RU2307155C2 - Processing line for producing of protein-vitamin feed product from distiller's spent grains - Google Patents

Abstract

FIELD: processing of distiller's spent grains into protein-vitamin feed product.

SUBSTANCE: processing line has main pipelines for feeding of distiller's spent grains and discharge of solid and liquid process products, vacuum pipeline, intermediate reservoir, dehydrator, ventilation chamber, cyclone, drier, evaporator, atmospheric condenser, intermediate reservoir for liquid processing products, apparatus for concentration of suspended filtrate particles, mixer, granulator, ready product collector, and packaging apparatus. Fan and air heater are positioned in front of drier for producing of hot air with different temperature of drying agent. Apparatus for concentration of suspended filtrate particles is formed as osmosis unit having semi-impermeable membranes with pore diameter of (20-30)·10^-10 m. Drier has casing made in the form of hyperboloid of rotation and is equipped with reflector located in its upper part and feeder and acceleration portion which are located in its lower part, said acceleration portion being designed for producing of gas suspension therein. Drier central pipe adapted for discharge of dried spent grains particles has flare portion and is designed so that its height may be adjusted.

EFFECT: simplified construction, favorable conditions for running of heat- and mass- exchanging processes between gaseous phase and material under process and, as a consequence, improved quality of ready product.

Description

The invention relates to a technology for processing post-alcohol grain stillage, which is a waste of alcohol production, and can be used to obtain protein feed.

Barda is a valuable protein and vitamin-containing feed for farm animals, poultry and can be used in the production of pet food (dogs, cats, etc.). It contributes to the breakdown of cellulose more actively than molasses, grain, bran and other plant products.

Known methods of processing and use of distillery waste for feeding animals [Secondary material resources of the food industry (Education and use). - M .: Economics, 1984, - p.135-137].

The traditional and easiest way to use bards is to feed the animals in their native form due to quick acidification and it has become difficult and economically unprofitable when stored and transported in this form over a distance of more than 20-30 km.

Distilleries constantly have difficulties with the sale of natural stillage in close proximity to the plant. In addition, during its transportation, nutrient losses are noted and conditions are created for environmental pollution, and during the 5-6 spring-summer months the bard does not find any demand.

The most rational method of disposal of post-alcohol grain stillage, in which it turns into a product with high nutritional value (the feed value of dry stillage is increased by 10 times compared to the native), which is transportable and lasts for several years, is drying.

When developing a bard processing line, the following should be considered:

- being the final stage of many industries, drying largely determines the energy and material consumption of the production, the quality of the finished product, the level of environmental pollution, so it is important to choose the optimal type of dryer;

- the maximum possible removal of moisture (concentration, dehydration) should be provided using low energy-intensive processes;

- it is necessary to use the components of the stillage more fully

- the line must take into account the treatment of production waste.

However, during drying of the stillage, clumping, inhomogeneity of drying, and adhesion of particles to the walls of the dryer are observed, and since the stillage is not uniform in composition, it is necessary to use a type of drying in which each particle of the stillage would receive the necessary amount of energy for the phase transformation of the moisture contained in it without formation large particle compounds.

A known standard scheme for producing dry vinasse is obtained, in which the initial vinasse is subjected to mechanical separation by filtration into a coarse-dispersed phase (pellet) and a coarse filtrate containing suspended particles, for which it is subjected to sedimentation in a sedimentation tank [M. Food industry waste and its use. - M .: - Pishchepromizdat, 1963, p. 200-202]. The settled filtrate is evaporated in traditional multi-unit plants and dried to a final moisture content of 10% on a steam roller dryer, and the pellet is brought to a dry state either independently or mixed with one stripped off concentrate on a drum dryer.

Analysis of the drying process in this scheme shows that for its implementation a large amount of steam is necessary, which causes a significant fuel consumption.

Evaporation of the stillage filtrate is complicated by the fact that it contains protein compounds and when humidity is above 75%, the particles adhere strongly to the steam pipes, and further drying becomes difficult [Fuks A.A. Technology of alcohol production. - M .: Pishchepromizdat, 1951, p. 483]. In addition, most of the bard's soluble substances, such as sugars, proteins, are easily destroyed at elevated temperatures.

The disadvantages of this scheme for the production of dry stillage are obvious:

- the use of obsolete drying apparatus, which, with high energy consumption for drying, does not provide the required performance and quality of the finished product;

- low productivity due to the use of sedimentation tanks;

- due to the viscosity of the evaporated filtrate, evaporation requires frequent mechanical cleaning;

- the complexity and intensity of production, which leads to high operating costs.

