CN104893956A - 一种一体化餐厨垃圾发酵制取乙醇的设备 - Google Patents
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Abstract
一种一体化餐厨垃圾发酵制取乙醇的设备,主要由发酵蒸馏釜(2)、精馏塔(3)、冷凝器(4)、乙醇收集罐(5)、尾气净化罐(6)、空压机(或鼓风机)(7)、螺旋排渣机(8)等组成;本申请提供了可以排净换热设备内的冷凝水,且原料的消毒、发酵、乙醇蒸馏提纯以及发酵渣的干燥在同一装置内依次进行的用餐厨垃圾或/和有机物为原料发酵制取乙醇的设备。
Description
技术领域
本发明涉及一种一体化餐厨垃圾(有机物为原料)发酵制取乙醇的设备,属于节能环保以及生化设备领域。
技术背景
随着人们日常生活的不断改善,餐厨垃圾的量愈来愈多,低成本的利用和管理好餐厨垃圾,使其无害化、减量化和资源化,杜绝餐厨垃圾进入饲料食物链,维护人们的食品卫生与健康,是当今社会关注的大事,有着重大的环境社会意义。
有关餐厨垃圾为原料生产乙醇的方法和设备已有许多报导;在CN102174591A中,公开了“一种连续固态发酵餐厨垃圾生产乙醇的方法”;其原料的杀毒汽爆灌、发酵塔、乙醇蒸馏器以及发酵渣的干燥器等设备是都分离开的;其缺点是物料在各个设备之间的中转时间长,生产流程长、设备多、占地面积大,使用率低,及生产成本高;特别地,传统的发酵设备内的蒸汽加热或冷水降温的换热器多为列管式或盘管式,其缺点是管式换热器容易发生“汽阻、积水”现象,常常发生管体裂缝、焊缝脱落、破损或故障,人体维修不方便;
常规的有机物(如秸秆)为原料发酵制取乙醇、生物有机肥、生物饲料、药品、食品、有机溶剂或有机原料等所采用的设备一般都是分体式,即物料的灭火、水解、糖化、发酵、蒸馏提纯和发酵渣的干燥设备都是分开的,这极大地增加了物料在各个设备之间的中转时间,降低了设备单位时间内的生产量,增加了生产成本;
本发明的目的就是要克服上述设备的缺点,提供一体化餐厨垃圾或/和有机物为原料发酵制取乙醇的设备;具体地,提供一种可以排净换热设备内的冷凝水,且原料的消毒、水解、糖化、发酵、乙醇蒸馏提纯以及发酵渣的干燥在同一装置内依次进行的用餐厨垃圾或/和有机物为原料发酵制取乙醇的设备。
发明内容
为解决上述技术问题,本发明的技术方案如下:一体化餐厨垃圾或/和有机物为原料发酵制取乙醇的设备,主要由圆筒形发酵蒸馏釜、精馏塔、冷凝器、乙醇收集罐、尾气净化罐、空压机或鼓风机、螺旋排渣机等组成;其中,原料如餐厨垃圾、水、酶制剂通过加料阀门与发酵蒸馏釜的上部相连通;发酵蒸馏釜的中部垂直配置多根钢制换热列管,多根列管的中心均垂直配置带螺旋搅叶的旋转轴,轴的下端用固定套固定,轴的顶端由配置在发酵蒸馏釜顶部连接调速电机的变速箱轴套固定;圆筒形发酵蒸馏釜中心的那一根换热列管内的旋转轴的下方配置刮板;每根垂直列管的上下二端管口分别与带法兰盘的孔板焊接在一起,组合成常规的列管换热器;列管的外部与圆筒形的发酵蒸馏釜的内壁之间的空间属于热载体如水蒸汽的加热或降温的密闭换热室;配置在列管换热器上下二端的法兰盘与圆筒形发酵蒸馏釜的上部筒体和下部筒体的法兰盘分别联接固定,并相连通;圆筒形发酵蒸馏釜的顶部配置有驱动搅拌轴旋转的调速电机;所述的圆筒形发酵蒸馏釜的顶部结构,可以是圆形封头或平顶结构;所述的轴被调速电机驱动,也可以在轴的顶端配置齿轮或皮带轮,由另一电机驱动旋转;圆筒形发酵蒸馏釜的下部配置带小孔的隔板或滤网,其隔板上部的釜外壁上配置排渣孔,该排渣孔联接发