RU51829U1 - INSTALLATION OF TESTING OF SOYBE AND PROCESSING OF THE GRAIN BASIS FOR FAST COOKING PRODUCTS - Google Patents

Abstract

The utility model relates to equipment for the heat treatment of leguminous products, including soy, using electrophysical methods and can be used in the food industry for testing soybeans and the production of grain basis for instant products.

This installation provides the following technical result in comparison with the prototype:

- high-quality testing of soybeans with initial intrinsic humidity, without preliminary wetting, is achieved by the destruction of urease, trypsin inhibitor (to a level of not more than 0.25 pH) and oligosaccharides (to a level of not more than 2%);

- obtaining high quality processed products with increased initial humidity, improving the nutritional properties of soy and grain due to a deeper conversion of starch into an easily digestible form;

- reduction of energy consumption of the processing process due to deeper air purification in the recirculation, air purification and heating systems;

- increase the range of processed raw materials, due to the expansion of the range of the initial moisture content of the raw materials.

Installation of testing soybeans and processing a grain base for instant products containing a loading hopper, an irradiation chamber in the form of a microwave chamber with a microwave energy source, exhaust and discharge fans, a closed recirculation, air purification and heating system, conditioner - batcher, pneumatic conveying system, heat exchange a device formed by three concentric vertically arranged cases, in the upper part an outer continuous and intermediate perforated, made in the form of truncated cones, with dyna with a loading hopper, in the lower part the bottom of the outer casing and the intermediate is connected to the input of the irradiation chamber, the inner casing forms a uniform gap with its perforated part with the intermediate casing along its entire length and its upper part is connected to the exhaust duct of a closed air recirculation, cleaning and heating system which is connected via a cyclone to the exhaust pipe

a fan connected through an electric heater to the outer casing of the heat exchanger, in which an annular groove is made, located obliquely on the inner conical surface of the continuous upper part of the inner casing, the lower point of the trough is located on the plane of connection with the lower perforated part of the inner casing and is connected to the outlet pipe, in a closed a steam separator is installed between the cyclone and the exhaust fan pipe to the air recirculation, cleaning and heating system, with fitted with a supply air pipe with a gate valve, a drain valve, the product line of the pneumatic conveying system through a filtering device is connected to the exhaust pipe of a closed air recirculation, air purification and heating system.

Description

The utility model relates to equipment for the heat treatment of leguminous products, including soy, using electrophysical methods and can be used in the food industry for testing soybeans and the production of grain basis for instant products.

A known method of processing non-fat soya beans [RF Patent RU 2038797, A 23 K 1/00, A 01 F 25/00, A 23 N 12/00, publ. 07/09/95] to increase the nutritional value of soy and reduce the content of anti-nutrients to a safe level. The method is based on soaking the beans in water for at least 3 hours. Surface moisture is removed by passing through a stream of air and microwave processing at a temperature of the mass of beans 90 ° C to a residual moisture content of 7%, followed by cooling the beans to ambient temperature.

A known method of inactivation of anti-nutritional substances of soybeans [RF Patent RU 2057464, A 23 L 1/211, publ. 04/10/96], which involves washing whole soybeans with water, soaking them in an alkaline solution with a pH value of 8.3-8.5 to a degree of swelling of 0.3-0.35 and heat treatment in the field of microwave currents at a temperature gradient of 7- 9 ° C in 1 minute to a moisture content of soybeans of 8-12%.

There is also a method of producing oilcake and oil from soy beans [RF Patent RU 2232799, C 11 V 1/00 publ. November 4, 2002], which includes the thermal and thermal treatment of russel with a moisture content of 7–20% in the electromagnetic field of the microwave range with a specific power of 0.2–2.0 kW / kg for 1–6 minutes and thermoplastic extrusion.

The implementation of the proposed processing methods allows to reduce the activity of trypsin inhibitors to acceptable values, and the urease pH characterizing the activity of inhibitors to zero, but does not provide a high-quality product due to residual bean or alkali aftertaste, in addition, protein denaturation or destruction due to the long processing time in the microwave field, which impairs its digestibility or reduces its amount, it is not possible to lower the level of oligosaccharides far about not harmless to the body [G.I.Mendelson. The value of soy protein products in human nutrition. Journal "Food Industry" N7, 2004, p. 84].

When implementing the above methods, it is assumed that the product is cyclically processed, beans are soaked and rinsed, which requires cumbersome special equipment and additional costs for the disposal of production wastes containing environmental pollutants.