A known method of drying a suspension of post-alcohol stillage vinasse to obtain a feed product, including anaerobic fermentation by sequentially affecting the vinasse components of a complex of enzymes and acid-forming bacteria to obtain a culture fluid and a protein feed residue [RF Patent No. 2128688, IPC ⁷ C12F 3/10, publ. 04/10/99].

Significant disadvantages of the proposed method are:

- high cost of implementation due to the complexity of the process;

- low productivity due to the length of the process;

- explosion hazard;

- the use of complex, energy-intensive drying equipment.

The closest in technical essence and the achieved effect is the production line for the production of protein-vitamin product [RF Patent No. 22217490, IPC Cl ⁷ . C12F 3/00, 3/10, publ. November 27, 2003], including lines for the supply of post-alcohol stillage and the removal of solid and liquid products of its processing, and interconnected means of interoperational transfer of an intermediate tank, a dewatering device made in the form of a vacuum filter with a converging web and a continuous tissue regeneration system, a supply device - removal of hot dry air, made with the possibility of interaction of air with solid products, a ventilation chamber and at least one cyclone, a dryer, an evaporator and a baro a metric condenser with a water supply line, while the evaporator and barometric condenser are located on the vacuum line between the vacuum filter and its vacuum pump, the line for removing liquid processed products is connected to the evaporator and is designed as a shutter, which includes an intermediate tank for liquid processed products, a device for concentrate the filtrate - a separator located at the outlet of the line for removal of liquid processed products, a mixer located in front of the granulator and knitted cage, granulator, a collection of finished products and packaging device.

To date, this line of production of protein-vitamin product is one of the few that allows you to get the most high-quality and natural finished product with a relatively low capital and operating costs. However, it also has disadvantages:

- the rotary-drum dryer is used in the line, and since the bard is in its composition highly moist and polydisperse materials, when drying the bard, aggregation, clumping, sticking of particles to the walls of the drying chamber are observed in it, and as a result, inhomogeneity of drying and possibly charring of some particles product

- high energy intensity of the process due to the use of preliminary drying of grains in front of the dryer and a large number of fans;

- a high degree of entrainment of product particles, and as a result, the use of additional cyclones in the line;

- inefficient use of a separator for concentrating the filtrate;

- the line does not provide for a more complete use of the components of the post-alcohol distillery stillage and does not provide for the treatment of liquid waste, since the further purpose of the separated filtrate is not indicated.

The technical task of the invention is to develop a technological line for the production of protein and vitamin feed from post-alcohol stillage, using a high-intensity drying device, simplifying the design of the drying device (lack of rotating elements), reducing energy costs, creating favorable conditions for carrying out heat and mass transfer between gas phase and the processed material, improving the quality of the finished product and ensuring a non-slip mode of operation.

The task is achieved by the fact that in the proposed production line for the production of protein and vitamin fodder product from post-alcohol grain stillage, including lines for supplying post-alcohol distillery stillage, removal of solid and liquid products of its processing and supply of vacuum, interconnected by means of interoperational transfer, intermediate capacity, device for dehydration, made in the form of a vacuum filter with a converging cloth and a continuous tissue regeneration system, ventilation chamber, cyclone, sushi ku, evaporator and barometric condenser located on the vacuum supply line between the vacuum filter and the vacuum pump, an intermediate tank for liquid processed products, a device for concentrating suspended filtrate particles, located on the pipe for liquid processed products, a mixer, a granulator, a collection of finished products and a device for packaging, it is new that a fan and air heater are installed in front of the dryer, providing dry hot air with different temperatures ture, for concentrating suspended particles filtrate apparatus is a reverse osmosis installation with semipermeable membranes with a pore diameter (20 ... 3.0) x 10 ^-10 m, the dryer housing has the shape of a hyperboloid of revolution is provided at the top of the reflector, and the lower part - a feeder and a booster section for receiving gas suspension, and the central tube of the dryer, designed to output the dried particles of the grains, has a bell and made with the possibility of changing its height.

The technical result consists in increasing the productivity of the line, increasing its reliability, in intensifying the process of heat and mass transfer, saving metal and energy production, recycling and purification of waste alcohol production (distilleries) and improving the quality of protein and vitamin feed product.

Figure 1 schematically shows a General view of the production line of protein-vitamin feed product from post-alcohol grain stillage;

figure 2 - vortex dryer in longitudinal section.

The technological line for the production of protein-vitamin fodder product from post-alcohol grain stillage consists of lines for supplying post-alcohol stillage and removal of solid and liquid products of its processing (Fig. 1), interconnected by means of interoperational transfer (various conveyors, pipelines, etc. in the form of lines ending with arrows), an intermediate tank 1, a dehydration device 2, made in the form of a vacuum filter with a converging cloth and a continuous tissue regeneration system, in Fan 3 and air heater 4, designed to produce dry hot air with different temperatures of the drying agent, a vortex dryer 5, a mixer 6, a cyclone 7, a granulator 9, a ventilation chamber 10 with a fan 8, a collection of finished products 11, a packaging device 12.

