JP2008156388A - Production system for product derived from rice, method for production, system for production planning and method for production planning - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production system for products derived from rice comprehensively utilizing each component produced from the rice, to provide a method for production, to provide a system for production planning and to provide a method for production planning. <P>SOLUTION: Methanol 21, methane gas 22, a direct fuel 23 or compost 24 is produced from at least one of rice straw 1, chaff 2, rice bran 3 and milled rice 4. Furthermore, ethanol 28, lactic acid 27 or a syrup 26 is produced from the milled rice 4. An oil and fat 25 is further produced from the rice bran 3. The produced methanol 21 and oil and fat 25 are subjected to synthesis to produce BDF (bio-diesel fuel) methyl 29a. The produced ethanol 28 and oil and fat 25 are subjected to synthesis to produce BDF ethyl 29b. The produced methanol 21 and lactic acid 27 are subjected to synthesis to produce methyl lactate 30a. The produced ethanol 28 and lactic acid 27 are subjected to synthesis to produce ethyl lactate 30b. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a rice grain-derived product production system, production method, production planning system, and production planning method.

  Although rice cereals are the best source of starch in Japan, each year, such as reduction of production for production adjustment, feed for surplus rice processing, old rice processing based on the stockpiling rice system so far Consideration about utilization has not been made. For example, production surplus rice and stockpiled old rice are edible rice that has been stored under regular fumigation and low-temperature management in the form of brown rice in the warehouses of each agricultural association or self-distributed rice handling company. Stockpile old rice is not suitable for food because it has a bromine odor due to fumigation during storage for more than 5 years, and it is dry and easily broken. For this reason, it is almost disposed of after 5 years of storage, and the amount is estimated to reach 300,000 tons per year. Even if the reduction and Aota mowing are carried out, excessive rice production has been put on the market due to the recent separation of rice and good harvesting, and it has been disposed of after it has become production surplus rice or stockpiled old rice.

  In addition, in recent years it has been prohibited by law to burn excess rice straw and rice husks produced from rice grains, so they can be composted or kneaded into the mud of the fields, but can be processed by themselves. It is not the amount generated. Nuka, which is generated from rice grains, is being reviewed as a healthy food by-product, but it is quickly rotted as fats and oils, and it cannot be burned like rice straw or rice husk. It becomes waste.

  Therefore, conventionally, as a method aiming at utilization of rice cereals, there has been proposed one that efficiently produces only one manufactured product such as a single lactic acid, ethanol, or a lactic acid derivative in a factory (for example, a patent) Reference 1 or 2).

JP 2005-143320 A JP 2005-154290 A

  However, the conventional methods for utilizing rice cereals as described in Patent Documents 1 and 2 have a problem that the utilization of comprehensive components of rice cereals is not sufficiently considered.

  The present invention has been made paying attention to such problems, and a rice grain-derived product production system, production method, production planning system, and production planning method capable of comprehensively using each component generated from rice grains. The purpose is to provide.

  In order to achieve the above object, a rice grain-derived product production system according to the present invention is a rice grain-derived product production system using rice straw, rice husk, rice bran, and white rice generated from rice grain, the rice straw, Methanol producing means for producing methanol from at least one of the rice husk, the rice bran and the white rice, ethanol producing means for producing ethanol from the white rice, lactic acid producing means for producing lactic acid from the white rice, Oil and fat production means for producing fats and oils from Nuka, methanol produced by the methanol production means, and oil and fat produced by the fat and oil production means, BDF methyl production means for producing biodiesel fuel, The ethanol produced by the ethanol production means is synthesized with the fat produced by the fat production means, BDF ethyl production means for producing fuel, methanol produced by the methanol production means, and lactic acid produced by the lactic acid production means, and methyl lactate production means for producing methyl lactate, and the ethanol And ethyl lactate producing means for producing ethyl lactate by synthesizing ethanol produced by the producing means and lactic acid produced by the lactic acid producing means.

  A method for producing a rice grain-derived product according to the present invention is a method for producing a rice grain-derived product using rice straw, rice husk, nuka and white rice generated from rice grain, wherein the rice straw, the rice husk, the rice bran and the rice Of the white rice, a methanol production process for producing methanol from at least one, an ethanol production process for producing ethanol from the white rice, a lactic acid production process for producing lactic acid from the white rice, and an oil production for producing fat from the nuka BDF methyl production process for producing biodiesel fuel by synthesizing the process, methanol produced in the methanol production process, and oil produced in the oil production process, and ethanol produced in the ethanol production process And BDF ethyl production to produce biodiesel fuel by synthesizing oil and fat produced in the oil production process A process for synthesizing methanol produced in the methanol production process and lactic acid produced in the lactic acid production process to produce methyl lactate, and ethanol produced in the ethanol production process. And lactic acid produced in the lactic acid production process to synthesize ethyl lactate to produce ethyl lactate.

  The production system and the production method of rice grain-derived products according to the present invention include processing rice bran obtained by milling brown rice into oil or methanol, processing white rice into one of ethanol, lactic acid or methanol, The shell can also be processed into methanol. Furthermore, BDF ethyl, BDF methyl, BDF methyl, ethyl lactate, and ethyl lactate, which are biodiesel fuels, can be produced by appropriately synthesizing the produced methanol, ethanol, lactic acid, and fats and oils.

  Thus, according to the production system and production method for rice grain-derived products according to the present invention, it is possible to comprehensively utilize each component of rice straw, rice husk, nuka and white rice generated from rice grains as biomass without waste. it can. Moreover, methanol, ethanol, biodiesel fuel, etc. can be manufactured from each component of raw rice grains, and alternative fuels such as gasoline, light oil, and kerosene can be provided. As a result, it is possible to cope with soaring gasoline, light oil, kerosene, etc. due to the recent oil resource depletion problem, and to escape from dependence on petroleum resources.

  The production system for rice grain-derived products according to the present invention is preferably provided in a single factory. Moreover, it is preferable that the production method of the rice grain origin product which concerns on this invention is implemented within a single factory. In this case, methanol, ethanol, biodiesel fuel, etc. can be produced efficiently. In addition, by adjusting production according to seasonal fluctuations in raw material procurement, it is possible to manufacture more efficiently and economically.

