RU2471558C2 - Method of automatic control over hydrothermal oats grain treatment in production of oat flour - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: treatment is performed in two steps, drying and frying. Drying is performed by air while frying is performed by superheated steam. Superheated steam is produced by steam generator equipped with electric heaters, pressure safety valve, level pickup and system of controlled valves. Barometric pressure steam is superheated in electric heater with several circuits of TEHs. Water for grain damping in forced into frying apparatus by pump from condensate collection tank. Used steam is discharged from frying apparatus by blower into steam air heater or, partially, to steam superheater. Downstream of steam air heater steam is fed into steam jackets. Formed condensate of heating steam is bypassed in condensate collector after the entire cycle while, in closed circuit conditions, it is fed into steam generator. Water heated in first steam air heater is fed into dryer. Therefrom, damp air is bypassed in heat pump plant with system of valves for it to be dried. Note here that portion of air is discharged from or fed in ambient air and, then, forced by blower via steam air heater into drier to make closed cycle. Grain is fed into steeper for time interval depending upon inlet temperature and moisture content. Wetted grain is fed into malleablising apparatus for time interval depending upon inlet temperature and pressure to be dried to moisture content of 14-12% and to be heated to 95°C. Therefrom, grain is fed into frying apparatus to fried to moisture content of 4-5% with intermittent wetting and heated to temperature of 75°C controlled in apparatus and at its outlet.

EFFECT: invention allows increasing the quality of finishedtproducts.

1 dwg

Description

The invention relates to the automation of technological processes and can be used to automate the process of hydrothermal processing of oat grain in the production of oat flour.

The closest in technical essence and the achieved effect is the method of production of oatmeal and the technological line for its implementation [RF Patent No. 2229102, IPC V02V 5/02. Method for the production of oat and technological line for its implementation / S.V. Kutsov, S.A. Shevtsov, E.A. Ostrikova. No. 2007106339/13; claimed 02/19/2007; published on July 20, 2008. Bulletin No. 20], which provides that the heat treatment of grain is carried out in two stages - drying and roasting, drying is carried out with air, and roasting is performed with superheated steam, the steam obtained in the steam generator and superheated in the superheater is fed to the fryer, and the spent superheated steam first, they are sent to a steam heater to heat the air supplied to the dryer, and then to the steam shirts of the sowing apparatus and the lock tub, while the vapor of moisture evaporated from the product and the condensate are removed from the steam shirts a first container for collecting condensate, and then to the steam generator power, followed by being fed into the fryer to form a closed cycle, part of the condensate is used for the intermediate moisture product into the roasting chamber; non-condensable gases formed are removed from the superheated steam recirculation loop; the air heated in the steam heater by the exhaust steam is supplied to the dryer, the exhaust air from the drying chamber is sent to a heat pump unit for drying, and then the fan is pumped into the dryer through the steam heater to form a closed cycle.

However, the known method has the following disadvantages:

- operational control of technological parameters is not provided at the stages of the hydrothermal treatment process (including feeding grain into the locker, soaking, languishing, drying and roasting) according to information received directly from the control object under conditions of random disturbances both from the side of changing the initial properties of the raw materials and from possible technological equipment failures, which in turn does not allow to obtain a finished product of high quality;

- rational modes of equipment operation are not established depending on the loads applied to it;

- the accuracy and reliability of control are not ensured due to the imposed bilateral restrictions on the controlled parameters and, as a result, conditions are not created for increasing the yield of the finished product and saving heat and energy costs.

An object of the invention is to improve the quality of finished products, energy efficiency, environmental safety, accuracy and reliability of controlling the process of cooking oatmeal, reducing specific heat and energy costs by improving the automatic control scheme and more precisely regulating the technological parameters of the process of hydrothermal processing of oat grain.

