank, adds decolorizing with activated carbon 0.4h, filters, leach activated carbon after decolouring; The add-on of activated carbon is: material per ton adds 2kg activated carbon;
Filtration step is specially: the material in last process enters storage tank, enter fresh feed pump again, filtered by film device, concentrated solution enters storage tank, enter fresh feed pump again to be filtered by film device, iterative cycles carries out, and film device is cleaned by scavenging pump, filters the penetrating fluid obtained enter next procedure by film device; Film device in have ceramic membrane, the acid fastness of ceramic membrane:>=95 % fastness to alkalies:>=92 % void content: 30-45%, ultimate compression strength: 11 Mpa, bending strength: 5.7 ± 0.1 Mpa, thermostability: 250 DEG C, density: 1.45 ~ 1.52Kg/m
3, treatment media temperature: 5 ~ 800 DEG C;
(5) to liquid glucose secondary decolourization, the condition of decolouring is, the amount adding activated carbon is: material per ton adds 2kg activated carbon, and bleaching time is 30min, filters after decolouring;
(6) liquid glucose after secondary decolourization is sent into ion-exchanger and carries out ion-exchange, the cation exchange resin column in the advanced first group of ion exchange column of liquid glucose, Zeo-karb with H
+metallic cation in ionic replacement liquid glucose, then enters resin anion(R.A) exchange column, anionite-exchange resin with OH
-acid radical anion in ionic replacement liquid glucose;
(7) liquid glucose after ion-exchange enters de-taste polymeric adsorbent and removes peculiar smell in liquid glucose, obtains liquid glucose for subsequent use, makes the colourity of liquid glucose lower than 10, specific conductivity is less than 30, pH value is 5, pure in smell free from extraneous odour;
(8) in five effect falling-film evaporators to above-mentioned steps in the liquid glucose that obtains concentrate, feed liquid after concentrated enters crystallizer, and the massecuite after crystallization, after whizzer is separated, enters pneumatic dryer, drying products is sieved by trommel screen, carries out finished product packing to qualified product; The condition of above-mentioned steps is respectively: in enrichment step, be concentrated into 72%, the rotating speed of centrifugation is 1500 rpm, and centrifugation time is 15min; Be dried to moisture in pneumatic dryer and be less than 9%, the requirement of screening is that 40 mesh sieve percent of pass reach 95%.
Embodiment 3
The crystalline dextrose production method of energy-conserving and environment-protective, comprises following step:
(1) in material-compound tank, starch concentration is adjusted to 20 ° of B é, pH value is regulated to be 5.9, add Thermostable α-Amylase, after feed liquid being stirred, powder stock pump is entered Jet liquefier, drop temperature controls at 115 DEG C, and from injector, feed liquid out enters laminar flow tank insulation 90min, makes its temperature remain on 100 DEG C; The add-on of described Thermostable α-Amylase is: starch dry matter per ton adds 500mL α-amylase;
(2) carry out second spraying again, temperature to 145 DEG C, high temperature maintains 4 minutes, to Thermostable α-Amylase deactivation, adopts residual heat collection to utilize system to waste heat recovery after second spraying;
(3) feed liquid enters vacuum flashing cooling system and cools to 65 DEG C of insulations, pH value is dropped to 6.5 simultaneously, adds saccharifying enzyme, enter saccharifying tank and carry out saccharification, after saccharification to terminal, feed liquid is sprayed and heats and 70 DEG C of enzymes that go out of lowering the temperature; The add-on of described saccharifying enzyme is: starch dry matter per ton adds 500mL α-amylase;
(4) after saccharification, discharging enters filtration step, adopts membrane filtration system deslagging filtering, and after filtering, clear liquid enters storage tank, adds decolorizing with activated carbon 0.5h, filters, leach activated carbon after decolouring; The add-on of activated carbon is: material per ton adds 4kg activated carbon;
Filtration step is specially: the material in last process enters storage tank, enter fresh feed pump again, filtered by film device, concentrated solution enters storage tank, enter fresh feed pump again to be filtered by film device, iterative cycles carries out, and film device is cleaned by scavenging pump, filters the penetrating fluid obtained enter next procedure by film device; Film device in have ceramic membrane, the acid fastness of ceramic membrane: >=95 % fastness to alkalies: >=92 % void content: 30-45%, ultimate compression strength: 11 Mpa, bending strength: 5.7 ± 0.1 Mpa, thermostability: 250 DEG C, density: 1.45 ~ 1.52Kg/m3, treatment media temperature: 5 ~ 800 DEG C;