  The rice grain-derived product production system according to the present invention includes a methane gas production means for producing methane gas from at least one of the rice straw, the rice husk, the nutka and the white rice, the rice straw, the rice husk, the Fuel production means for producing fuel from at least one of Nuka and the white rice, Compost production means for producing compost from at least one of the rice straw, the rice husk, the Nuka and the white rice, It is preferable to have a sugar solution production means for producing a sugar solution from white rice.

  The method for producing a rice grain-derived product according to the present invention includes a methane gas production process for producing methane gas from at least one of the rice straw, the rice husk, the nutka and the white rice, the rice straw, the rice husk, A fuel production process for producing fuel from at least one of Nuka and the white rice, a compost production process for producing compost from at least one of the rice straw, the rice husk, the Nuka and the white rice, and And a sugar solution production process for producing a sugar solution from white rice.

  When producing this methane gas, fuel, compost and sugar liquor, Nuka is processed into oil, methanol, methane gas, compost or fuel, and white rice is treated with sugar liquid, ethanol, lactic acid, methanol, methane gas, compost or fuel. The rice straw and rice husk can be processed into either methanol, methane gas, compost or fuel. Thereby, each component of rice straw, rice husk, rice bran, and white rice generated from rice grains can be comprehensively utilized as biomass efficiently without waste.

  The production planning system for rice-derived products according to the present invention uses rice straw, rice husk, nuka and white rice generated from rice grains as raw materials, methanol, methane gas, fuel, compost, sugar solution, lactic acid and methane gas produced from the raw materials. A production planning system for rice grain-derived products for producing production and sales plans for primary products and biodiesel fuel, ethyl lactate and methyl lactate secondary products produced from the primary products Priority information indicating the priority of each primary product and the priority of each secondary product, inventory information indicating the stock status of each raw material, each primary product and each secondary product, and the season indicating seasonal fluctuations in the procurement amount of each raw material Fluctuation information, market price information indicating the market price of each secondary product, manufacturing cost information indicating the manufacturing cost of each secondary product, and competition indicating the price of competitor products of each secondary product Storage means for storing product information, and storage index information including storage form, storage period, storage easiness of each raw material, each primary product and each secondary product in advance, and the storage means stored in the storage means Based on the priority information, the inventory information, and the seasonal variation information, the production amount calculation means for calculating the production amount and the delivery date of each primary product and each secondary product, and the market price information stored in the storage means , Based on the manufacturing cost information and the competitive product information, profit determining means for determining whether a profit is generated or a loss is generated when each secondary product is sold, and when a loss occurs in the profit determining means If determined, based on the storage index information stored in the storage means, adjustment instruction means for instructing the change, storage or sale of the production amount of each primary product and each secondary product, When the production instruction of each primary product and each secondary product is instructed by the adjustment instruction means, based on the storage index information stored in the storage means, the primary product or the secondary product that is difficult to store, Change the production to a primary product or secondary product that can be easily stored, and then calculate the production amount of each primary product and each secondary product again, and the production amount calculation means or the production amount adjustment means. And a production plan creation means for creating a production plan based on the production amount and delivery date of each primary product and each secondary product.

  The method for producing rice grain-derived products according to the present invention includes rice straw, rice husk, nuka and white rice generated from rice grains as raw materials, methanol, methane gas, fuel, compost, sugar solution, lactic acid and methane gas produced from the raw materials. A production planning method for rice-derived products for producing production and sales plans for primary products and biodiesel fuel, ethyl lactate and methyl lactate secondary products produced from the primary products Priority information indicating the priority of each primary product and the priority of each secondary product, inventory information indicating the stock status of each raw material, each primary product and each secondary product, and the season indicating seasonal fluctuations in the procurement amount of each raw material Fluctuation information, market price information that indicates the market price of each secondary product, manufacturing cost information that indicates the manufacturing cost of each secondary product, and competitive product information that indicates the price of a competitive product of each secondary product In addition, a storage step of storing in advance storage index information including storage forms, storage periods, storage easiness of each raw material, each primary product and each secondary product, and the priority order information stored in the storage step A production amount calculating step for calculating a production amount and a delivery date of each primary product and each secondary product based on the inventory information and the seasonal variation information; the market price information stored in the storage step; and the manufacturing Based on the cost information and the competitive product information, it is determined that there is a loss in the profit determination step for determining whether a profit is generated or a loss is generated when each secondary product is sold, and in the profit determination step. If the storage index information stored in the storage step is instructed to change, store or sell the production amount of each primary product and each secondary product The primary product that is difficult to store based on the storage index information stored in the storage step when the change of the production amount of each primary product and each secondary product is instructed in the adjustment instruction step and the adjustment instruction step Alternatively, the production of the secondary product is changed to a primary product or a secondary product that can be easily stored, and the production amount adjusting step for recalculating the production amount of each primary product and each secondary product; And a production plan creation step of creating a production plan based on the production amount and delivery date of each primary product and each secondary product calculated in the production amount adjustment step.

  The production planning system and production planning method for rice-derived products according to the present invention uses seasonal variation information to produce production plans for each primary product and each secondary product corresponding to seasonal variations in the procurement amount of each raw material and climate variations. Can be created. Further, the occurrence of loss can be prevented by using market price information, manufacturing cost information and competitive product information, and economic efficiency can be improved. In this way, the components of rice straw, rice husk, rice bran, white rice generated from rice grains can be comprehensively utilized as biomass without waste, and an efficient and economical production plan can be created.

  The production planning system for rice-derived products according to the present invention is based on the production amount and delivery date of each primary product and each secondary product calculated by the production amount calculating means or the production amount adjusting means. Raw material calculation means for calculating the amount, arranged raw material calculation means for calculating the available amount of each raw material based on the seasonal variation information and the storage index information stored in the storage means, and calculation by the raw material calculation means When the required amount of each raw material exceeds the orderable amount of each raw material calculated by the arranged raw material calculating means, each primary product and each secondary product based on the storage index information stored in the storage means Production amount readjustment means for recalculating the production amount and delivery date of the production plan, and the production plan creating means is calculated by the production amount calculation means, the production amount adjustment means or the production quantity readjustment means. Primary product On the basis of the pre-production and delivery of each secondary product, it is preferable to create a production plan.