The stated technical problem is achieved in that in a method for automatically controlling the process of hydrothermal processing of oat grain in the production of oat flour, which provides that the heat treatment of grain is carried out in two stages - drying and frying, drying is carried out with air, and frying is carried out with superheated steam, and the steam obtained in the steam generator and superheated in the superheater are fed into the fryer, and the spent superheated steam is first sent to the steam heater to heat the air supplied to the su ilk, and then into the steam shirts of the languishing apparatus and the lock tub, while the vapors of moisture evaporated from the product and the condensate from the steam shirts are taken first to a condensate collecting tank, and then to power the steam generator, followed by feeding into the fryer with the formation of a closed cycle, part condensate is used for intermediate moistening of the product in the frying chamber; non-condensable gases formed are removed from the superheated steam recirculation loop; the air heated in the steam heater by the exhaust steam is fed to the dryer, the exhaust air from the drying chamber is sent to a heat pump installation for drying and then the fan is pumped into the dryer through the steam heater to form a closed cycle, it is new that all stages of the hydrothermal processing process of oat grain during the production of oatmeal, they are controlled and regulated by sensors and automatic control devices, so saturated steam is obtained in a steam generator equipped with electric heating elements E, the pressure relief valve, level sensor and a system of adjustable taps; superheating of atmospheric pressure steam is carried out in an electric superheater with several circuits of heaters operating depending on the temperature of the steam entering the fryer, superheated steam is supplied to the fryer by a fan, with a pressure regulated depending on the humidity and temperature of the supplied grain during loading and the operation stage apparatus (loading, roasting, humidification, unloading), water for moistening the grain into the fryer is pumped from the tank for collecting condensate with pressure regulation in the plant depending on the stage of operation of the apparatus, the temperature and humidity of the grain fed to the roasting device, the exhaust steam from the fryer is removed by a fan to a steam air heater to heat the air or partially to the superheater depending on the temperature of the air supplied to the dryer, after the air heater, steam is supplied to the steam locker shirts and Depending on the grain temperature at the outlet of the apparatus, the formed condensate of the heating steam in a closed loop mode is supplied to the steam generator, providing a level of dkosti, not allowing TENam overheat; air heated in a steam heater is supplied to the dryer with a pressure regulated depending on the temperature and humidity of the grain supplied to the dryer, moist air is taken from the dryer to a heat pump unit with a system of valves and valves for drying, and part of the air is removed or introduced from the surrounding media depending on the air flow rate at the inlet to the dryer, and then pumped into the dryer through the steam heater with a fan to form a closed cycle; the grain is fed to the locker, for a period depending on the temperature and humidity at the inlet, the soaked grain is fed to the somber, for the period depending on the temperature and humidity at the entrance to the apparatus, the grain is dried in the dryer with air to a humidity of 14 ... 12% and heated not higher than 95 ° C, controlled in the dryer and at the entrance to the fryer, grain is fed from the dryer to the fryer, where it is fried to a moisture content of 4 ... 5% with periodic humidification and heated to not higher than 75 ° C, controlled in the apparatus and on leaving the fryer a.

The technical result consists in improving the taste of the finished product due to the activation of odorizing substances, the continuous withdrawal of non-condensed gases formed from the thermal decomposition of the cell system of grain raw materials and having a high content of carcinogenic hydrocarbons from the recirculation loop, and also due to the reduction in the mass fraction of waste due to the combined heat treatment technology pre-drying with air and frying with superheated steam without excessive exposure to high temperatures with a gradual decrease in the moisture content of grain raw materials, and automated process control; to increase the shelf life of the finished product by reducing the oxidation of fats during the heat treatment; process intensification due to faster moisture exchange during frying; reduction of energy consumption for the heat treatment process through the use of a cyclic scheme of steam use with the stages of generation, overheating, cooling, condensation and a closed cycle of air use using a heat pump installation; the creation of an environmentally friendly, resource-saving technology for producing corn by utilizing and recovering the heat of the spent superheated steam during frying, rational use of the heat of the drying agent during drying due to timely regulation, using the spent superheated steam and drying agent as sources of secondary energy for drying and heating.

Figure 1 presents a diagram that implements the proposed method for automatically controlling the process of hydrothermal processing of oat grain in the production of oat flour.