酵渣出口阀门,并与螺旋排渣机的进口相联通将发酵渣排出釜外;发酵蒸馏釜的底部经阀门与空压机或鼓风机的送风出口相联通;发酵蒸馏釜的底部配置换热室;发酵蒸馏釜的上部经阀门联接乙醇精馏塔的底部,精馏塔的顶部与冷凝器的气相物质进口相联通,冷凝器的液体物料出口与乙醇收集罐的进料口相连通;乙醇收集罐的上部的废气出口与废气净化罐内部的废气接受管相连通;发酵蒸馏釜上部的废气排放管的出口经阀门与废气净化罐的废气接受管相连通;发酵蒸馏釜的上部与发酵渣加热干燥时水蒸气的排放阀门相联通;压力表配置在发酵蒸馏釜的顶部,温度计的探头插孔配置在换热钢制列管内;入孔配置在发酵蒸馏釜的上部侧壁上;
本发明中,原料的杀菌消毒采用高温水蒸气加热进行实施,其方式是将高温水蒸气经过阀门38通入发酵蒸馏釜2内,与物料直接接触进行加热升温,或将高温水蒸汽经阀门30通入发酵蒸馏釜2内的换热钢制列管19外壁的加热室29中,给管19内的物料间接升温加热;其蒸汽冷凝水经阀门17排出;或是将热载体如水蒸气或导热油输入换热室20,给发酵蒸馏釜2内的物料进行间接加热升温进行消毒灭活;
本发明中,原料在发酵蒸馏釜2内发酵完成时乙醇含量一般在10-30%左右,还需要进一步的加热浓缩和精馏,最后才得到95%以上的乙醇;本发明在加热浓缩或精馏时所需要的热量,主要采用如下加热方式:
将高温水蒸汽经阀门30通入发酵蒸馏釜2内的换热钢制列管19外壁的加热室29中,给管19内的物料间接加热升温;其蒸汽冷凝水经阀门17排出;或/和是将热载体如水蒸气或导热油输入换热室20,给发酵蒸馏釜2内的物料进行间接加热升温;发酵蒸馏釜2内受热后的乙醇从液相转变成气相,气相乙醇经阀门11进入精馏塔3进行提纯,然后,按传统技术进行收集和储备;
本发明中,发酵蒸馏釜2内的发酵渣干燥所需要的热量,主要采用如下加热方式:
将高温水蒸汽经阀门30通入发酵蒸馏釜2内的换热钢制列管19外壁的加热室29中,给管19内的发酵渣间接加热升温;其蒸汽冷凝水经阀门17排出;或/和是将热载体如水蒸气或导热油输入换热室20,给发酵蒸馏釜2内的物料进行间接加热升温;受热后的发酵渣中的水分从液相转变成水蒸汽,水蒸气经阀门13进入废气净化罐6进行吸附、冷凝和净化处理;
本发明中,可以定期的或不定期的将一定量的空气用空压机7经过阀门23输入到发酵蒸馏釜2内,空气串过铺有筛网的隔板24,以防网孔被阻塞,导致糟水向下流动时受阻;
本发明中,如果需要采取好氧发酵工艺,如用糖类、乙醇或醋酸为原料制造柠檬酸,需要氧气进行发酵时,其操作方法:将一定量的空气用空压机7经过阀门23输入到发酵蒸馏釜2内,空气串过铺有筛网的隔板24,气流上升,与发酵物料接触,进行发酵;
本发明的原料包括:餐厨垃圾、碳水化合物和生物质;其中包括:农业有机废弃物(如各类秸秆、稻壳、稻草、棉杆、壳、枝、叶、根、草)、林业废弃物(如零散木材、木屑、树枝、枝丫、截头、树皮、果壳、果皮)、畜禽粪便、污泥、生活污水和有机废水、草本和木本植物;
本发明与现有的技术比较具有如下优点:
用水蒸汽给发酵塔加热时不产生汽阻或冷凝积水,发酵设备内的换热管不易损害,经久耐用;原料的杀菌消毒、降温、发酵、乙醇的精馏提纯和发酵渣的干燥等主要工序,均在同一设备中进行,降低了产品单位产量的设备投资和设备的占地面积,缩短了各个设备之间的出料或加料的时间,降低了生产成本,提高了工作效益;
附图说明
图1为本发明的结构图;
图2为发酵蒸馏釜的剖面图
下面结合附图和实施例对本发明做进一步的描述,但本实施例不受其限制;