  The production planning method for rice grain-derived products according to the present invention requires each raw material based on the production amount and delivery date of each primary product and each secondary product calculated in the production amount calculating step or the production amount adjusting step. A raw material calculation step for calculating the amount, an arranged raw material calculation step for calculating an available amount of each raw material based on the seasonal variation information and the storage index information stored in the storage step, and a calculation in the raw material calculation step When the required amount of each raw material exceeds the orderable amount of each raw material calculated in the arranged raw material calculation step, each primary product and each secondary product based on the storage index information stored in the storage step A production amount readjustment step for recalculating the production amount and the delivery date of the production plan, wherein the production plan creation step comprises the production amount calculation step, the production amount adjustment step, Based on the production and delivery of the primary products and the secondary products that are calculated by the production of re-adjustment step, it is preferable to create a production plan.

  When calculating the necessary amount and the orderable amount of each raw material, it is possible to prevent the shortage of each raw material and to create a more appropriate production plan.

  According to the present invention, it is possible to provide a production system, a production method, a production planning system, and a production planning method for a rice grain-derived product that can comprehensively utilize each component generated from rice grains.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1 to 6 show a rice grain-derived product production system, production method, production planning system, and production planning method according to an embodiment of the present invention. In addition, the production method of the rice grain origin product of embodiment of this invention is a method performed by the production system. Moreover, the production plan method of the rice grain origin product of embodiment of this invention is a method performed by the production planning system.

  As shown in FIGS. 1 and 2, the rice grain-derived product production system according to the embodiment of the present invention is provided in a single factory, and includes methanol production means 11, methane gas production means 12, fuel production means 13, and the like. It has a compost production means 14, an oil and fat production means 15, a sugar solution production means 16, a lactic acid production means 17, an ethanol production means 18, a biodiesel production means 19, and a lactic acid ester production means 20.

  The methanol production means 11 produces methanol 21 from at least one of rice straw 1, rice husk 2, rice bran 3 and white rice 4 which are raw materials generated from rice grains. The methane gas production means 12 produces methane gas 22 from at least one of rice straw 1, rice husk 2, rice bran 3, and white rice 4. The fuel production means 13 produces direct fuel 23 in the form of pellets from at least one of the rice straw 1, rice husk 2, nutka 3 and white rice 4. The compost manufacturing means 14 is configured to manufacture the compost 24 from at least one of the rice straw 1, the rice husk 2, the rice bran 3, and the white rice 4. The fat and oil producing means 15 produces fats and oils 25 such as dietary oil from the nutka 3. The sugar liquid producing means 16 is adapted to produce a sugar liquid 26 from the white rice 4. The lactic acid production means 17 produces lactic acid 27 from the white rice 4. The ethanol production means 18 produces ethanol 28 from the white rice 4.

  The biodiesel production means 19 synthesizes the methanol 21 produced by the methanol production means 11 and the oil / fat 25 produced by the oil / fat production means 15 to produce a methyl type biodiesel fuel (BDF methyl 29a). BDF ethyl production for producing ethyl biodiesel fuel (BDF ethyl 29b) by synthesizing methyl production means, ethanol 28 produced by ethanol production means 18 and fat 25 produced by fat production means 15 Means.

  The lactic acid ester production means 20 synthesizes the methanol 21 produced by the methanol production means 11 and the lactic acid 27 produced by the lactic acid production means 17 to produce methyl lactate 30a, and ethanol production means. 18 and ethyl lactate producing means for producing ethyl lactate 30b by synthesizing ethanol 28 produced in 18 and lactic acid 27 produced by lactic acid producing means 17.

  Thereby, from rice straw 1 and rice husk 2, methanol 21, methane gas 22, direct fuel 23, and compost 24 can be manufactured as primary products. In the methanol production means 11, the rice straw 1 and rice husk 2 are made into powder and blown with high-temperature steam and oxygen gas, and gasification is performed at around 1000 ° C. After gasification, carbon dioxide, hydrogen sulfide, hydrochloric acid gas, etc. are removed by washing with water at room temperature, and ash is also washed away. Methanol 21 can be produced by blowing heated steam into the remaining methane gas, carbon monoxide, and hydrogen in the presence of a copper-zinc catalyst at around 200 ° C. again. Further, the methane gas production means 12 can produce the methane gas 22 by converting the rice straw 1 and rice husk 2 into chips and then adding water and performing anaerobic fermentation. The methane gas production method includes adding a moisture of about 30-50% of the weight and leaving it in an airtight container to generate gas in an anaerobic state. There are two methods, a wet method for obtaining methane gas 22 generated from a closed tank while applying gentle stirring. Portions that cannot be used for methanol 21 and methane gas 22 are directly used as raw materials for fuel 23 and compost 24.

  From Nuka 3, fats and oils 25 such as edible oil, methanol 21, methane gas 22, direct fuel 23, and compost 24 can be manufactured as primary products. The edible oil produced by the fats and oils production means 15 contains linoleic acid, oleic acid and vitamin E, and is good for health because of its low linolenic acid, and is less susceptible to deterioration than other edible oils. Has the advantage of long life. However, quality control of Nuka 3 before oil production is important, and it is easy to rot. Therefore, Nuka 3 oil is not directly edible but oil 25 for BDF raw material. The recovered waste oil 25a is also used for the BDF raw material. Nuka 3 is also used as a raw material for methanol 21, methane gas 22, direct fuel 23, and compost 24.

  From white rice 4, sugar solution 26, lactic acid 27, ethanol 28, methanol 21, methane gas 22, direct fuel 23, and compost 24 can be produced as primary products. By the sugar liquid production means 16, the white rice 4 can be liquefied by liquefaction / saccharifying enzyme amylase to easily produce a sugar liquid 26 of about 15 to 20%. The sugar solution 26 can be used as a food supplement, a fermentation raw material, a nutritional drink, etc., but if the main meal white rice 4 is used as the sugar solution 26, it is economically suitable for sugarcane and sugar beet raw material. is not. For this reason, the ethanol production means 18 produces ethanol 28 through ethanol fermentation using the sugar solution 26 as a raw material. Thereby, it can be used not only for drinking but also as an additive for gasoline or a raw material for producing lactate. Further, by performing lactic acid fermentation using the sugar solution 26 as a raw material by the lactic acid production means 17, lactic acid 27, which is an organic acid, can be produced. It is also a raw material for polylactic acid, which is one of the sexual materials. Furthermore, methanol 21 can be produced by the starch production conversion by the methanol production means 11. Since both ethanol 28 and methanol 21 are raw materials for esters, they can be used as auxiliary raw materials for BDF in biodiesel production means 19. The lactic acid ester can be produced by the reaction of the produced lactic acid 27 with ethanol 28 or methanol 21 by the lactic acid ester production means 20. In addition, since the white rice 4 is easily spoiled, it is also used as a raw material for the methane gas 22, the direct fuel 23, and the compost 24.