The automatic control scheme for the process of hydrothermal processing of oat grain during the production of oatmeal contains a lock tub 1, a sieve apparatus 2, a dryer 3, a fryer 4, a condensate collecting tank 5, a steam generator 6, a superheater 7, an evaporator of a heat pump unit 8, a duplicate evaporator 9, and a heat pump condenser units 10, compressor of the heat pump unit 11, fans 12, 13 and 14, steam air heater 15, valves 16, pump 17, microprocessor 18. The circuit also includes lines for moving working media: 0.2 - wet product, 0.2.1 - dried product, 0.2.2 - fried product, 1.8 - condensate, 2.1 - exhaust steam, 2.2 - saturated steam, 2.3 - superheated steam, 3.2 - dried air, 3.3 - recirculated air, 3.4 - hot air , 5.1 - non-condensed gases. The circuit also includes sensors and actuators (A, B, B, G, D, E, F, Z, I, K, L, M, N, O, P, P, C, T, U, F, X, C, H, W, SH, E, S, Y, I - input control channels, a, b, c, d, d, e, f, s, and, k, l, m, n, o, p, p, s, t, y, f, x, c, h, w, w, u, e - output control channels).

A method of automatically controlling the process of hydrothermal processing of oat grain in the production of oatmeal is as follows.

The prepared raw materials (oats), washed and refined, are fed into the locker 1 along the line 0.2 along with water. Due to the supply of waste steam with a temperature of 100 ... 105 ° C through line 2.1 to the steam jacket of the lock tub 1, the product is heated to a temperature of 35 ... 40 ° C and stands for a certain period, the duration of the period being regulated depending on the moisture content of the grain at the inlet of the tub, and the flow rate the steam in the steam jacket is regulated by a valve depending on the temperature of the grain at the inlet of the vat.

Then, along line 0.2, the swollen oats enters tomilny apparatus 2 with a steam jacket, into which exhaust steam is supplied via line 2.1 with a temperature of 100 ... 105 ° С. Stewing oats in apparatus 2 lasts a certain period, and the length of the period is regulated depending on the moisture content of the grain at the inlet of the apparatus, and the steam consumption in the steam jacket is regulated by a valve depending on the temperature of the grain at the inlet of the apparatus, and at the exit of the languishing apparatus, the grain reaches moisture 24 ... 26%. Condensate from the steam shirts of the lock tub 1 and the languid apparatus 2 is discharged via line 1.8 to the condensate collection tank 5. Thermal decomposition products - carcinogens - are continuously discharged with non-condensed gases through line 5.1, thereby creating environmentally friendly conditions in the production technology of high-quality pulp.

Oat from languishing apparatus 2 enters dryer 3, where it is dried by air coming in through line 3.4, with a temperature of 85 ... 95 ° С to a humidity of 14 ... 12%, the flow rate being regulated by a fan 12, the air temperature is regulated by a steam heater 15 depending on temperature and humidity product in the dryer. The air supplied through line 3.4 to the dryer 3 is heated in the steam heater 15 with spent steam at a temperature of 115 ... 120 ° C, coming through line 2.1, and the steam flow is regulated by a valve, directing part of the flow to the superheater 7 with the formation of a closed cycle, depending on the temperature air at the outlet of the heater. The exhaust recirculated air after the dryer through line 3.3 is sent for dewatering in the evaporators 8 and 9 of the heat pump unit. Air is discharged or fed through line 3.1 using a valve, depending on the air flow rate at the inlet to the dryer and the inlet to the heat pump installation. Condensate from evaporators 8 and 9 is discharged through line 1.8. The dried air after evaporators 8 and 9 is fed first to the condenser 10, where it is heated to a temperature of 50 ... 60 ° C, and then through line 3.2 by a fan 12 to a steam air heater 15, where it is heated to a temperature of 85 ... 95 ° C.