在图1中,1-入孔;2-圆筒形发酵蒸馏釜;3-精馏塔;4-冷凝器;5-乙醇收集罐;6-尾气净化罐;7-空压机(或鼓风机);8-螺旋排渣机;9-压力表;10-调速电机;11-精馏阀门;12-原料进塔阀门;13-发酵时废气出口阀门;14-法兰盘;15-温度计;16-冷水进釜阀门;17-冷凝水(疏水)出塔阀门;18-发酵渣出口阀门;19-钢制换热列管;20-热载体(水蒸气或导热油)换热室;21-热载体出口阀门;22-发酵废水出口阀门;23-空气进塔阀;24-滤网隔板;25-可旋转的刮板;26-热载体(水蒸气)进口阀门;27-旋转轴的固定套;28-带搅拌器的旋转轴;29-加热或降温的换热室;30-热载体(水蒸气)进釜阀门;31-热水出釜阀门;32-达标气体排放管;33-废气接受管;34-乙醇出料阀门;35-乙醇;36-净化液体;37-净化液排出阀门;38-热载体(水蒸气)进釜阀门;39-发酵渣干燥时水蒸气排泄阀门;
一体化餐厨垃圾或/和有机物为原料发酵制取乙醇的设备,主要由圆筒形发酵蒸馏釜2、精馏塔3、冷凝器4、乙醇收集罐5、尾气净化罐6、空压机或鼓风机7、螺旋排渣机8等组成;其中,原料如餐厨垃圾、水、酶制剂通过加料阀门12与发酵蒸馏釜2的上部相连通;发酵蒸馏釜2的中部垂直配置多根钢制换热列管19,多根列管19的中心均垂直配置带螺旋搅叶的旋转轴28,轴28的下端用固定套27固定,轴28的顶端由配置在发酵蒸馏釜2顶部连接调速电机的变速箱轴套固定;圆筒形发酵蒸馏釜2中心的那一根换热列管内的旋转轴28的下方配置刮板25;每根垂直列管19的上下二端管口分别与带法兰盘14的孔板焊接在一起,组合成常规的列管换热器;列管19的外部与圆筒形的发酵蒸馏釜2的内壁之间的空间属于热载体如水蒸汽的加热或降温的密闭换热室29;配置在列管换热器上下二端的法兰盘14与圆筒形发酵蒸馏釜2的上部筒体和下部筒体的法兰盘14分别联接固定,并相连通;圆筒形发酵蒸馏釜2的顶部配置有驱动搅拌轴28旋转的调速电机10;所述的圆筒形发酵蒸馏釜2的顶部结构,可以是圆形封头或平顶结构;所述的轴28被调速电机10驱动,也可以在轴28的顶端配置齿轮或皮带轮,由另一电机驱动旋转;圆筒形发酵蒸馏釜2的下部配置带小孔的隔板或滤网24,其隔板24上部的釜2外壁上配置排渣孔,该排渣孔联接发酵渣出口阀门18,并与螺旋排渣机8的进口相联通将发酵渣排出釜2外;发酵蒸馏釜2的底部经阀门23与空压机或鼓风机7的送风出口相联通;发酵蒸馏釜2的底部配置换热室20;发酵蒸馏釜2的上部经阀门11联接乙醇精馏塔3的底部,精馏塔3的顶部与冷凝器4的气相物质进口相联通,冷凝器4的液体物料出口与乙醇收集罐5的进料口相连通;乙醇收集罐5的上部的废气出口与废气净化罐6内部的废气接受管33相连通;发酵蒸馏釜2上部的废气排放管的出口经阀门13与废气净化罐6的废气接受管相连通;发酵蒸馏釜2的上部与发酵渣加热干燥时水蒸气的排放阀门39相联通;压力表9配置在发酵蒸馏釜2的顶部,温度计15的探头插孔配置在换热钢制列管19内;入孔1配置在发酵蒸馏釜2的上部侧壁上。
实施例1将某宾馆收集的餐厨垃圾首先进行油水分离,得到固体餐厨垃圾,每100克固体餐厨垃圾的成分分析:总糖25.3克,非还原性糖13.1克,还原性糖9.6克,蛋白质3.4克,脂肪9.9克,纤维素11.2克;将此固体餐厨垃圾经过破碎机进行粉碎成浆,通过阀门12加入到发酵蒸馏釜2内,将一定量的水经阀门12加入发酵蒸馏釜2内,受螺旋搅拌轴28和刮板25的转动,原料与水在发酵蒸馏釜2内进行充分混合均匀,然后,进行如下工序:
1.杀菌消毒处理:
将高温水蒸汽经阀门38输入发酵蒸馏釜2内,水蒸气均匀地串过隔板24小孔,不断地上升,与搅拌中的物料均匀的接触而发酵蒸馏使釜2内的物料温度升温至150℃,消毒灭活时间为10分钟,发酵蒸馏釜2内的温度由温度计15监控,压力由压力表9显示监控;彻底杀灭有害细菌和病毒;
2.发酵:
关闭杀菌消毒过程中的高温蒸汽阀门38,给发酵蒸馏釜2内的物料降温至发酵工艺要求的低温如15-35℃,发酵是放热的生化反应,物料温度会自行上升,为了控制发酵工艺所要求的25-35℃的温度范围,发酵蒸馏釜2内的物料的降温方法是:
将冷水经阀门16输入到换热室29内,热水从阀门31排出,或将冷水从阀门21进入换热室20,热水从阀门26排出;通过温度计15和冷水的流速控制整个发酵过程中的物料25-35℃的温度范围;当发酵蒸馏釜2内的物料温度降至30℃时,将一定配比的酶制剂按照每100克餐厨垃圾加入:4000U糖化酶、200IU纤维素酶、300U酸性蛋白酶和0.015克“丹宝利”牌耐高温酿酒活性干酵母经阀门12,加入到发酵蒸馏釜2内,进行糖化和/或发酵;发酵中发酵蒸馏釜2内的温度由温度计15监控,压力由压力表9显示监控;在带搅拌器的旋转轴的顺转或逆转搅拌下,餐厨垃圾、酶制剂和水进行充分接触和混合,隔绝空气,进行厌氧发酵制取乙醇,发酵时间为39小时,PH控制在4-5,用醋酸、柠檬酸或糟液调节发酵物料的酸碱度;温度控制在25-35℃的温度范围,发酵中产生的废气经过阀门13进入尾气净化罐6进行环保达标净化处理,环保合格的气体从管32的出口排放;经检测原料转化率合格后,发酵完毕,关闭冷水进釜阀门16;
3.乙醇的加热蒸发和精馏提纯:
采用高温水蒸气给发酵蒸馏釜2和精馏塔3供热制取高浓度的乙醇;具体地,将高温水蒸汽经阀门30输入到发酵蒸馏釜2内的换热室29,20内,从发酵蒸馏釜2的底部和中部间接地给发酵蒸馏釜2的物料加热,加热的水蒸汽从阀门30、26进入换热室,蒸汽的冷凝水从阀门17、21排出;在搅拌装置10、28、25的搅拌下,物料被均匀地加热,当物料温度上升至乙醇的汽化温度时,乙醇从液相转化成气相乙醇,气相乙醇被蒸发,经阀门11进入精馏塔3进行常规方法的精馏,高浓度乙醇的气相物质从精馏塔3的顶部流出,进入冷凝器4进行冷凝成液态,得到纯度为95%Wt%的乙醇,并流入乙醇收集罐5内储备待用,乙醇35经阀门34排出装置;按照通用公知的分子筛塔脱水法吸附法处理95%Wt%的乙醇,最后,得到无水乙醇产品;蒸馏乙醇中产生的不凝结性气体经过管道33通入尾气净化罐6的净化液体36中,进行吸附和净化环保达标处理,环保合格的气体从管32的出口排放;在乙醇加热蒸发和精馏提纯中,发酵蒸馏釜2和精馏塔3内的温度,由温度计15监控;压力由压力表9显示监控;当釜2内的乙醇蒸发完毕后,停止加热,终止蒸发及精馏程序;
3.发酵渣的干燥:
采用高温水蒸气给发酵蒸馏釜2内的蒸馏剩余物或发酵渣进行脱水,然后进行加热干燥;具体地,将阀门22打开,将釜2内发酵渣中含有的发酵剩余的糟水经过铺有滤网的带孔隔板24进行过滤,发酵渣在滤网上面,而糟水串过滤网隔板24自动向下流出,排出圆筒形罐体1外,至不能自动流出明水为止,关闭阀门22,并按传统工艺设备收集、利用或净化排出的糟水;对发酵渣加热干燥时,将高温水蒸汽经阀门30输入到发酵蒸馏釜2内的换热室29,20内,从发酵蒸馏釜2的底部和中部间接地给发酵蒸馏釜2的物料加热,加热的水蒸汽从阀门30、26进入换热室,蒸汽的冷凝水从阀门17、21排出;在搅拌装置10、28、25的搅拌下,发酵渣被均匀地加热,发酵渣中的水分不断地受热后汽化,转变水蒸气,水蒸气经阀门39不断地向发酵蒸馏釜2的外面排出,并按传统工艺设备收集和处理水蒸气;当发酵渣中的水分含量蒸发降至15%Wt%时,停止加热干燥;打开排渣阀门18,启动搅拌装置10、25、28和螺旋排渣机8,不断地将干燥合格的发酵渣经过排渣阀18排出发酵蒸馏釜2外;