  Further, as a secondary product, methanol 21 and fats and oils 25 can be synthesized to produce BDF methyl 29a. When producing BDF methyl 29a, adjustment of the production process mainly begins with production of methanol 21 from rice straw 1 and rice husk 2, production of fats and oils 25 from nuka 3 or recovery of waste oil 25a. Methanol 21 is prepared in about 3 times the amount of oil 25, and unreacted substances are recovered and reused. After mixing methanol 21 with caustic soda or caustic potassium, the oil and fat 25 is esterified. The oil and fat 25 is preferably a raw material with less free fatty acid from which moisture and impurities are removed. After the reaction, the remaining methanol 21 can be recovered, and glycerin at the bottom can be removed to obtain crude BDF methyl 29a. Thereafter, dealkalization by water washing and dehydration treatment are performed to obtain BDF methyl 29a as a product.

  Furthermore, as a secondary product, ethanol 28 and fats and oils 25 can be synthesized to produce BDF ethyl 29b. When producing BDF ethyl 29b, ethanol 28 produced from white rice 4 is used instead of methanol 21. The manufacturing process is the same as in the case of methanol 21.

  Ethyl lactate 30b can be produced by synthesizing ethanol 28 and lactic acid 27 as a secondary product. In the case of producing ethyl lactate 30b, the production starts with saccharification of white rice 4 and is divided into two parts, followed by a lactic acid fermentation process and an ethanol fermentation process. After purification, ethanol 28 is ester-reacted with about twice the amount of lactic acid 27, and unreacted substances are recovered and reused. Lactic acid esters are separated by distillation and commercialized.

  As a secondary product, methanol 21 and lactic acid 27 can be synthesized to produce methyl lactate 30a. When producing methyl lactate 30a, methanol 21 produced mainly from rice straw 1 and rice husk 2 is used instead of ethanol 28. The manufacturing process is the same as that for ethanol 28.

  Thus, according to the production system and production method for rice grain-derived products of the embodiment of the present invention, each component of rice straw 1, rice hull 2, rice bran 3 and white rice 4 generated from rice grain can be used as biomass without waste. It can be used comprehensively. Moreover, methanol 21, ethanol 28, biodiesel fuel, pellet fuel, etc. can be manufactured from each component of the raw rice grains, and alternative fuels such as gasoline, light oil, and kerosene can be provided. As a result, it is possible to cope with soaring gasoline, light oil, kerosene, etc. due to the recent oil resource depletion problem, and to escape from dependence on petroleum resources.

  In carrying out the production system and production method for rice grain-derived products according to the embodiment of the present invention, the balance between supply and demand of energy such as methanol 21, ethanol 28, and biodiesel fuel, and adjustment of product prices are important points. For this reason, the production planning system and the production planning method for rice-derived products according to the embodiment of the present invention adjust the production by computer analysis based on the market price and the demand while balancing the raw material and the product production amount. Do.

In the rice grain-derived product production planning system and production planning method of the embodiment of the present invention, the following points are considered.
Materials necessary for producing BDF are mainly oil and fat 25 and alcohol. The fats and oils 25 are obtained from oil produced directly from Nuka 3 or from collected used waste oil 25a. If the alcohol is methanol 21, it is obtained from the processing of rice straw 1 and rice husk 2. Moreover, if it is ethanol 28, it will obtain from ethanol fermentation of the white rice 4, but it will adjust so that methanol 21 may be mainly utilized. In the reaction, it is considered that about 20% of methanol 21 that is highly evaporated is added. In consideration of seasonal fluctuations in the amount of raw materials obtained, it will be adjusted so that it can be stored.

  In addition to the adjustment of the manufacturing process, the items to be manufactured are adjusted based on the selling price in the market. For example, in the case of BDF, if the price of light oil competing in the market is 100 yen / Liter or more, if the BDF production price is less than 80 yen / Liter, it can produce profits only for production, but light oil costs 90 yen / liter. In the case of becoming a Liter, it is necessary to make a decision to cancel production or store the manufactured BDF. If it does so, the inconvenience of the production balance that the oil production of Nuka 3 and the rice straw 1 and the methanol 21 of the rice husk 2 will be overproduced will occur. Therefore, in order to avoid such a situation, a function for automatically controlling and judging the manufacturing, sales, storage, and change of the manufactured product is provided.

  For the production of overproduced Nuka 3, it is best to sell it edible if the quality is good, but if it is waste oil 25a for BDF, storage or direct fuel 23 is considered. For example, when the production cost is about 35 yen / liter, the over-produced methanol 21 is sold if the market price is 45 yen / liter or more. Further, the overproduced ethanol 28 also has a function of determining that, for example, when the manufacturing cost is about 50 yen / liter, the market price is 60 yen / liter or more.

  The difficult problem here is the balance between supply and demand balance and profits. For example, if the market price of BDF is 95 yen / Liter and the market price of methanol 21 is 60 yen / Liter, it is more advantageous to sell methanol 21 from the viewpoint of profit efficiency. However, since the methanol 21 is sold, if the fats and oils 25 of Nuka 3 for BDF are stored in an overproduced state, it cannot be said that it is an effective utilization method of raw materials. For this reason, priority is given to manufacturing, and a function of using a product with a large storage amount and selecting and producing a product that increases profit is also considered.

  As a criterion for securing profits against market prices, first, in terms of achieving a quantitative balance in the use of comprehensive raw materials, consideration is given to securing profits by focusing on the production of BDF methyl 29a. Next, the importance of secondary products such as BDF ethyl 29b, ethyl lactate 30b, and methyl lactate 30a is emphasized. However, depending on the market price, it is also considered to provide a special case in the case where it is judged that the profit rate at the market price of lactic acid 27, ethanol 28, and methanol 21 as the primary products is extremely high.