The dried product is fed through the line 0.2.1 to the fryer 4, where the superheated steam coming through the line 2.3 with a temperature of 120 ... 125 ° C is fried to a moisture content of 4 ... 5%. The temperature of the product in the fryer should not exceed 70 ... 75 ° C. Superheated steam is supplied to the fryer by a fan 13, with a pressure regulated depending on the humidity and temperature of the supplied grain and the stage of operation of the apparatus (loading, frying, humidification, unloading), and the intensity of steam heating in the superheater 7 depends on the operation of fan 13. Water for humidification of grain in the fryer is served by a pump 17 from the tank for collecting condensate with pressure regulation depending on the stage of operation of the apparatus, temperature and humidity supplied to the roasting grain.

From the condensate collecting tank 5, the condensate through line 1.8 enters the steam generator 6 with electric heating elements, a pressure relief valve, a level sensor and a system of adjustable taps through the valve, depending on the water level and pressure in the steam generator. The electric heating elements work depending on the steam pressure in the steam generator and the steam flow rate at the outlet of the superheater 7. The atmospheric pressure steam is superheated in an electric superheater 7 with several heating circuits operating depending on the temperature of the steam entering the fryer.

The fried product in line 0.2.2 goes to the grain plant.

Further processing of oats in the production of oatmeal is carried out according to the Kostroma method, the essence of which is as follows. When hardening, languishing, and mainly when drying oats, its shell (film) and the core swell and lose moisture unevenly, and therefore stresses are created in the grain, which contribute to the separation of the film from the core. This facilitates the process of breaking oats - removing the film from it. When delivered, the collapsed oats are sent to a centrifugal brushing machine for separating the flour and from it to the husk for collecting husks (films). Oat, freed from flour and film, enters the grinder, where unbroken grains are taken from it. The cleaned oats are ground according to the scheme of simple re-grinding on a roller mill with grinding of the last fraction on a mill mill. For grinding, the first pair of rolls having 10 flutes per 1 cm is used, and the second pair is smooth rolls. The grinding products are separated by sieving with silk sieves No. 29 and 32. The finished product is packaged in cardboard boxes of 250-300 g.

A method for automatically controlling the process of hydrothermal processing of oat grain in the production of corn is presented on the example of a technological line for the production of corn [RF Patent No. 2229102, IPC V02V 5/02. Method for the production of oat and technological line for its implementation / S.V. Kutsov, S.A. Shevtsov, E.A. Ostrikova. No. 2007106339/13; claimed 02/19/2007; published on July 20, 2008. Bulletin No. 20].

Oats of the 1st type of the 2nd subtype coming to processing, growing in the Voronezh region, containing 7% of grains of another type, are fed for cleaning. The prepared raw materials (oats), washed and refined, are fed into the locker 1 along the line 0.2 along with water. Due to the supply of waste steam with a temperature of 100 ... 105 ° C through line 2.1 to the steam jacket of the lock tub 1, the product is heated to a temperature of 35 ... 40 ° C and lasts 1.5 hours, and the duration of the process decreases if the grain moisture at the inlet of the tub is above 12 %, and the steam consumption in the steam jacket is increased by means of a valve if the temperature of the grain with water at the inlet of the vat is less than 18 ° C.

Then, along line 0.2, the swollen oats enters tomilny apparatus 2 with a steam jacket, into which exhaust steam is supplied via line 2.1 with a temperature of 100 ... 105 ° С. Stewing oats in the apparatus 2 lasts 1 hour, and the duration of the period increases if the grain moisture at the inlet of the apparatus is less than 18%, and the steam consumption in the steam jacket increases if the temperature of the grain at the inlet of the apparatus is less than 35 ° C, and at the exit of apparatus grain reaches a moisture content of 24 ... 26%. Condensate from the steam shirts of the lock tub 1 and the languishing apparatus 2 is discharged via line 1.8 to the condensate collection tank 5. Thermal decomposition products - carcinogens - are continuously discharged with non-condensed gases through line 5.1, thereby creating environmentally friendly conditions in the production technology of high-quality pulp.