(5) to liquid glucose secondary decolourization, the condition of decolouring is, the amount adding activated carbon is: material per ton adds 3kg activated carbon, and bleaching time is 35min, filters after decolouring;
(6) liquid glucose after secondary decolourization is sent into ion-exchanger and carries out ion-exchange, the cation exchange resin column in the advanced first group of ion exchange column of liquid glucose, Zeo-karb with H
+metallic cation in ionic replacement liquid glucose, then enters resin anion(R.A) exchange column, anionite-exchange resin with OH
-acid radical anion in ionic replacement liquid glucose;
(7) liquid glucose after ion-exchange enters de-taste polymeric adsorbent and removes peculiar smell in liquid glucose, obtains liquid glucose for subsequent use, makes the colourity of liquid glucose lower than 10, specific conductivity is less than 30, pH value is 6.5, pure in smell free from extraneous odour;
(8) in five effect falling-film evaporators to above-mentioned steps in the liquid glucose that obtains concentrate, feed liquid after concentrated enters crystallizer, and the massecuite after crystallization, after whizzer is separated, enters pneumatic dryer, drying products is sieved by trommel screen, carries out finished product packing to qualified product; The condition of above-mentioned steps is respectively: in enrichment step, be concentrated into 72%, the rotating speed of centrifugation is 1500 rpm, and centrifugation time is 15min; Be dried to moisture in pneumatic dryer and be less than 9%, the requirement of screening is that 40 mesh sieve percent of pass reach 95%.
Claims (6)
1. a crystalline dextrose production method for energy-conserving and environment-protective, is characterized in that, described method comprises following step:
Starch milk → liquefaction → saccharification of sizing mixing → slagging-off decolorization filtering → ion-exchange → concentrated → Crystallization Separation → oven dry → crystalline dextrose;
Described method specifically comprises following step:
(1) in material-compound tank, starch concentration is adjusted to 16-20 ° of B é, pH value is regulated to be 5.5-5.9, add Thermostable α-Amylase, after feed liquid being stirred, powder stock pump is entered Jet liquefier, drop temperature controls at 108-115 DEG C, and from injector, feed liquid out enters laminar flow tank insulation 60-90min, makes its temperature remain on 95-100 DEG C; The add-on of described Thermostable α-Amylase is: starch dry matter per ton adds 300-500mL Thermostable α-Amylase;
(2) carry out second spraying again, temperature is to 135-145 DEG C, and high temperature maintains 3-5 minute, to Thermostable α-Amylase deactivation, adopts residual heat collection to utilize system to waste heat recovery after second spraying;
(3) feed liquid enters vacuum flashing cooling system and cools to 55-65 DEG C of insulation, pH value is dropped to 4.5-6.5 simultaneously, adds saccharifying enzyme, enter saccharifying tank and carry out saccharification, after saccharification to terminal, feed liquid is sprayed and heats and 70 DEG C of enzymes that go out of lowering the temperature; The add-on of described saccharifying enzyme is: starch dry matter per ton adds 300-500mL α-amylase;
(4) after saccharification, discharging enters filtration step, adopts membrane filtration system deslagging filtering, and after filtering, clear liquid enters storage tank, adds decolorizing with activated carbon 0.4-0.6h, filters, leach activated carbon after decolouring; The add-on of activated carbon is: material per ton adds 2-4kg activated carbon; Filtration step is specially: the material in last process enters storage tank, enter fresh feed pump again, filtered by film device, concentrated solution enters storage tank, enter fresh feed pump again, filtered by film device, iterative cycles carries out, film device is cleaned by scavenging pump, filters the penetrating fluid obtained enter next procedure by film device; Ceramic membrane is had, the acid fastness of ceramic membrane:>=95 %, fastness to alkali:>=92 %, void content: 30-45%, ultimate compression strength: 11 MPa, bending strength: 5.7 ± 0.1 MPa, thermostability: 250 DEG C, density: 1.45 ~ 1.52kg/m in described film device
3, treatment media temperature: 5 ~ 800 DEG C;
(5) to liquid glucose secondary decolourization, the condition of decolouring is, the amount adding activated carbon is: material per ton adds 1-4kg activated carbon, and bleaching time is 25-35min, filters after decolouring;