  Production of agricultural products such as rice fluctuates mainly due to climate. As a result, the production and sale of products utilizing such agricultural biomass has become less attractive as a manufacturing industry, with a significant risk due to fluctuations in market prices. As a means for avoiding the case where the production amount of such raw materials is linked to the market price, diversification of the products in each raw material has been devised. Considering a mechanism that avoids the risk of fluctuations in market prices by using this diversification to determine and adjust the operational status of the manufacturing process.

  In actual operation, prioritize product production for each raw material, prioritize product combinations, criteria for securing profits against market prices, raw material storage period, storage fee and storage amount, product storage period Taking into account the need to determine overall judgment criteria, such as storage fees and storage quantities, and the criteria.

Hereinafter, a production planning system and a production planning method for rice grain-derived products according to embodiments of the present invention will be described based on the drawings.
As shown in FIG. 3, a computer that executes the production planning system includes an input means 51 such as a keyboard and a mouse, a storage means 52 that stores various information, a main control unit 53 having a calculation function and a control function. And output means 54 including a monitor or the like.

The input unit 51 is configured to input information stored in the storage unit 52, instructions to the main control unit 53, and the like.
The storage means 52 includes a memory, and includes priority information 55, inventory information 56, seasonal variation information 57, market price information 58, manufacturing cost information 59, profit determination information 60, competitive product information 61, storage index information 62, and configuration information. 63 is stored in advance. The storage unit 52 stores various types of information input in advance by the input unit 51 and stores various types of updated information whenever the various types of information are updated by the input unit 51 as needed.

  As shown in Tables 1 and 2, the priority information 55 indicates the priority of each primary product to be manufactured and the priority of each secondary product. Prioritization of primary products is based on the ranking shown in Table 2, considering the added value. However, the methane gas 22, the direct fuel 23, and the compost 24 are specified and manufactured in the case of extra measures that do not take profits and added values into consideration. The prioritization of secondary products is also given the order shown in Table 1, considering the value added. In addition, if the synthesis and processing are further advanced, biodegradable plastic from lactic acid 27, biodegradable rubber from Nuka 3, biodegradable ceramics, biodegradable lubricant from oil 25, solvent, etc. However, in the embodiment of the present invention, the production is limited to the range of combinations of two substances.

  The inventory information 56 indicates the inventory status of each raw material, each primary product, and each secondary product. As shown in Table 3, the seasonal variation information 57 indicates the seasonal variation of the procurement amount of each raw material. The market price information 58 indicates the market price of each secondary product. The manufacturing cost information 59 indicates the manufacturing cost of each secondary product. As shown in Table 4, the profit determination information 60 indicates the minimum profit required by selling each secondary product. As shown in Table 5, the competitive product information 61 indicates the price of the competitive product of each secondary product.

  As shown in Tables 6 and 7, the storage index information 62 indicates information including the storage form, storage period, and ease of storage of each raw material, each primary product, and each secondary product. As shown in Table 6, regarding the storage form of raw materials, rice straw 1 and rice husk 2 are stored in a silo at room temperature and dried. The powder maintains spontaneous ventilation due to the risk of spontaneous ignition and methane fermentation when wet. Nuka 3 is refrigerated because it is easy to spear. In principle, the white rice 4 is stored at a low temperature as brown rice until just before use. However, there is a balance with the use of Nuka 3 and in the case where the production of the oil 25 is preceded, the white rice 4 may be stored. Regarding the storage period of raw materials, rice straw 1 and rice husk 2 should take into account the harvesting time of rice and set a period of 9 months. Nuka 3 is set to 6 months for refrigeration, brown rice is set to 2 years for cold storage, and white rice 4 is set to 6 months for refrigeration. Assuming that the product is used in the production process before this period is exceeded, if it is impossible, the methane gas 22, the direct fuel 23, and the compost 24 are produced and processed in this order. Nuka 3 and white rice 4 that should be considered for refrigerated storage are set on the premise that they will be used for early production and post-processing in consideration of the high storage costs. As shown in Table 7, the longest storage period is set for each of the primary product and the secondary product, and after that period, the sales procedure is set regardless of the market price index. In summer, fats and oils 25 need to be stored at a low temperature, and sugar solution 26 needs to be refrigerated, so the storage fee is expensive, and methane gas 22 and compost 24 are basically considered for self-consumption and are considered for early sales. Set to

  As shown in Table 8, the configuration information 63 indicates the raw material of each secondary product and the amount of raw material used to produce a predetermined amount of each secondary product. For example, 40% by weight when converting rice straw 1, rice husk 2 and nutka 3 to methanol 21, 10% when removing rice bran 3 from brown rice, 90% when converting white rice 4 to sugar solution 26, 35% when the sugar solution 26 is used as the ethanol 28, 60% when the sugar solution 26 is used as the lactic acid 27, 10% when the oil 25 is made from the Nuka 3 and BDF from the oil 25 and the methanol 21 or the ethanol 28. 60% (oil / fat ratio) can be produced, and when lactic acid 27 ester is produced from lactic acid 27 and methanol 21 or ethanol 28, 80% (lactic acid ratio) can be produced.

  As shown in FIG. 3, the main control unit 53 includes a CPU, and is configured to receive data from the input unit 51 and the storage unit 52, calculate and process the data, and send the data to the output unit 54 and the storage unit 52. The main control unit 53 includes a demand prediction unit 64, a production amount calculation unit 65, a profit determination unit 66, an adjustment instruction unit 67, a production amount adjustment unit 68, a raw material calculation unit 69, an arranged raw material calculation unit 70, and a production amount readjustment unit 71. And required capacity calculation means 72, possible capacity calculation means 73, production amount final adjustment means 74, and production plan creation means 75.

  The demand forecasting means 64 performs demand forecast for each secondary product based on past demand patterns and market trends. The production amount calculation unit 65 calculates the production amount and delivery date of each primary product and each secondary product based on the priority order information 55, the inventory information 56, and the seasonal variation information 57 stored in the storage unit 52. It has become. Based on the market price information 58, the manufacturing cost information 59, the competitive product information 61, and the profit determination information 60 stored in the storage means 52, the profit determination means 66 generates a profit when each secondary product is sold. It is determined whether a loss occurs. When it is determined that the loss is generated by the profit determination unit 66, the adjustment instruction unit 67 changes or stores the production amount of each primary product and each secondary product based on the storage index information 62 stored in the storage unit 52. Or to direct sales. The production amount adjusting unit 68 is difficult to store based on the storage index information 62 stored in the storage unit 52 when the adjustment instruction unit 67 instructs to change the production amount of each primary product and each secondary product. The production of the primary product or the secondary product is changed to the primary product or the secondary product that can be easily stored, and the production amount of each primary product and each secondary product is calculated again.