The closest in technical essence to the proposed installation is the installation for micronization of grain products [RF Patent RU 2168911, A 23 L 1/18, 1/025, 3/01, A 23 V 9/04, F 26 V 3/34 publ. 06/20/2001], containing a loading hopper with a heat exchanger, an irradiation chamber, exhaust and discharge fans, a closed recirculation system for cleaning and heating the air, a conditioner-dosing unit and a pneumatic conveying system, the heat exchanger being formed by three concentric vertically arranged housings in the upper part of the heat exchanger external solid and intermediate perforated bodies are made in the form of truncated cones connected to the loading hopper in the lower part of the heat exchange the bottom of the outer casing and the intermediate perforated casing are connected to the input of the irradiation chamber, the inner casing of the heat exchanger forms a uniform gap with its perforated part with the intermediate perforated casing along its entire length and is connected to the exhaust duct of the closed recirculation, air purification and heating system with its upper part, which is connected through a cyclone to the first branch pipe of an exhaust fan, the output of which is evenly distributed through a heat heater green lead-in ducts with the outer casing of the heat exchanger; moreover, a microwave chamber with a microwave energy source is used as an irradiation chamber, located coaxially with the heat exchanger, the output of which is connected to the conditioner - dispenser, under which there is a pneumatic conveying system from the discharge fan, the receiving device, and

product pipeline, the duct from the source of microwave energy is connected to the second pipe of the exhaust fan.

This installation has proven itself in the processing (micronization) of leguminous crops at an initial moisture content of 10-13%, while ensuring the optimal ratio of quality, processing time and energy consumption. Grain as a result of processing has a low residual moisture content of 5%, it is brittle, it does not have sufficient ductility for use as a grain base for instant products. To obtain the necessary quality of the grain base, it is required to increase the initial moisture content of the grain (up to 15-17%). When processing grain with high humidity, the moisture content in the hot air passing through the grain layer increases, directly depends on the initial moisture content of the grain. Therefore, when processing grain with high humidity, moisture condenses in the heat exchanger on the inner cone-shaped surface of the upper part of the inner casing, collects in droplets, flows down the cone-shaped surface and enters the grain in the zone of air blowing, moisture returns to the grain, which leads to growth energy costs, processing time, processing quality deterioration. Moreover, in a closed system of recirculation, purification and heating of air, in a cyclone, complete purification of air from moisture is not provided, there is the possibility of air with residual moisture content entering the heat heater, which contributes to its failure.

At this facility, it is possible to test soybeans (heat treatment with a residual amount of urease up to 0.25 pH) with an in-house moisture content of up to 12%, without additional moisture, while ensuring the destruction of anti-nutrients. However, due to the good soya purge, even at 12% humidity, the purged hot air is excessively saturated with moisture, moisture returns to the processed grain, the processing is lengthened, it is impossible to obtain a temperature gradient at the microwave processing stage to destroy oligosaccharides to a safe level.

The purpose of creating a utility model is to create a soybean testing facility and processing a grain base for instant products, which allows to obtain high-quality tested soybeans when processing the initial product with its own moisture content, without preliminary wetting; improving the quality of processing cereals with high initial humidity; reduction of energy consumption of the processing process; increase in the range of processed raw materials.

This goal is achieved by the fact that in a known installation for micronization of grain products [RF Patent RU 2168911, A 23 L 1/18, 1/025, 3/01, A 23 V 9/04,

F 26 V 3/34 publ. 06/20/2001], comprising: loading hopper; an irradiation chamber in the form of a microwave - camera with a source of microwave energy; exhaust and discharge fans; closed recirculation system for cleaning and heating the air; conditioner - dispenser; pneumatic transport system; the heat exchange device formed by three concentric vertically arranged housings, in the upper part the outer continuous and intermediate perforated, are made in the form of truncated cones connected to the loading hopper, in the lower part the bottom of the outer case and the intermediate are connected to the input of the irradiation chamber, the inner case forms its perforated part with the intermediate body along its entire length has a uniform gap and its upper part is connected to the exhaust duct of a closed recirculation system, about cleaning and heating the air, which is connected through a cyclone to the exhaust fan pipe connected through a heat electric heater to the outer casing of the heat exchanger, in addition to the heat exchanger, an annular trough is arranged obliquely on the inner conical surface of the continuous upper part of the inner casing, the lower point of the trough is located on the plane of docking with the lower perforated part of the inner case and connected to the outlet pipe; in a closed system of recirculation, cleaning and heating of air between the cyclone and the exhaust fan pipe, a steam separator is installed, equipped with a supply air pipe with a valve, a drain valve; the product pipeline of the pneumatic conveying system through the filtering device is connected to the exhaust pipe of a closed recirculation system.