实施例2玉米秸秆经过除石、除铁、清洗、用切割机切成1公分以下,通过公知的方法进行预处理或汽爆,将预处理后的玉米秸秆碎片通过阀门12加入到发酵蒸馏釜2内,将一定量的水经阀门12加入发酵蒸馏釜2内,配成10%的玉米秸秆发酵基料,加入适量的营养盐,接入里斯木酶Rut-C30菌种纤维素酶,在50℃保温30小时进行发酵,纤维素转化成糖液,其转化率达到72.6%Wt%;糖化完毕后,将物料在发酵蒸馏釜2内降温至30℃,然后,依照上述实施例1的方法和设备,进行酒精的发酵,经过30℃发酵24小时,乙醇的生成浓度达到10%体积百分比,糖的乙醇转化率达到92.5%;乙醇经过蒸馏塔的蒸馏、分子筛塔的吸附脱水,最后得到无水乙醇产品。
Claims (1)
1.一体化餐厨垃圾发酵制取乙醇的设备,主要由圆筒形发酵蒸馏釜(2)、精馏塔(3)、冷凝器(4)、乙醇收集罐(5)、尾气净化罐(6)、空压机(或鼓风机)(7)、螺旋排渣机(8)组成,其特征在于:原料通过加料阀门(12)与发酵蒸馏釜(2)的上部相连通;发酵蒸馏釜(2)的中部垂直配置多根钢制换热列管(19),多根列管(19)的中心均垂直配置带螺旋搅叶的旋转轴(28),轴(28)的下端用固定套(27)固定,轴(28)的顶端由配置在发酵蒸馏釜(2)顶部连接调速电机的变速箱轴套固定;圆筒形发酵蒸馏釜(2)中心的那一根换热列管内的旋转轴(28)的下方配置刮板(25);每根垂直列管(19)的上下二端管口分别与带法兰盘(14)的孔板焊接在一起;列管(19)的外部与圆筒形的发酵蒸馏釜(2)的内壁之间的空间属于热载体的加热或降温的密闭换热室(29);配置在列管换热器上下二端的法兰盘(14)与圆筒形发酵蒸馏釜(2)的上部筒体和下部筒体的法兰盘(14)分别联接固定,并相连通;圆筒形发酵蒸馏釜(2)的顶部配置有驱动搅拌轴(28)旋转的调速电机(10);所述的圆筒形发酵蒸馏釜(2)的顶部结构,可以是圆形封头或平顶结构;所述的轴(28)被调速电机(10)驱动,也可以在轴(28)的顶端配置齿轮或皮带轮,由另一电机驱动旋转;圆筒形发酵蒸馏釜(2)的下部配置带小孔的隔板或滤网(24),其隔板(24)上部的釜(2)外壁上配置排渣孔,该排渣孔联接发酵渣出口阀门(18),并与螺旋排渣机(8)的进口相联通将发酵渣排出釜(2)外;发酵蒸馏釜(2)的底部经阀门(23)与空压机(7)的送风出口相联通;发酵蒸馏釜(2)的底部配置换热室(20);发酵蒸馏釜(2)的上部经阀门(11)联接乙醇精馏塔(3)的底部,精馏塔(3)的顶部与冷凝器(4)的气相物质进口相联通,冷凝器(4)的液体物料出口与乙醇收集罐(5)的进料口相连通;乙醇收集罐(5)的上部的废气出口与废气净化罐(6)内部的废气接受管(33)相连通;发酵蒸馏釜(2)上部的废气排放管的出口经阀门(13)与废气净化罐(6)的废气接受管相连通;发酵蒸馏釜(2)的上部与发酵渣加热干燥时水蒸气的排放阀门(39)相联通;压力表(9)配置在发酵蒸馏釜(2)的顶部,温度计(15)的探头插孔配置在换热钢制列管(19)内;入孔(1)配置在发酵蒸馏釜(2)的上部侧壁上。
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