RU2562715C1 - Barometric destruction of multiphase media and device to this end - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to barometric destruction of multiphase vegetable media. Proposed process comprises the steps that follow. Pre-cleaned stock is loaded into working pressure chamber to be sealed thereafter. Said medium is steamed to deep plies at 0.5 MPa and 200°C. Produced stock is purged with heat carrier gas at 2 MPa and 400°C. Operating parameters are maintained invariable for up to 60 seconds. Pressure chamber is instantly depressurized and swelled product is withdrawn therefrom. Simultaneously with the main jobs, effected are automated and in-line control over the process working parameters. All process jobs are performed in working pressure chamber without transfer into intermediate intake chamber or ejection into atmosphere. Barometric destruction device comprises the unit of automated and in-line control over the process working parameters including the system of temperature, pressure and moisture pickups and pressure control shutoff valves.

EFFECT: lower specific electric power input (by 10%), higher swelling number (up to 3,7 units), higher total nutrient value (by 10%).

4 cl, 1 dwg

Description

FIELD OF THE INVENTION

The invention relates to thermomechanical methods for the destruction of multiphase plant media (leguminous seeds, crop waste). It contains technological operations of automated control and operational control of the process of barothermal expansion. It can be used for processing multiphase plant media into compound feeds mainly for the agricultural sector and into valuable products for the food industry.

Description of the prior art

A known method of grain expansion, carried out in installations V-35M [1] and "Gun for the explosion of grain" [2], intended for the production of expanded (exploded) grains of corn, rice, oats, etc.

The method of expansion of grain is as follows. In a cylinder heated to a gas burner to 220-240 ° C load grain of a certain moisture content. After loading, the cylinder is sealed with a lid and the cylinder is heated with a burner and rotated to eliminate burning of grain. The grain inside the cylinder heats up, the moisture present in the grain evaporates and the pressure in the cylinder gradually rises. When the pressure reaches 1.0-1.2 MPa, the heating of the cylinder is stopped, and by abruptly opening the cover, the internal cavity of the cylinder is connected to the atmosphere. The grain is exposed to a sharp pressure drop, the moisture inside the grains instantly turns into steam and, exploding the grains, increases their volume by 15-20 times. The vapor escapes, and the voids formed in the grain are filled with air. Expanded grains are thrown from the cylinder into the hopper.

The main disadvantages of this method of swelling of grain include:

- low energy potential of the process of grain expansion (expansion index) limited by the structural-operational parameters of the plants - pressure up to 1.0-1.2 MPa, temperature up to 220-240 ° C;

- the lack of automated thermal imaging control of the process of grain expansion, and therefore the impossibility of reducing the specific energy consumption of plants and improving the quality of destruction (index of expansion) of grain using operational process control;

- the absence of a technological operation of steaming grain in a continuous flow mode of expansion, i.e. the process of saturating the grain with moisture (the cold method of conditioning the grain or smoothing) is a separate expensive temporary operation, which takes from 2.5 to 23 hours.

A known method for the production of expanded fodder grain [3], including loading grain material into an airtight chamber, processing grain material in a chamber and unloading. The grain material is compacted in a loading valve, thermally processed in a sealed chamber at a temperature of 300-340 ° C, a pressure of 6-8 MPa and an exposure of 20-90 s, compacted in a discharge valve, swell at a temperature of 20 ° C and a pressure of 0.1 MPa.

The main disadvantages of this method are:

- the lack of technological operations of automated control and operational management of the expansion process, as a result of which the permissible tightness of the vessel in continuous flow mode will not be ensured by loose layers of grain between the screws of the screws of the loading and unloading valves with a clearance from the body of 0.5 mm and an operating pressure of 6 -8 MPa;

- low efficiency of the process of steaming grain in a continuous flow mode due to the short time of passage of grain through chamber 6 (exposure time 20-90 s);

- increased wear of the discharge valve (screw jamming is possible) due to additional resistance to grain movement, which will begin to swell not in the last turn of the screw, but in the screw channel as the pressure decreases from 6-8 MPa to 0.1 MPa.

A known method of producing an exploded product from feed grain of sorghum [4], including soaking the grain in water at a temperature of 18-20 ° C for 29 hours until the grain reaches a moisture content of 35-37% and drying the grain with IR rays at a wavelength of 0.9- 1.1 μm and a radiant flux density of 11-13 kW / m ² for 2.0-2.5 minutes to a moisture content of 28-30%. Then the grain is treated with IR rays at the same wavelength and density of the radiant flux of 20-22 kW / m ² for 90-100 s until it reaches a temperature of 170-180 ° C.