The production line is also equipped with an evaporator 13, a vacuum pump 14 and a barometric condenser 15, an intermediate tank 16 for liquid processed products, a device for concentrating the filtrate 17.

As a device for concentrating suspended particles of the filtrate 17, a reverse osmosis unit with semi-impermeable membranes with a pore diameter of (20 ... 30) · 10 ^-10 m is used.

Drying of grains of barda to improve the quality and digestibility of constituent substances must be carried out at a temperature of 50 ... 60 ° C, since at a higher level proteins are converted into an indigestible form, the grains are darkened due to the reaction of melanoidin formation and caramelization, and the destruction of some vitamins.

Lumps formed during the drying of bards can be disaggregated both by mechanical action (various agitators, oscillating devices, etc.) and by the creation of various active hydrodynamic regimes in drying devices.

The use of a vortex dryer with swirling flows of coolant and grains of vinasse allows to intensify heat and mass transfer during the drying process. When particles of a grain move in a vortex dryer, they continuously interact with each other and with the wall of the dryer, which leads to an increase in the relative velocity of the interacting phases, to a decrease in the residence time of the material in the apparatus, and an increase in the concentration of the solid phase. When the dryer 5 is operating, an active hydrodynamic regime is created in it.

The technological line works as follows.

The post-alcohol grain stillage from the distillation apparatus (not shown conditionally) through the supply line of the after-alcohol grain stillage comes to the intermediate tank 1 (Fig. 1), where it is accumulated in the required volume for the uninterrupted operation of the BOP type vacuum filter 2 with a converging web and a continuous tissue regeneration system.

After the vacuum filter 2, the post-alcohol distillation stillage is divided into two streams, one of which includes a solid product (grains), and the other liquid (filtrate). The shot looks like a loose mass with a moisture content of 40% to 60%. The filtrate includes 2 ... 4% of solids, some of which are in suspension, and some are dissolved.

The operation of the filter 2 provides a vacuum pump 14. To obtain a deeper vacuum, an evaporator 13 and a barometric condenser 15 are used.

From the canvas of the vacuum filter 2, the pellet is fed into the dryer 5 by means of an interoperational transmission (this is usually a screw conveyor).

The dryer operates as follows.

The wet pellet through the loading pipe 18 (Fig. 2) enters the zone of the booster section 19. At the same time, the drying agent is supplied from the heater 4 through the pipe 20. The solid phase is distributed in the booster section in the flow of the drying agent. The drying agent (air) is pumped by the fan 3 into the air heater 4, the installation of which ensures the production of dry hot air of various required temperatures (the temperature of the coolant can be changed depending on the humidity of the initial product). In heater 4, the air is heated to a predetermined temperature and is divided into two streams. The main stream enters the accelerator section of the dryer 19, and a small portion of dry hot air is supplied to the ventilation chamber 10. The gas suspension formed in the acceleration section enters the vortex chamber 21, where the drying process is intensive and where the air stream moving in a spiral interacting with solid particles phase, makes them move along closed paths. As they dry, the particles rise upward by the flow of a drying agent, the speed of which increases due to a smooth decrease in the flow cross section due to the configuration of the housing 22 of the dryer 5, made in the form of a hyperboloid of rotation, and the bell 23 of the central pipe 24. An increase in the relative velocity of the gas and grain moves to intensify the drying process , while the centrifugal force acting on the particles and lumps of the grains increases, and hence the friction force between the particles and the walls of the dryer increases oh chamber, which leads to abrasion of particles and lumps of grains with a continuous update of their surface.

With further movement of the drying agent through the housing 22, its speed decreases due to an increase in the bore due to the configuration of the housing. The speed of the particles also decreases, and under the influence of gravity, the dried particles of the grains fall into the socket 23 of the Central pipe 24 and are discharged from the drying chamber, and the spent drying agent through the reflector 25 is discharged through the pipe 26.

By changing the height of the Central pipe 24, which is carried out by the regulating device 27, regulation of the residence time of the grains in the drying chamber is achieved.

The presence of a fan and a heater in front of the dryer allows you to control the temperature of the coolant, and the presence of the feeder 18 and the booster section 19 to obtain a gas suspension.

Thus, a dryer with an active hydrodynamic regime ensures the intensity of the drying process, the regulation of the residence time of the grains in the drying chamber, and therefore, the production of high-quality dry grains.