The essence of the utility model is the phased effect of hot air and microwave energy on the processed product. At the first stage, dry hot air provides evaporation of moisture from the surface of the grains at a speed higher than the speed of its movement from the inner layers to the surface. This allows you to dry the surface layer of grains, increase the mobility of water molecules in the capillaries and cells of the grain, bring its temperature closer to the boiling point, and obtain a partial pressure inside the capillaries exceeding the coolant pressure. With increased humidity of the processed grain, the excess moisture of the hot air partially condenses in the heat exchanger on the inner cone-shaped surface of the upper part of the inner casing. Condensate is collected in an annular trough and is discharged through the outlet pipe, which eliminates the ingress of this moisture into the grain. The final cleaning of hot air from moisture is carried out in a closed system of recirculation, purification and heating of air, in a steam separator, in

which on the inner wall of the cyclone, in contact with it flows of hot and cold outboard air, condensate settles and is discharged through a tap. The degree of purification is determined by the temperature and the amount of outside air, while the hot air is cooled and the outside air is heated. In a closed system of recirculation, purification and heating of the air, the loss of air and a decrease in its temperature are compensated by the heated outside air of the steam separator and pneumatic conveying system. At the second stage of processing, under the influence of the microwave field in the processed product, internal moisture boils due to abrupt jump-like heating, structural changes of the grain occur, destruction of low molecular weight proteins (trypsin and urease inhibitors), conversion of starch to easily digestible form, destruction of oligosaccharides. The processing results are fixed by the subsequent exposure of the processed product in a microwave field that decreases according to the exponential law at a constant temperature.

Fig. Shows the installation of testing soybeans and processing the grain base for instant products (hereinafter referred to as the installation) and the process flow diagram (arrows indicate the direction of grain movement and the air passage, qualitative changes in the product and the state of air flows during processing are characterized by the type and color of the arrows) , the numbers indicate:

1 - loading hopper; 2 - radiation chamber; 3 - microwave - camera; 4 - source of microwave energy; 5 - exhaust fan; 6 - a forcing fan; 7 - a closed system for recirculation, purification and heating of air; 8 - conditioner - dispenser; 9 - pneumatic transport system; 10 - heat exchange device; 11 - outer casing; 12 - intermediate housing; 13 - inner case; 14 - the bottom of the outer casing; 15 - the gap between the inner and outer cases; 16 - exhaust duct; 17-cyclone; 18 - pipe exhaust fan; 19 - heat electric heater; 20 - an annular groove; 21 - the upper part of the inner; housing; 22 - outlet pipe; 23 - steam separator; 24 - supply air pipe; 25 - valve; 26 - drain valve; 27 - filtering device; 28 - a cyclone;

29 - outer shell - housing; 30 - product pipeline.

The installation contains a loading hopper 1, an irradiation chamber 2 in the form of a microwave camera 3 with a microwave energy source 4, exhaust 5 and forcing 6 fans, a closed system for recirculation, purification and heating of air 7, conditioner - dispenser 8, pneumatic conveying system 9, heat transfer device 10, outer 11, intermediate 12, inner 13 of the heat exchanger case, bottom 14 of the outer case, gap 15 between the inner and outer cases, exhaust duct 16 of the closed air recirculation, air purification and heating system, cyclone 17, exhaust pipe 18 fan, heat heater 19, an annular groove 20 on the inner surface of the upper part 21 of the inner case, the outlet pipe 22, the steam separator 23, the supply air pipe 24, the valve 25, the drain valve 26, the filter device 27.

In the loading hopper 1 of a cylindrical shape in the heat exchanger 10, three vertically arranged housings 11-13 are made. In the upper part of the heat exchanger device 10, the outer 11 continuous and intermediate 12 perforated bodies are made in the form of truncated cones connected to the feed hopper 1. In the lower part of the heat exchanger device 10, the bottom 14 of the outer 11 body and the intermediate 12 perforated body are connected to the input of the radiation chamber 2. The inner housing 13, of the heat exchange device 10, with its perforated part repeats the shape of the intermediate housing 12 and forms a uniform gap 15 with it, the dimensions of which are selected for reasons of steady motion of the minimum layer of grain by gravity, under the weight of its own weight, with a maximum flow around hot air. The shape and size of the perforation holes are selected so that grain does not spill through them and grain rotation is ensured when the perforated parts of the intermediate shells 12 and inner 13 slide on the surface, which facilitates grain mixing during movement and improves the access of hot air to the grain surface. The upper part 21 of the inner 13 of the casing is made in the form of a continuous cone with the apex connected to the exhaust duct 16 of a closed system of recirculation, purification and heating of air 7. On the inner cone-shaped surface of the upper part 21 of the inner 13 of the casing there is an annular groove 20 located obliquely, the lower point of which is on the docking plane of the upper solid and lower perforated parts of the inner 13 of the housing and connected to the outlet pipe 22. The dimensions and angle of inclination of the gutter 20 are selected from considerations ensure the removal of condensed liquid on the inner conical surface of the inner 13 of the housing.