Oat from languishing apparatus 2 enters dryer 3, where it is dried with air at a temperature of 85 ... 95 ° C to a moisture content of 14 ... 12%, and air consumption increases with a fan 12 and air temperature increases with a steam heater 15 if the temperature of the product in the dryer is less 70 ° C and grain moisture at the inlet to the dryer less than 24%. The air supplied through line 3.4 to the dryer 3 is heated in the steam heater 15 with spent steam at a temperature of 115 ... 120 ° C, coming through line 2.1, and the steam flow is regulated by a valve, directing part of the flow to the superheater 7 with the formation of a closed cycle if the air temperature is exit from the heater less than 85 ° C. The exhaust recirculated air after the dryer through line 3.3 is sent for dewatering in the evaporators 8 and 9 of the heat pump unit. Air is discharged through line 3.1 using a valve if the air flow at the inlet to the dryer is higher than at the inlet to the heat pump installation. Air is fed through line 3.1 using a valve if the air flow at the inlet to the dryer is less than at the inlet to the heat pump installation. Condensate from evaporators 8 and 9 is discharged through line 1.8. The dried air after evaporators 8 and 9 is fed first to the condenser 10, where it is heated to a temperature of 50 ... 60 ° C, and then through line 3.2 by a fan 12 to a steam air heater 15, where it is heated to a temperature of 85 ... 95 ° C.

The dried product is fed through line 0.2.1 to the fryer 4, where it is fried with superheated steam at a temperature of 120 ... 125 ° С to a moisture content of 4 ... 5%. The temperature of the product in the fryer should not exceed 70 ... 75 ° C. Superheated steam is supplied to the fryer by the fan 13, and the steam consumption decreases if the moisture content of the supplied grain is less than 12% and the temperature is more than 75 ° C, and the fan is turned off if the device is operating in the loading, humidification or unloading mode, and the intensity of steam heating in the superheater 7 increases (a greater number of electric heating elements work), if the steam consumption increases. Water for moistening the grain into the fryer is pumped 17 from the condensate collecting tank when the apparatus is in humidification mode with a higher pressure if the grain temperature in the apparatus is more than 75 ° C and the moisture content of the grain supplied to the frying is less than 12%.

From the condensate collecting tank 5, condensate is supplied via line 1.8 to the steam generator 6 with electric heating elements, a pressure relief valve, a level sensor and a system of adjustable taps if the water level is less than the minimum allowable and the flow stops when filling to the maximum allowable level. The overpressure in the steam generator is relieved by a pressure relief valve. Electric heating elements work if the steam pressure in the steam generator is less than the maximum allowable and the steam consumption at the outlet of the superheater 7 is created by the fan 13.

The fried product in line 0.2.2 goes to the grain plant. Further processing of oats in the production of oatmeal is carried out according to the Kostroma method, the essence of which is as follows. When you lock, languish, and mainly when drying the oats, its shell (film) and the core swell and lose moisture unevenly, and therefore stresses are created in the grain that contribute to the separation of the film from the core. This facilitates the process of breaking oats - removing the film from it. When delivered, the collapsed oats are sent to a centrifugal brushing machine for separating the flour and from it to the husk for picking husks (films). Oat, freed from flour and film, enters the grinder, where unbroken grains are taken from it. The cleaned oats are ground according to a simple re-grinding scheme on a roller mill with the grinding of the last fraction on a mill mill. For grinding, the first pair of rolls having 10 flutes per 1 cm is used, and the second pair is smooth rolls. The grinding products are separated by sieving with silk sieves No. 29 and 32. The finished product is packaged in cardboard boxes of 250-300 g.

Table 1 shows some indicators of oatmeal obtained by the prototype and the proposed method.