The main disadvantages of this method are:

- high energy costs for the operation of micronization of grain (flux density of infrared rays - from 11 to 22 kW / m ² ), due to the lack of automated technological operations of thermal imaging and barometric control and operational control of the process of explosion of a product from sorghum feed grain;

- the lack of a technological process of steaming grain in a continuous flow mode, because the process of saturation of grain with moisture (a cold method of conditioning the grain or smoothing) is a separate time-consuming operation, which is carried out at a temperature of 18-20 ° C for 29 hours.

A known method of producing a grain component and product [5], in which the grain is washed with the removal of inorganic impurities, the grain is dried to an internal moisture content of 12-17%, heat treatment of a portion of grain with its heating in the volume of the working chamber under compression between two heated surfaces and a glass up to a pressure of 30.5-33.5 kg / cm ² , holding for 9-10 s until the internal moisture of the grain turns into steam, a sharp increase in the volume of the working chamber and depressurization with the explosion of grain with steam throughout the mass to break whole grain and the formation of a compacted slice from parts of the grain, the subsequent crushing of the slice.

The main disadvantages of the method are:

- the lack of technological operations of automated thermal imaging and barometric control and operational control of the process of production of the grain product, which means the impossibility of increasing the index of swelling of grain and the impossibility of reducing the specific energy consumption of the process;

- low energy potential of the operation of expansion of grain (expansion index), limited by the structural-operational parameters of the installation - pressure change in the range from 30.5 to 33.5 kgf / cm ² , the temperature is not indicated;

- lack of a technological process of steaming grain in a continuous flow mode of expansion, because the process of saturation of grain with moisture is carried out by the operation of washing the grain with the removal of inorganic impurities.

The closest analogue selected as a prototype is a method for the production of expanded grain [6], which includes loading grain material into the chamber, sealing the chamber, processing the grain material in the chamber and unloading the grain material in the receiving hopper, while the treatment with the gaseous heat carrier 3-300 s, the pressure of the gaseous coolant is 0.3-3 MPa, and the temperature of the gaseous coolant is 50-400 ° C.

The main disadvantages of the method are:

- the lack of technological operations of automated thermal imaging and barometric control and operational control of the process of production of expanded grain, which leads to an increase in specific energy consumption in all operations;

- low energy potential of the process of swelling of grain, due to the need to move grain from the sealed chamber to the receiving chamber through an unloading valve, preventing the pulse pressure release from the chamber and increasing the index of swelling of grain;

- the high cost of production of plants that implement this method of production of expanded grain due to the need to provide a high degree of tightness of both the high-pressure chamber and the receiving chamber, which should be made of high-precision parts.

Thus, the technological operations of automated control and operational management are not included in the existing technology of barothermal production of expanded multiphase media (leguminous seeds and crop waste).

Disclosure of invention

The objective of the invention is to eliminate the disadvantages of the previously mentioned inventions, ensuring the continuity (flow) of the process of barothermal degradation of plant media, reducing energy consumption and improving the quality of feed, due to structural transformations in plant components.

The technical result of the invention is:

1) a decrease in the specific energy consumption of the process of barothermal destruction by 10% .;

2) an increase in the expansion index of multiphase plant media (leguminous seeds and crop waste) to 3.7 units;

3) increasing the total (energy) nutritional value of barothermal feed for farm animals by at least 10%, due to the following structural physical and chemical transformations of plant materials:

- compensates for the deficit of metabolic energy in the feed during separation of the film (shell of grain seeds 30-40% of the volume) of seeds for cattle by 11.5%, for poultry 8-10%;

- the level of fiber content in cattle decreases - from 10.3% to 2.2%, in poultry from 5.6% to 2.2%. Each percent reduction in fiber increases food digestibility by 1.2-1.6%. When separating (destroying) the seed film, the content of fiber components — cellulose, pentosans, minin — which form acetic, butyric, lactic, and propionic acids, decreases;

- there is protection against the destruction of grain protein in the rumen of cows in the range of 42-66%, depending on the seed culture - barley, chickpeas, vetch, beans. Digestibility of protein in the intestines of cattle increases from 65.2 to 70.5%;

- increased stability of fats due to the destruction of the lipase enzyme and reduced oxidation of intracellular fat;