A closed system for recirculation, purification and heating of air 7 is a serial connection of the exhaust duct 16, exhaust air from the inner 13 of the housing of the heat exchanger 10, the cyclone 17, the steam separator 23, equipped with a supply air pipe 24 with a valve 25 and a drain valve 26 connected to the exhaust fan 5 through a pipe 18, a heat electric heater 19, which is connected to the outer casing 11 of the heat exchange device. Cyclone 17 is made of a cylindrical type with a screw insert for swirling the air flow [V.I. Gorbatyuk Processes and devices for food production. M .: Kolos, 1999, 335 pp., P. 132.], Which lengthens the path of its passage, therefore, helps to improve air purification from dust, moisture, due to the sedimentation of its droplets on the walls of the cyclone. The steam separator 23 is made in the form of a cyclone 28, equipped with an outer shell-body 29, filled through the supply air pipe 24 with a valve 25 with cold outside air, which then flows through the pipe 18 to the exhaust fan 5. The moisture released inside the cyclone 28 is discharged through the drain valve 26. Structurally, these are two cylindrical containers inserted one into another, between the walls of which air is passed. The valve 25 serves to adjust the supply of cold air.

Irradiation chamber 2 consists of a microwave chamber 3, a microwave energy source 4 with forced cooling, the generated heat is used in a closed system of recirculation, purification and heating of air 7. The microwave chamber is compact, the dimensions provide an impact on the processed grain with a microwave field with a specific power not less than 35 kW / kg with an electric component of the electromagnetic field of at least 200 V / cm. and a gradient of temperature increase of 10-15 ° C per second. It is located under the loading hopper 1, coaxially with the heat exchanger 10. The output of the microwave chamber 3 is connected to the conditioner - dispenser 8, which is made with an adjustable speed of conditioning of the grain.

The pneumatic conveying system 9 consists of a blower fan 6, a product pipe 30 and a filtration device 27 connected to an exhaust fan of a closed system for recirculation, purification and heating of air 7.

To prevent heat loss during processing, the structural elements of the heat exchange device 10, the recirculation system, purification and heating of the air 7 and the irradiation chamber 2 are made insulated.

Installation works as follows.

The pre-cleaned grain is fed into the loading hopper 1, by gravity fills the gap 15 between the intermediate 12 and the inner 13 of the housing of the heat exchanger 10, where it is blown with hot air supplied from a closed system for recirculation, cleaning and heating of air 7 with an exhaust fan 5 through an electric heater 19, the air passes through the space between the outer 11 and intermediate 12 buildings, through the perforated walls of the intermediate 12 and internal 13 buildings and, giving part of the heat to the grain, is sucked off by the same exhaust valve 5 through its pipe 18, through the exhaust duct 16, cyclone 17, where it is cleaned of small impurities of grain, dust and partly moisture, through a steam separator 23, where it is finally cleaned from moisture, and again enters through the electric heater 19 to the heat exchanger 10. Hot air passes through the grain under pressure to remove surface moisture, and heats it to a predetermined temperature, the value of which is automatically controlled by the amount of heat given off by the heat heater 19. Saturation of hot air the moisture of the ear passing through the grain layer directly depends on the initial moisture content of the grain, therefore, when processing grain with high humidity, moisture condenses on the inner conical surface of the upper part 21 of the inner housing 13, collects in droplets, flows down the conical surface and enters the inclined annular groove 20 which through the pipe 22 is displayed outside. Air losses in the recirculation, air purification and heating system 7 are compensated by warm air from a microwave source of energy 4, outboard heated from a steam separator 23 and heated from a filtering device 27 of the pneumatic conveying system 9. Then, the preheated grain flows by gravity into the microwave chamber 3, where under the action of Microwave energy supplied from a microwave energy source 4, intense volumetric heating of the grain occurs, affecting the internal free and bound moisture, due to which there are structural changes in the grain by two per to the formulations - a sharp increase in pressure in the cells, overpressure in the pores and capillaries, a situation arises when the time of the flow of liquid and steam from the capillaries exceeds the heating time, a thermal explosion occurs, as a result of which the grain cells are destroyed [V. Kononov, A. F. Nosovets . The theory of micronization of grain by microwave energy. Questions of special radio electronics. Series: General Questions of Radioelectronics, Issue 1, Moscow-Taganrog, 2003, p.146]. As a result of this, starch turns into an easily digestible form of dextrin, urease activity decreases in soy, trypsin inhibitors, oligosaccharides are destroyed, and protein digestibility increases. At the same time, soy deodorization occurs, the bean taste disappears, pathogenic microorganisms and fungi are destroyed. When moving through the microwave chamber 3 grain, after exposure to microwave energy, a certain time is maintained in the microwave field, which decreases according to the exponential law, at a constant grain temperature, this fixes the processing results. Significantly increased grain enters the conditioner - dispenser 8, where it is flattened to fix the processing results, to prevent the restoration of molecular bonds, and enters the pneumatic conveying system 9, where it is picked up by the air flow created by the blowing fan 6, a grain-air mixture is formed, which is transported through the product pipeline 30 to unload. During transportation, the grain is cooled, and the air is heated, cleaned in the filtration device 27, and enters the exhaust fan 5. The unit is equipped with automation elements that allow you to maintain optimal grain processing modes, while the ratio of convective and microwave energy is 2.5 : 1 [V.M. Kononov, A.F. Nosovets, I.M. Chekrygina. Optimum energy ratios for micronization of grain crops. Questions of special radio electronics. Series: General Issues of Radio Electronics, Issue 1, Moscow-Taganrog, 2004, pp. 261-265].