  The raw material calculation unit 69 is based on the configuration information 63 stored in the storage unit 52 and the production amount and delivery date of each primary product and each secondary product calculated by the production amount calculation unit 65 or the production amount adjustment unit 68. The required amount of each raw material is calculated. The arrangement raw material calculation means 70 calculates the possible arrangement amount of each raw material based on the seasonal variation information 57, the storage index information 62 and the configuration information 63 stored in the storage means 52. The production amount readjustment means 71 stores the storage stored in the storage means 52 when the required amount of each raw material calculated by the raw material calculation means 69 exceeds the available amount of each raw material calculated by the arranged raw material calculation means 70. Based on the index information 62, the production amount and delivery date of each primary product and each secondary product are calculated again.

  The required capacity calculation means 72 is based on the production quantity and delivery date of each primary product and each secondary product calculated by the production quantity calculation means 65, the production quantity adjustment means 68 or the production quantity readjustment means 71. And the required capacity to produce each secondary product. The possible capacity calculation means 73 calculates the capacity that can be used to produce each primary product and each secondary product from factory equipment, personnel, operating conditions, and the like. When the required capacity calculated by the required capacity calculation means 72 exceeds the available capacity calculated by the possible capacity calculation means 73, the production amount final adjustment means 74 adjusts the load of the manufacturing process and copes with the load adjustment. If it is not possible, based on the storage index information 62 stored in the storage means 52, the production amount and delivery date of each primary product and each secondary product are calculated again. The production plan creation means 75 includes a production quantity calculation means 65, a production quantity adjustment means 68, a production quantity readjustment means 71 or a production quantity final adjustment means 74, and the production quantity and delivery date of each primary product and each secondary product. A production plan is created based on this.

  The output unit 54 is configured to display characters, images, and the like on a screen, and to print documents and drawings. The output unit 54 can display various information stored in the storage unit 52 and the production plan created by the production plan creation unit 75.

Next, with reference to FIG. 4 thru | or FIG. 6, the process sequence of the production plan system of the rice grain origin product is demonstrated.
First, priority order information 55, inventory information 56, seasonal variation information 57, market price information 58, manufacturing cost information 59, profit determination information 60, competitive product information 61, storage index information 62, and configuration information 63 are stored in advance. Store in the means 52. Next, demand prediction of the secondary product is performed by the demand prediction means 64 based on past demand patterns and market trends (step 81). The demand forecast is mainly based on consumption of light oil for automobiles and consumption of biodegradable solvents. When the order based on the production amount in the demand forecast is different from the priority order of the secondary products shown in Table 1, the production amount calculation means 65 adjusts the production amount of the primary product so as to match the priority order (step 82).

  The production amount calculation means 65 checks the inventory information 56, and if there is a raw material inventory and a primary product inventory that should be used immediately, production adjustment is performed so as to produce a secondary product using the raw material (step 83). At that time, the item and the production amount are determined so as to match the priority order of the secondary products shown in Table 1, but there are cases where they do not match depending on the raw material or the primary product. In that case, priority is given to the consumption of raw materials or primary products, and no adjustment is made based on the priority order of secondary products. When a primary product that is not used as a secondary product is produced from raw materials, the items and the production amount are determined based on the priority order of the primary products shown in Table 2. In addition, the production amount calculation means 65 checks the inventory information 56, and if there is an expiration date in the secondary product inventory, or if there is an inventory exceeding the expiration date in the target period, sales instruction data is created ( Step 84), and output by the output means 54. Further, the production amount calculation means 65 verifies the raw material that is difficult to obtain seasonally based on the seasonal variation information 57, and adjusts the delivery date and the production amount when it is determined that the raw material is not feasible (step). 85). The raw materials that are likely to be difficult to obtain seasonally are rice straw 1 and rice husk 2, which must be collected and stored in Japan during the harvest period from July to October. Also, at this time, brown rice, which can be said to be a raw material for Nuka 3 and white rice 4, can be said to be on the market in large quantities, but it is desirable to secure inexpensive brown rice for feed and processing that is not edible. In this way, the production amount calculation means 65 calculates the production amount and delivery date for each product of the secondary product and the primary product (step 86).

  The profit determination means 66 uses the value obtained by subtracting the manufacturing cost of the manufacturing cost information 59 from the market price of the market price information 58 as the predicted profit (step 87), and compares it with the profit determination information 60. When it is determined that the predicted profit is larger than the profit determination information 60 and sufficient profit is generated, the planned sales price is compared with the corresponding competitive product price in the competitive product information 61. When the planned sales price is lower than the competitive product price, the raw material calculation unit 69 uses the configuration information 63 and the production amount and delivery date of each primary product and each secondary product calculated by the production amount calculation unit 65. The required amount of each raw material is calculated (step 88).

  When it is determined that the predicted profit is smaller than the profit determination information 60 and the predicted profit is insufficient and a loss occurs, and when the planned sales price is higher than the competitive product price, the storage index information 62 is stored by the adjustment instruction means 67. Based on the above, it is examined whether or not to store as stock, and if so, storage instruction data is created and output by the output means 54 (step 89). If not stored, sales instruction data is created for the secondary product and output by the output means 54 (step 90), and the primary product is instructed to change the production amount to another product. For example, products such as lactic acid 27, methanol 21 and ethanol 28 that are easy to store are stored as stock, and primary products such as sugar solution 26 and oil 25 that are not easily stored are changed to other products and stored. Sales are made for secondary products that are not easy, and sales instruction data is created.

  When the adjustment instruction unit 67 instructs the change of the production amount, the production amount adjustment unit 68 converts the primary product or secondary product that is difficult to store into the primary product or secondary product that is easy to store based on the storage index information 62. The production is changed to the next product, and the production amount of each primary product and each secondary product is calculated again (step 91). The raw material calculation means 69 calculates the required amount of each raw material based on the configuration information 63 and the production amount and delivery date of each primary product and each secondary product calculated by the production amount adjustment means 68 (step 88). ). Based on the seasonal variation information 57, the storage index information 62, and the configuration information 63, the order material calculation means 70 calculates the possible order amount of each material. When the required amount of each raw material exceeds the orderable amount, the production amount readjustment means 71 adjusts the production amount and delivery date of each primary product and each secondary product based on the storage index information 62, and calculates again. (Step 92).