(6) liquid glucose after secondary decolourization is sent into ion-exchanger and carries out ion-exchange, the cation exchange resin column in the advanced first group of ion exchange column of liquid glucose, Zeo-karb with H
+metallic cation in ionic replacement liquid glucose, then enters resin anion(R.A) exchange column, anionite-exchange resin with OH
-acid radical anion in ionic replacement liquid glucose;
(7) liquid glucose after ion-exchange enters de-taste polymeric adsorbent and removes peculiar smell in liquid glucose, obtains liquid glucose for subsequent use, makes the colourity of liquid glucose lower than 10, specific conductivity is less than 30, pH value is 5-6.5, pure in smell free from extraneous odour;
(8) in five effect falling-film evaporators to above-mentioned steps in the liquid glucose that obtains concentrate, feed liquid after concentrated enters crystallizer, and the massecuite after crystallization, after whizzer is separated, enters pneumatic dryer, drying products is sieved by trommel screen, carries out finished product packing to qualified product; The condition of above-mentioned steps is respectively: in enrichment step, be concentrated into 72%, the rotating speed of centrifugation is 1500 rpm, and centrifugation time is 15min; Be dried to moisture in pneumatic dryer and be less than 9%, the requirement of screening is that 40 mesh sieve percent of pass reach 95%.
2. the crystalline dextrose production method of a kind of energy-conserving and environment-protective as claimed in claim 1, is characterized in that,
In step (1), in material-compound tank, starch concentration is adjusted to 18 ° of B é, pH value is regulated to be 5.7, add Thermostable α-Amylase, after feed liquid being stirred, powder stock pump is entered Jet liquefier, drop temperature controls at 110 DEG C, from injector, feed liquid out enters laminar flow tank insulation 80min, makes its temperature remain on 97-98 DEG C; The add-on of described Thermostable α-Amylase is: starch dry matter per ton adds Thermostable α-Amylase 400mL.
3. the crystalline dextrose production method of a kind of energy-conserving and environment-protective as claimed in claim 1, is characterized in that, in described second spraying step, temperature to 140 DEG C, high temperature maintains 4 minutes, to Thermostable α-Amylase deactivation, adopts residual heat collection to utilize system to waste heat recovery after second spraying.
4. the crystalline dextrose production method of a kind of energy-conserving and environment-protective as claimed in claim 1, it is characterized in that, in described step (3), feed liquid enters vacuum flashing cooling system and cools to 55-65 DEG C of insulation, pH value is dropped to 4.5-6.5 simultaneously, add saccharifying enzyme, enter saccharifying tank and carry out saccharification, after saccharification to terminal, feed liquid is sprayed and heats and 70 DEG C of enzymes that go out of lowering the temperature; The add-on of described saccharifying enzyme is: starch dry matter per ton adds 400mL α-amylase.
5. the crystalline dextrose production method of a kind of energy-conserving and environment-protective as claimed in claim 1, it is characterized in that, in described step (4), after saccharification, discharging enters filtration step, adopt membrane filtration system deslagging filtering, after filtering, clear liquid enters storage tank, adds decolorizing with activated carbon 0.5h, filter after decolouring, leach activated carbon; The add-on of activated carbon is: material per ton adds 3kg activated carbon.
6. the crystalline dextrose production method of a kind of energy-conserving and environment-protective as claimed in claim 1, is characterized in that, in described step (5), the amount adding activated carbon is: material per ton adds 2kg activated carbon, and bleaching time is 30min, filters after decolouring.
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| CN104805228A (en) * | 2015-04-02 | 2015-07-29 | 广西大学 | Sugar juice evaporation method |
| CN105821095A (en) * | 2015-09-14 | 2016-08-03 | 呼伦贝尔东北阜丰生物科技有限公司 | Optimization method for crystallization of glucose |
| CN105543310A (en) * | 2016-02-16 | 2016-05-04 | 河南鑫源生物科技有限公司 | Method for producing starch sugar |
| CN109234467A (en) * | 2018-09-30 | 2019-01-18 | 飞潮（无锡）过滤技术有限公司 | The ceramic membrane treatment process of saccharified liquid in a kind of fructose syrup production process |
| CN112359150A (en) * | 2020-10-29 | 2021-02-12 | 齐齐哈尔龙江阜丰生物科技有限公司 | Crystallization process of crystallized glucose |
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