After dryer 5, the pellet has a moisture content of 15 ... 20% and can be granulated in device 9. From the granulator 9, the product enters the ventilation chamber 10, where it is blown with hot dry air coming from the air heater 4, brought to a moisture content of 6 ... 10%, after which it enters the collection of 11 finished products, is packed on the device 12, for example, in bags or poured in bulk in a lockable container and transported to a warehouse or consumer. The protein content in the finished product can reach 45%.

A certain amount of solids (up to 2.5%) remains in the filtrate. In the past, this product was routed along the main line, as a rule, to a sump and only partially to boilers (not shown conditionally), replacing about 75% of the water added to the grain, or (as in the prototype) by separation. However, the separator does not provide the most complete concentration of suspended and dissolved particles in the filtrate, as a result of which a large amount of biologically active substances remains in the separated liquid, therefore this liquid requires further energy-intensive cleaning.

For this reason, the production line is equipped with a device for concentrating suspended filtrate particles — a reverse osmosis unit 17 with semi-impermeable membranes with a pore diameter of (20 ... 30) · 10 ^-10 m, which has high specific productivity, and most importantly, the possibility of concentrating hot filtrate bards without preliminary cooling at a temperature of 100 ° C and above. At the same time, the productivity of the membrane installation sharply increases with a decrease in energy consumption. As a result of this, two fractions are obtained: a concentrate with a solids content of up to 2.5% and permeate. Permeate can either completely return to the stage of preparing a batch for production, or be discharged into the sewer. The concentrate can be used as a standalone product with a protein content of up to 56% or it can be transferred to the technological process - mixer 6, where after mixing with a pellet the latter is enriched with protein to its content, for example, 44% and higher. In this case, the granulator receives a wetter starting product. Product granules become denser and heavier.

To increase the product yield and purify exhaust air from devices 5 and 10, the latter passes through a cyclone-type air purifier - cyclone 7, in which solid particles of protein-vitamin product are separated, which subsequently enter granulator 9. Almost pure air is released into the atmosphere.

Thus, the proposed production line for the production of protein-vitamin fodder product from post-alcohol grain stillage has the following advantages:

- the line uses the original drying method in active hydrodynamic mode, which ensures 100% contact of the heat carrier and the product to be dried, which allows to intensify the process, to achieve the required productivity and drying quality;

- the use of a fan and air heater provides dry hot air of the required temperature, preventing the darkening of the grains due to the reaction of melanoidin formation and caramelization, the destruction of vitamins in it;

- the execution of the housing of the dryer in the form of a hyperboloid of rotation allows you to improve the quality of the dried grains of stillage by ensuring the necessary length of time the particles of material in suspension;

- the presence of the feeder and the acceleration section in the dryer allows you to get a gas suspension immediately before entering the drying chamber, without requiring additional complex devices;

- the residence time of the product in the dryer is easily controlled by changing the height of the Central pipe;

- allows you to get protein-vitamin feed product, characterized by high quality;

- since a reverse osmosis membrane system is used in the line for concentrating suspended particles of the filtrate, which makes it possible to more fully use the components of the post-alcohol stillage stillage, cyclone and vortex dryer, the production of protein-vitamin feed product implemented by the proposed production line is waste-free, allowing minimizing harm, applied to the natural environment.

The above advantages of the invention allow us to conclude that the technology implemented by the technological line is the most promising, utilizing waste from alcohol production - post-alcohol grain distillery grains.

Claims (1)

A technological line for the production of protein and vitamin fodder product from post-alcohol grain stillage, including lines for supplying post-alcohol distillery stillage, removal of solid and liquid products of its processing and vacuum supply, interconnected by means of interoperational transfer, an intermediate tank, and a dewatering device made in the form of a vacuum filter with a converging web and a continuous tissue regeneration system, a ventilation chamber, a cyclone, a dryer, an evaporator and a barometric condenser, located data on the vacuum supply line between the vacuum filter and the vacuum pump, an intermediate container for liquid processed products, a device for concentrating suspended particles of the filtrate, located on the pipe for removing liquid processed products, a mixer, a granulator, a collection of finished products and a packaging device, characterized in that before the dryer, a fan and air heater are installed, providing dry hot air with various temperatures, a device for concentrated suspended parts its filtrate is a reverse osmosis unit with semi-impermeable membranes with a pore diameter of (20 ... 30) · 10 ^-10 m, while the dryer body is in the form of a hyperboloid of rotation, equipped with a reflector in the upper part, and a feeder and an acceleration section in the lower part for receiving gas suspension, and the Central tube of the dryer, designed to output the dried particles of the grains, has a bell and made with the possibility of changing its height.

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