  The required capacity calculation means 72 calculates the required capacity required to produce each primary product and each secondary product based on the production volume and delivery date of each primary product and each secondary product calculated so far. To do. Further, the available capacity calculating means 73 calculates the capacity available for producing each primary product and each secondary product from the factory equipment, personnel, operation status, and the like (step 93). When the required capacity exceeds the available capacity, the production volume final adjustment means 74 adjusts the load of the manufacturing process, and when the load adjustment cannot cope, each primary product and each secondary product are determined based on the storage index information 62. The production amount and delivery date of the next product are adjusted and calculated again (step 94). A production plan is created by the production plan creation means 75 based on the production amount and delivery date of each primary product and each secondary product calculated so far (step 95), and output by the output means 54. Further, the production process can be scheduled from the production plan information (step 96), a sales plan can be made (step 97), and output by the output means 54.

  In terms of comprehensive utilization of raw materials, there is no change in prioritization in product manufacturing. However, the factory is managed by adjusting the balance regarding the production volume for each product. The market price information 58, the competitive product information 61, and the inventory information 56 indicating the storage amount of raw materials and products are entered and changed in a timely manner by artificially judging the availability of raw materials and market fluctuations.

  The production planning system and the production planning method for rice grain-derived products according to the embodiment of the present invention use the seasonal variation information 57, and each primary product and each secondary corresponding to seasonal variation and climate variation of the procurement amount of each raw material. A product production plan can be created. Further, by using the market price information 58, the manufacturing cost information 59, and the competitive product information 61, it is possible to prevent the occurrence of loss and improve the economic efficiency. Since the necessary amount of each raw material and the amount that can be arranged are calculated, it is possible to prevent the shortage of each raw material. Thus, it is possible to comprehensively utilize each component of rice straw 1, rice husk 2, rice bran 3 and white rice 4 generated from rice grains as biomass, and to create an efficient and economical production plan it can.

  According to the production system and production method for rice grain-derived products of the embodiment of the present invention, all the components of rice grains can be effectively recycled without waste, and many of the manufactured products that have been dependent on petroleum resources so far Can be produced as a biomass component-use manufactured product. In addition, according to the production planning system and production planning method for rice grain-derived products according to the embodiment of the present invention, the conventional single production process flow is held in a composite manner, and these are organically used as biomass resource production processes. Can be used as a comprehensive biomass utilization system in a single factory.

It is a flowchart which shows the relationship between a raw material and a product of the production system and production method of the rice grain origin product of embodiment of this invention. It is process drawing which shows the manufacturing process of the production system and production method of the rice grain origin product shown in FIG. It is a block diagram which shows the structure of the production plan system of the rice grain origin product of embodiment of this invention. It is a flowchart which shows the process sequence of the production plan system of the rice grain origin product shown in FIG. It is a flowchart which shows the process sequence following the FIG. 4 of the production plan system of the rice grain origin product shown in FIG. It is a flowchart which shows the process sequence following the FIG. 5 of the production plan system of the rice grain origin product shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Rice straw 2 Rice husk 3 Nuka 4 White rice 11 Methanol production means 12 Methane gas production means 13 Fuel production means 14 Compost production means 15 Oil and fat production means 16 Sugar solution production means 17 Lactic acid production means 18 Ethanol production means 19 Biodiesel production means 20 Lactic acid Ester production means 21 Methanol 22 Methane gas 23 Direct fuel 24 Compost 25 Oils and fats 26 Sugar liquid 27 Lactic acid 28 Ethanol 29a BDF methyl 29b BDF ethyl 30a Methyl lactate 30b Ethyl lactate 51 Input means 52 Storage means 53 Main control section 54 Output means 55 Priority information 56 Stock Information 57 Seasonal Change Information 58 Market Price Information 59 Manufacturing Cost Information 60 Profit Judgment Information 61 Competitive Product Information 62 Storage Index Information 63 Composition Information 64 Demand Prediction Means 65 Production Volume Calculation Means 66 Profit Judgment Stage 67 adjustment instruction means 68 production amount adjusting means 69 feed calculating means 70 arrange raw calculating means 71 production readjustment means 72 required capacity calculation unit 73 can capacity calculating means 74 Production final adjustment means 75 production plan creation means

Claims (8)