- increased digestibility of proteins due to the destruction in the molecules of secondary bonds, as a result, amino acids become available for complete digestibility of the small intestine. The composition of amino acids during barothermal treatment remains virtually unchanged;

- increases the digestibility of starch passing into the structure of gelatin, due to loosening of the grain structure;

- substances that have anti-nutritional effects on animals are destroyed (urease, protease and trilein inhibitors, allergens, aflatoxins). The destruction of natural stabilizers (lycetin and tocopherols) does not occur, and the negative effect of the destruction of vitamins, fats and amino acids is minimized due to the speed of technological operations under the influence of the maximum temperature (up to 400 ° C);

- the organoleptic properties of plant feed are improved due to the destruction of the crystalline structure of starch grains of the endosperm (the grain acquires a golden color, pleasant taste and smell of toasted grain);

- improved sanitary status of feed, due to the destruction of molds and anaerobic bacteria.

The essence of the invention lies in the fact that in the process of barothermal degradation, including loading pre-purified raw materials into a working pressure chamber, sealing the pressure chamber, steaming the multiphase medium to deep layers with a pressure of up to 0.5 MPa and a temperature of up to 200 ° C, blowing the raw material with a gaseous coolant at a pressure of 2 MPa and temperatures up to 400 ° C, holding the operating parameters constant for up to 60 s, instantaneous depressurization of the working pressure chamber (pressure and temperature release to normal conditions - 0.1 MPa and 20 ° C), p leading to loosening (swelling) of the structure of plant media, extraction of the finished product from the pressure chamber, simultaneously with the main operations, in parallel, they carry out automated control and operational control of operational parameters of the process (pressure, temperature, humidity, operation time).

Distinctive features are:

- parallel operations of automated control and operational management of operational parameters, which ensures the flow (continuity) of the process of barothermal destruction;

- the impact on the multiphase medium in the working pressure chamber, without moving into the intermediate receiving chamber or emission into the atmosphere;

- use of a control and management unit with a system of sensors and locking control elements.

Short description of the circuit

Features of the invention will be further understood from the following description of the attached drawing, in which a diagram of a device for implementing barothermic destruction of multiphase plant media.

To implement the present method for the destruction of multiphase plant media, a device is proposed consisting of a working pressure chamber 1 and a heat chamber 2 connected to each other by a pipe 3 equipped with a locking element.

The working pressure chamber 1 got its name due to the fact that the value of the pressure parameter has a decisive effect on the destruction process. Heat chamber 2 got its name due to the fact that the value of the temperature parameter has a decisive effect on the destruction process.

The loading and unloading of multiphase plant medium is carried out through a pivotally mounted cover 4 of the working pressure chamber 1.

The working pressure chamber 1 is connected to the following elements:

- a steam generator 5 using a pipeline 6 for supplying steam;

- with a cylinder 7 of high-pressure food gas using a pipeline 8;

- with safety relief valve 9;

- with a control unit 10 (hereinafter - CUB) of the technological process.

The CUB is connected to a system of pressure, temperature, humidity sensors installed in the body of the working pressure chamber 1, heat chamber 2, steam generator 5, cylinder 7 and to shut-off control elements installed on pipelines 3, 8, 6 and the relief valve 9.

The heat chamber 2 is equipped with a device 11 for heating the food gas passing from the cylinder 7 into the pressure chamber 1, and then through the valve 9 into the atmosphere or sewer.

The implementation of the invention

The process of barothermal destruction consists of seven traditional sequential technological operations, on each of which two operations of automated control and operational control of operational parameters of the process (pressure, temperature, humidity, operation time) are carried out in parallel.

1) Loading of multiphase plant media.

Open the lid mounted on the swivel hinge 4. The multiphase plant material is poured into the working pressure chamber 1 through the receiving window.

2) Sealing the pressure chamber.

Close the lid 4 with a mechanism that ensures complete tightness of the pressure chamber 1 at operating parameters of pressure up to 2 MPa and temperature up to 400 ° C.

3) Steaming.

KUB 10 launches a steam generator 5. Pre-purge of multiphase plant materials by steam occurs. The steam passes into the working pressure chamber 1, and then is discharged into the atmosphere or sewer through the relief valve 9. The steam is supplied under pressure from 0.11 to 0.5 MPa. Under the influence of steam at a temperature of 100 ... 130 ° C, the multiphase plant medium is moistened and heated, the outer layers soften (the structure of the shell of grain seeds and waste plant material), and excess pressure promotes the penetration of moisture into the internal structure of plant media. There is an effective wetting of the processed raw materials to the full depth. In this case, the vapor only penetrates inside and does not cause boiling of moisture and rupture of the plant environment. Steam treatment time for various environments does not exceed 10 minutes. To complete the steaming operation, KUB 10 turns off the steam generator 5.