This installation provides the following technical result in comparison with the prototype:

- high-quality testing of soybeans with initial intrinsic humidity, without preliminary wetting, is achieved by the destruction of urease (to a level of not more than 0.25 pH), a trypsin inhibitor and oligosaccharides (to a level of not more than 2%);

- obtaining high quality processed products with increased initial humidity, improving the nutritional properties of soy and grain due to a deeper conversion of starch into an easily digestible form;

- reduction of energy consumption of the processing process due to deeper air purification in the recirculation, air purification and heating systems;

- increase the range of processed raw materials, due to the expansion of the range of the initial moisture content of the raw materials.

The installation for testing soybeans and processing grain bases for instant products can be used in the food industry in the production of food products containing soybeans, in the production of instant food products on a grain basis, as well as in the feed industry in the production of highly nutritious feed.

The practical industrial applicability of the installation is straightforward. The installation is made in the form of a cabinet, all structural elements are mounted on a frame made of metal profiles. Connection elements, support stands, product processing devices are made from the condition of ensuring mechanical strength, taking into account the mass of the processed product. Biological protection of the installation is provided by protective covers and a closed structure.

The installation makes the most of commercially available components and devices: VT-300-45-2.1 and 1.0 EV-1-4-4-3270 fans, AIP100S4-1P44 electric motor, M-168 magnetron with power supply and closed cooling system based on water radiator 3302-1301.010-34 and electric pump P8-ONV-M ..

The installation is made in the form of a structurally complete separate module, is easily interfaced with existing equipment, and is built into existing legume processing lines. Power supply - an industrial three-phase electrical network with a voltage of 380 V, 50 Hz.

Claims (1)

An installation for testing soybeans and processing a grain base for instant products, containing a loading hopper, an irradiation chamber in the form of a microwave camera with a microwave energy source, exhaust and pump fans, a closed system for recirculation, cleaning and heating of air, a conditioner-dosing unit, and a pneumatic conveying system, a heat exchange device formed by three concentric vertically arranged bodies, in the upper part an outer continuous and intermediate perforated, made in the form of truncated cones, connected connected to the loading hopper, in the lower part the bottom of the outer casing and the intermediate are connected to the input of the irradiation chamber, the inner casing forms a uniform gap with its perforated part with the intermediate casing along its entire length and its upper part is connected to the exhaust duct of a closed air recirculation, cleaning and heating system , which is connected through a cyclone to a pipe of an exhaust fan connected through an electric heater to the outer casing of a heat exchanger, characterized in that the heat exchanger has an annular groove located obliquely on the inner cone-shaped surface of the continuous upper part of the inner case, the bottom point of the groove is located on the plane of connection with the lower perforated part of the inner case and is connected to the outlet pipe, in a closed system for recirculation, cleaning and heating of air between the cyclone and the pipe of an exhaust fan a steam separator is installed, equipped with a supply air pipe with a valve, a drain valve, a pneumatic product pipe from the transportation system through the filtering device is connected to the exhaust pipe of a closed-circuit recirculation, air purification and heating system.