A production system for rice-derived products using rice straw, rice husk, nuka and white rice generated from rice grains,
Methanol production means for producing methanol from at least one of the rice straw, the rice husk, the nutka and the white rice;
Ethanol production means for producing ethanol from the white rice,
Lactic acid production means for producing lactic acid from the white rice,
An oil and fat production means for producing oil and fat from the Nuka;
BDF methyl production means for producing biodiesel fuel by synthesizing the methanol produced by the methanol production means and the fat produced by the fat production means;
BDF ethyl production means for producing biodiesel fuel by synthesizing ethanol produced by the ethanol production means and fats and oils produced by the fat production means;
Methyl lactate production means for producing methyl lactate by synthesizing methanol produced by the methanol production means and lactic acid produced by the lactic acid production means,
Ethyl lactate production means for producing ethyl lactate by synthesizing ethanol produced by the ethanol production means and lactic acid produced by the lactic acid production means,
A system for producing rice-derived products, characterized by comprising: Methane gas production means for producing methane gas from at least one of the rice straw, the rice husk, the rice bran, and the white rice;
Fuel production means for producing fuel from at least one of the rice straw, the rice husk, the rice bran, and the white rice;
Compost producing means for producing compost from at least one of the rice straw, the rice husk, the rice bran, and the white rice;
A sugar solution producing means for producing a sugar solution from the white rice;
The production system of the rice grain origin product of Claim 1 characterized by the above-mentioned. A method for producing a rice-derived product using rice straw, rice husk, nuka and white rice generated from rice grain,
A methanol production process for producing methanol from at least one of the rice straw, the rice husk, the rice bran, and the white rice;
An ethanol production process for producing ethanol from the white rice;
Lactic acid production process for producing lactic acid from the white rice,
An oil and fat production process for producing oil and fat from the Nuka;
BDF methyl production process for producing biodiesel fuel by synthesizing methanol produced in the methanol production process and oil produced in the oil production process;
BDF ethyl production process for producing biodiesel fuel by synthesizing ethanol produced in the ethanol production process and oil produced in the oil production process;
Synthesizing methanol produced in the methanol production process and lactic acid produced in the lactic acid production process to produce methyl lactate,
Synthesizing ethanol produced in the ethanol production process and lactic acid produced in the lactic acid production process to produce ethyl lactate,
A method for producing a rice grain-derived product, comprising: A methane gas production process for producing methane gas from at least one of the rice straw, the rice husk, the rice bran, and the white rice;
A fuel production process for producing fuel from at least one of the rice straw, the rice husk, the rice bran, and the white rice;
A compost production process for producing compost from at least one of the rice straw, the rice husk, the rice bran, and the white rice;
A sugar solution production process for producing a sugar solution from the white rice;
The method for producing a rice grain-derived product according to claim 3, comprising: Made from rice straw, rice husk, rice bran, and white rice generated from rice grains, the primary product of methanol, methane gas, fuel, compost, sugar solution, lactic acid and methane gas produced from the raw material, and the primary product A production planning system for rice-derived products for producing production and sales plans for biodiesel fuel, ethyl lactate and methyl lactate secondary products,
Priority information indicating the priority order of each primary product to be manufactured and the priority order of each secondary product, inventory information indicating the stock status of each raw material, each primary product and each secondary product, and seasonal fluctuations in the procurement amount of each raw material Seasonal variation information, market price information indicating the market price of each secondary product, manufacturing cost information indicating the manufacturing cost of each secondary product, competitive product information indicating the price of a competitive product of each secondary product, and each raw material Storage means for storing in advance storage index information including storage forms, storage periods, storage easiness of each primary product and each secondary product;
Production amount calculating means for calculating the production amount and delivery date of each primary product and each secondary product based on the priority order information, the inventory information and the seasonal variation information stored in the storage means;
Profit determination means for determining whether a profit is generated or a loss is generated when each secondary product is sold based on the market price information, the manufacturing cost information, and the competitive product information stored in the storage means When,
Adjustment instructing to change, store or sell the production amount of each primary product and each secondary product based on the storage index information stored in the storage unit when it is determined that a loss occurs in the profit determination unit Indicating means;
When the adjustment instruction means instructs to change the production amount of each primary product and each secondary product, based on the storage index information stored in the storage means, the primary product or the secondary product that is difficult to store is selected. A production volume adjusting means for changing production to a primary product or secondary product that is easy to store, and recalculating the production volume of each primary product and each secondary product;
Production plan creation means for creating a production plan based on the production amount and delivery date of each primary product and each secondary product calculated by the production amount calculation means or the production amount adjustment means,
A production planning system for rice-derived products, comprising: Raw material calculation means for calculating the required amount of each raw material based on the production amount and delivery date of each primary product and each secondary product calculated by the production amount calculation means or the production amount adjustment means,
Arranged raw material calculating means for calculating the available amount of each raw material based on the seasonal variation information and the storage index information stored in the storage means;
When the necessary amount of each raw material calculated by the raw material calculating means exceeds the orderable amount of each raw material calculated by the arranged raw material calculating means, each primary is based on the storage index information stored in the storage means. Production amount readjustment means for recalculating the production amount and delivery date of the product and each secondary product,
The production plan creation means generates a production plan based on the production amount and delivery date of each primary product and each secondary product calculated by the production quantity calculation means, the production quantity adjustment means or the production quantity readjustment means. To create
The production planning system for a rice grain-derived product according to claim 5, characterized in that: Made from rice straw, rice husk, rice bran, and white rice generated from rice grains, the primary product of methanol, methane gas, fuel, compost, sugar solution, lactic acid and methane gas produced from the raw material, and the primary product A production planning method for rice-derived products to create production and sales plans for biodiesel fuel, ethyl lactate and methyl lactate secondary products,
Priority information indicating the priority order of each primary product to be manufactured and the priority order of each secondary product, inventory information indicating the stock status of each raw material, each primary product and each secondary product, and seasonal fluctuations in the procurement amount of each raw material Seasonal variation information, market price information indicating the market price of each secondary product, manufacturing cost information indicating the manufacturing cost of each secondary product, competitive product information indicating the price of a competitive product of each secondary product, and each raw material A storage step of storing in advance storage index information including storage forms, storage periods, storage easiness of each primary product and each secondary product;
A production amount calculating step for calculating a production amount and a delivery date of each primary product and each secondary product based on the priority order information, the inventory information and the seasonal variation information stored in the storing step;
Profit determination step for determining whether a profit is generated or a loss is generated when each secondary product is sold based on the market price information, the manufacturing cost information, and the competitive product information stored in the storage step. When,
Adjustment instructing change, storage or sale of the production amount of each primary product and each secondary product based on the storage index information stored in the storage step when it is determined that loss occurs in the profit determination step An instruction step;
When it is instructed to change the production amount of each primary product and each secondary product in the adjustment instruction step, a primary product or a secondary product that is difficult to store is selected based on the storage index information stored in the storage step. A production adjustment step that changes production to an easy-to-store primary or secondary product and recalculates the production of each primary and secondary product,
A production plan creation step for creating a production plan based on the production amount and delivery date of each primary product and each secondary product calculated in the production amount calculation step or the production amount adjustment step,
A method for producing a rice grain-derived product, comprising: A raw material calculation step for calculating a required amount of each raw material based on the production amount and delivery date of each primary product and each secondary product calculated in the production amount calculation step or the production amount adjustment step;
Based on the seasonal variation information stored in the storage step and the storage index information, an arrangement raw material calculation step for calculating an arrangement possible amount of each raw material,
When the required amount of each raw material calculated in the raw material calculation step exceeds the orderable amount of each raw material calculated in the arranged raw material calculation step, each primary is based on the storage index information stored in the storage step. A production volume readjustment step for recalculating the production volume and delivery date of the product and each secondary product,
In the production plan creation step, the production plan is determined based on the production amount and delivery date of each primary product and each secondary product calculated in the production amount calculation step, the production amount adjustment step or the production amount readjustment step. To create
The production plan method of the rice grain origin product of Claim 7 characterized by the above-mentioned.

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