4) Purge with high pressure food gas.

KUB 10 starts the heating device 11 and cylinder 7. A sequential supply of food gas (for example, nitrogen, or carbon dioxide, or air) begins through line 8 to the heat chamber 2 and line 3 to the working pressure chamber 1, and then through the relief valve 9 to atmosphere or sewer. For various types of plant media, the purge pressure is from 0.5 to 2 MPa, the temperature is up to 400 ° C, the processing time is up to 5 minutes. Instant heating of the high-pressure food gas is carried out by the heating device 11 when the food gas passes through the heat chamber 2.

When a high-pressure dry gas purge is used, moisture evaporates from the outer layers of the raw material, while the deeper layers retain moisture heated above 100 ° C. When a high-pressure edible gas is blown with food gas, it is possible to control the moisture level of the raw material (excluding its overmoistening), as well as change the humidity of the finished expanded product, i.e. additionally dry. Automated control and operational control of the purge process is carried out by KUB 10, which is connected to shut-off control elements and a system of pressure, temperature and humidity sensors.

5) Exposure to the operational parameters of the process.

KUB 10 closes the relief valve 9 and using a cylinder 7 in the working pressure chamber 1, the pressure is reached that is optimal for the destruction of the intumescent plant material. The operation of maintaining the operational parameters of the process at their optimum values of pressure up to 2 MPa, temperature up to 400 ° C, humidity up to 50% and operation time up to 60 s allows creating conditions for effective loosening of the plant material structure (expansion) and destruction of the shells of leguminous seeds, with the aim of maintaining the minimum necessary level of moisture in deeper layers.

6) Depressurization of the working chamber.

KUB 10 closes the shut-off element in the pipeline 3, then the relief valve 9 instantly opens. Overpressure is released from the working pressure chamber 1 into the atmosphere or sewer. The pressure in the working pressure chamber 1 drops to 0.1 MPa. In this case, the moisture contained in the multiphase plant medium, heated to a temperature above 100 ° C, instantly boils and turns into steam. As a result, the structure of the plant environment loosens (swells), the bulk density decreases by grain seeds by 3.7 times, by bean seeds by 1.2 times. In the working pressure chamber 1, it is possible to dilute the pressure to 0.05 MPa in order to have a milder temperature and barometric effect on a specific group of plant materials (for example, cereal sunflower and millet seeds) while maintaining their beneficial properties. For this, the relief valve 9 is connected to a vacuum cylinder, in which the vacuum reaches 0.05 MPa.

At a pressure in the working chamber 1 below atmospheric, the destruction of plant media occurs at a lower temperature (at a pressure of 0.06 MPa, the boiling point of water is 85.5 ° C). Such a technological operation allows the temperature and barothermal destruction of the film structures of plant media in low ranges of values, which reduces the destruction of vitamins, fats and amino acids to a minimum.

In the inventive device, in contrast to existing designs of analogues, the depressurization of the working chamber to atmospheric pressure occurs through a relief valve 9 equipped with a silencer, and not through a window opened by a cover 4. This method allows to reduce the noise level from the sound of the explosion, to exclude the spread of material in the surrounding space, increase the durability of the mechanism for opening and closing the lid 4.

7) Unloading of multiphase plant media.

Open the cover 4 of the working pressure chamber 1 and through the receiving window carry out the unloading of the finished expanded multiphase plant medium.

The physicochemical properties of plant media (for example, leguminous seeds, crop waste - bran, sunflower husk, meal, cake, hay, straw, etc.) are different, which means that the operational parameters of the barothermal destruction process for each medium are different. Thus, in order to achieve the highest expansion index for each plant medium, it is advisable to carry out barothermic destruction of the media, dividing them into groups. For this, laboratory studies of the selection of plant media are carried out according to the criteria: fiber content, protein breakdown level, fat stability, protein structure transformation, starch breakdown to sugars, destruction of anti-nutritional substances (urease, protease and trilein inhibitors, allergens, aflatoxins), organoleptic properties and sanitary status of plant environments.