Table 1 Grain characteristics Prototype The proposed method Humidity% 5.00 5.00 Organoleptic properties: taste oatmeal sweet fatty, uniformly sweet color cream, plain stable cream, plain smell malt malt Shelf life, month 6 7

Thus, the proposed method for automatically controlling the process of hydrothermal processing of oat grain in the production of corn has the following advantages:

- improving the taste of the finished product due to the uniform activation of odorizing substances, the continuous withdrawal from the recirculation loop of non-condensed gases formed as a result of thermal decomposition of the cell system of grain raw materials and having a high content of carcinogenic hydrocarbons, as well as by reducing the mass fraction of fumes due to the combined heat treatment technology that provides pre-drying with air and frying with superheated steam without excessive exposure to high temperatures with a warm reduction in the moisture content of grain raw materials, and automated process control;

- increase the shelf life of the finished product by reducing the oxidation of fats in the process of automatically controlled heat treatment;

- intensification of the process due to faster moisture exchange during frying with automatic maintenance of a given temperature of the product;

- reduction of energy consumption for the heat treatment process through the use of a cyclic scheme for the use of steam with the stages of generation, overheating, cooling, condensation, automatically controlled, and a closed cycle of air use with the use of a heat pump installation;

- the creation of an environmentally friendly, resource-saving technology for the production of corn by utilizing and recovering the heat of the spent superheated steam during frying, rational use of the heat of the drying agent during drying due to timely regulation, using the spent superheated steam and drying agent as sources of secondary energy for drying and heating.

Claims (1)

A method of automatically controlling the process of hydrothermal processing of oat grain in the production of oatmeal, which provides that the thermal treatment of grain is carried out in two stages - drying and roasting, drying is carried out by air, and roasting is carried out with superheated steam, and the steam obtained in the steam generator and superheated in the superheater is fed to the fryer, and the spent superheated steam is first sent to a steam heater to heat the air supplied to the dryer, and then to the steam shirts of the languishing apparatus and full-time tank, the pair evaporated from the product moisture and condensate from the steam shirts withdrawn initially into a container for collecting condensate, and then to the steam generator power, followed by being fed into the fryer to form a closed loop, condensation portion is used for the intermediate moisture product into the roasting chamber; non-condensable gases formed are removed from the superheated steam recirculation loop; the air heated in the steam heater by the exhaust steam is fed to the dryer, the exhaust air from the drying chamber is sent to a heat pump installation for drying and then the fan is pumped into the dryer through the steam heater to form a closed cycle, characterized in that all stages of the hydrothermal processing of oat grain at The production of oatmeal is controlled and regulated by sensors and automatic control devices, so saturated steam is obtained in a steam generator equipped with electric heating elements mi, pressure relief valve, level sensor and system of adjustable taps; superheating of atmospheric pressure steam is carried out in an electric superheater with several circuits of heating elements operating depending on the temperature of the steam entering the fryer, superheated steam is supplied to the fryer by a fan, with a pressure regulated depending on the humidity and temperature of the supplied grain and the operation of the apparatus - loading, roasting, humidifying and unloading, water to moisten the grain into the fryer is pumped from a condensate collecting tank with a pressure control depending on tapa of the apparatus, temperature and humidity of the grain fed to the roasting device, exhaust steam from the fryer is ventilated by a fan to a steam heater for heating air or partially to a superheater depending on the temperature of the air supplied to the dryer; after the heater, steam is fed into the steam shirts of the lock tub and the languishing machine depending on the temperature of the grain at the outlet of the apparatus, the resulting condensate of the heating steam in a closed loop mode is fed to the steam generator, providing a liquid level not allowing heating elements to overheat; air heated in a steam heater is supplied to the dryer with a pressure regulated depending on the temperature and humidity of the grain supplied to the dryer, moist air is taken from the dryer to a heat pump unit with a system of valves and valves for drying, and part of the air is removed or introduced from the environment depending on the air flow rate at the inlet to the dryer and then by the fan it is pumped into the dryer through a steam heater with the formation of a closed cycle; the grain is fed into the locker for a period depending on the temperature and humidity at the inlet, the soaked grain is fed into the somber for a period depending on the temperature and humidity at the inlet of the device, in the dryer the grain is air-dried to a moisture content of 14-12% and heated no higher at a temperature of 95 ° C, controlled in the dryer and at the entrance to the fryer, grain is fed from the dryer to the fryer, where it is fried to a moisture content of 4-5% with periodic moistening and heated up to a temperature of 75 ° C, controlled in the apparatus and at the exit of roasting apparatus.