From the sensors installed in the working pressure chamber 1, heat chamber 2, steam generator 5 and cylinder 7, they receive real-time signals at the CUB 10. In contrast to the existing visual methods for recording the parameters of the destruction process by metering devices, the proposed method allows operational control of the operational parameters of the destruction process (pressure and time of operations, temperature and humidity). The result is the product with the highest expansion index, which ranges from 45% to 75% of the composition of the compound feed for farm animals.

The expression for determining the index of swelling of plant materials:

where ρ _N is the initial density of the material under normal environmental conditions (temperature - 20 ° C, pressure - 0.1 MPa, humidity of the material - 14%); ρ _K is the final density of the material after barothermal destruction (temperature - up to 100 ° C, pressure - 0.1 MPa, humidity of the material - 10%).

An example of the calculation of feed raw materials.

1) Wheat seed bloating index:

2) Legume soybean bloating index:

In the literature, to date, the authors have not found descriptions of methods and devices for barothermal destruction of multiphase media using automated control and operational process control operations. The application of these technological operations allows to reduce the specific energy consumption of the process and increase the expansion index of multiphase plant media. To conduct automated control and operational management of the inventive device is equipped with a control unit KUB with a sensor system for recording pressure, temperature, humidity and shut-off control elements. All technological operations of exposure to a multiphase medium are carried out in a working pressure chamber, without moving to an intermediate receiving chamber or discharge into the atmosphere. This allows us to conclude that the claimed technical solution meets the first condition for patentability of the invention - novelty.

In contrast to the above descriptions of inventions (RF patents 2490937, 2507864, 2423873, 2432779) and structures of the B-35M and "Gun for the explosion of grain", the inventive method and device for barothermic destruction of multiphase media can ensure the continuity of the process and increase the energy potential of destruction, that provides the claimed technical result.

The technical solution achieving this result does not follow explicitly from the prior art. Therefore, the proposed solution meets the second condition for patentability of the invention is an inventive step.

The manufactured prototype of the device was laboratory tested at the Orenburg Scientific Center of the Ural Branch of the Russian Academy of Sciences and the Orenburg Regional Business Incubator, and production experiments and operations were carried out at Biotechnika LLC (a small innovative agricultural enterprise in the Orenburg Region). Therefore, the claimed technical solution meets the third condition for patentability of the invention - industrial applicability.

Thus, the claimed method and device can effectively carry out barothermic destruction of multiphase media due to the parallel implementation of automated control operations and operational control of process parameters.

Information sources

1. I.T. Krotov et al. Technological equipment for food concentrate enterprises. - Voronezh: Publishing house of the University of Voronezh, 1990.

2.http: //mustang.kiev.ua/pushka_dlja_vzriva_zerna.html

3. RF patent 2490937, A23L 1/18, publ. 08/27/2013.

4. RF patent 2507864, A23K 1/14, publ. 02/27/2014.

5. RF patent 2423873, A23L 1/00, publ. 07/20/2011.

6. RF patent 2432779, A23L 1/18, publ. 11/10/2011.

Claims (4)

1. The method of barothermal destruction of multiphase media, including the operation of loading pre-purified raw materials into a working pressure chamber, sealing the pressure chamber, steaming the multiphase medium to deep layers with a pressure of up to 0.5 MPa and a temperature of up to 200 ° C, blowing the raw material with a gaseous coolant at a pressure of up to 2 MPa and temperature up to 400 ° C, exposure values of operational parameters unchanged up to 60 s, instant depressurization of the working pressure chamber, extraction of the expanded product from the pressure chamber, characterized in that at the same time Basic Operations carried out parallel operation of the automated monitoring and control operational parameters of the process, with all manufacturing operations impact on the multiphase medium is carried out in the working pressure chamber, without moving the intermediate receiving chamber or ejection into the atmosphere. 2. The device for barothermic destruction of multiphase media by the method according to p. 1, characterized in that they use an automated control unit and operational control of the KUB operational process parameters with a sensor system for recording pressure, temperature, humidity and shutoff control elements. 3. The device for barothermic destruction of multiphase media according to claim 2, characterized in that the depressurization operation of the working pressure chamber to atmospheric pressure occurs through a safety relief valve connected to a vacuum cylinder or silencer. 4. The device barotermic destruction of multiphase media according to claim 2, characterized in that the operation of purging the material is carried out by high-pressure food gas up to 2 MPa, which is heated by a device placed in a heat chamber to 400 ° C.