WO2020228760A1 - 一种智能型层架循环履带式固态发酵设备及有氧固态发酵方法 - Google Patents

一种智能型层架循环履带式固态发酵设备及有氧固态发酵方法 Download PDF

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Publication number
WO2020228760A1
WO2020228760A1 PCT/CN2020/090179 CN2020090179W WO2020228760A1 WO 2020228760 A1 WO2020228760 A1 WO 2020228760A1 CN 2020090179 W CN2020090179 W CN 2020090179W WO 2020228760 A1 WO2020228760 A1 WO 2020228760A1
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Prior art keywords
fermentation
fermentation tank
tank
shelf
concentration
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PCT/CN2020/090179
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English (en)
French (fr)
Inventor
肖毅
肖兵南
王会明
刘莹莹
蒋小文
Original Assignee
湖南民康生物技术研究所
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Priority claimed from CN201920682385.2U external-priority patent/CN210151096U/zh
Priority claimed from CN201910433292.0A external-priority patent/CN110157613B/zh
Application filed by 湖南民康生物技术研究所 filed Critical 湖南民康生物技术研究所
Publication of WO2020228760A1 publication Critical patent/WO2020228760A1/zh
Priority to ZA2021/08829A priority Critical patent/ZA202108829B/en

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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M1/00—Apparatus for enzymology or microbiology
    • C12M1/02—Apparatus for enzymology or microbiology with agitation means; with heat exchange means
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M1/00—Apparatus for enzymology or microbiology
    • C12M1/16—Apparatus for enzymology or microbiology containing, or adapted to contain, solid media
    • C12M1/18—Multiple fields or compartments
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M1/00—Apparatus for enzymology or microbiology
    • C12M1/34—Measuring or testing with condition measuring or sensing means, e.g. colony counters
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M1/00—Apparatus for enzymology or microbiology
    • C12M1/36—Apparatus for enzymology or microbiology including condition or time responsive control, e.g. automatically controlled fermentors
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M1/00—Apparatus for enzymology or microbiology
    • C12M1/36—Apparatus for enzymology or microbiology including condition or time responsive control, e.g. automatically controlled fermentors
    • C12M1/38—Temperature-responsive control

Definitions

  • the invention relates to the technical field of solid-state fermentation, in particular to a layered rack circulating crawler type solid-state fermentation equipment and a solid-state fermentation method.
  • Anaerobic fermentation is mainly anaerobic bacterial fermentation, including the decomposition of cellulose, sugar and protein hydrolysis to produce alcohol, acid and methane (biogas), etc., suitable for waste water biological treatment, wine and vinegar and other food production, the process is slow ; Aerobic fermentation is the decomposition and transformation of organic matter by aerobic bacteria (bacteria, fungi, actinomycetes) under aerobic conditions, which can produce substances needed by people under artificial control. The fermentation process is relatively fast. It is used in medicine, Industrial production such as feed, food and waste treatment. Biological fermentation is divided into solid and liquid fermentation according to the form.
  • controllable precision fermentation is mostly liquid fermentation; solid fermentation is mostly extensive fermentation, which is widely used in production and life.
  • solid-state fermentation especially aerobic solid-state fermentation, has significant characteristics and advantages: wide sources of raw materials, large fermentation volume, high efficiency, low production cost, wide applicability, etc. Therefore, it is widely used in the fields of biological medicine, biological food, biological feed and veterinary medicine, biological pesticide and fertilizer, biological chemical industry and environmental purification.
  • Fermentation equipment is the foundation of the fermentation industry. With the improvement of fermentation technology, controllable and precise fermentation is required, and the requirements for equipment are also getting higher and higher.
  • liquid fermentation equipment Fermentation tank system
  • solid-state fermentation equipment lags behind, so far there is no conditional controllable solid-state fermentation equipment that can meet the needs of industrial production. This severely restricts the research and application of solid-state fermentation technology.
  • the equipment manufacturing cost is high and the operation is inconvenient.
  • Xiao Yi et al. reported in 2015 a kind of crawler-type fermentation tank (ZL 201510388026.2), and wrote an article "10m 2- layer crawler-type fermentation tank production and performance measurement” and "fermented dross to produce high-activity and high-nutrition feed Analysis of the effect of the equipment and process of the “Hunan Agricultural Science” in 2017 Issue 10 and “Feed Industry” Issue 2018.11;
  • the equipment is a double-layer conveyor belt with a complex structure, less compactness, and a large area. Material conveying is not smooth; lack of supporting material handling (disinfection, etc.) conveying equipment may easily cause material contamination in the process.
  • Solid-state fermentation is a kind of natural fermentation, which is different from liquid submerged fermentation.
  • the most notable features are low water activity, poor mass and heat transfer, and uneven fermentation.
  • the growth of bacteria, the absorption of nutrients and the secretion of metabolites are not uniform everywhere, making it difficult to detect and control fermentation parameters, and many liquid fermentation biosensors cannot be applied to solid fermentation.
  • the parameters of solid-state fermentation detection or regulation include medium water content (water activity), pH value, air humidity, CO 2 and O 2 content, temperature, and bacterial growth, but they have not been seen in the literature.
  • To the more complete mathematical models of solid-state fermentation although some research reports on the kinetics of solid-state fermentation, they all appear in the form of drawings, and there is no mature solid-state fermentation parameter detection and regulation system.
  • the 10M 2- layer circulating crawler fermentation tank (dynamic) reported by Xiao Yi et al. in 2018 is only a simple control of temperature and humidity, which is not intelligent.
  • the disinfection and transportation of solid-state fermentation materials is the key to ensuring that the fermentation process is free from contamination by bacteria and ensuring the quality of fermented products.
  • Most solid-state fermentation devices (boxes, tanks, etc.) cannot be directly sterilized by high-pressure and high-temperature sterilization, but the fermentation device is used first.
  • Jiang Qin et al. reported in 2011 that a disinfection and sterilization tank was installed above the fermentation tank.
  • the above-mentioned existing solid-state fermentation equipment all have their own shortcomings, especially they are not suitable for the fermentation of large fungi. Because the fermentation of large fungi requires stable temperature and humidity, sufficient oxygen and no bacteria, they also need shallower conditions. Fermentation materials and moderate turning and longer fermentation time (easy to be contaminated by bacteria); among the above equipment, only shallow pan fermentation reactors, disc fermentation reactors and fluidized bed fermentation reactors can barely be used, but all It is difficult to strictly meet the fermentation requirements, and large-scale safe (non-polluting) production cannot be implemented. It can be seen that the research and development of new intelligent large-scale solid-state fermentation equipment is the key to solving the bottleneck restricting the development of the solid-state fermentation industry.
  • the purpose of the present invention is to provide a tier-frame circulating crawler solid-state fermentation equipment and a solid-state fermentation method; it solves the problem that the solid-state fermentation equipment in the prior art cannot fully agitate, cannot circulate materials, etc.
  • the technical problems of difficult mass heat transfer and difficult fermentation process control also solve the problems of large area of existing fermentation equipment and low space utilization.
  • a layer frame circulating crawler solid-state fermentation equipment comprising a fermentation tank, the fermentation tank is provided with a feed inlet and a discharge port, and the fermentation tank is provided with a lifting bed frame circulating crawler fermentation bed or a spiral bed frame circulating crawler fermentation bed,
  • the lifting-type bed frame circulating crawler fermentation bed further includes at least one fermentation bed, and further includes a hoist.
  • the fermentation bed includes at least two crawler-type layer frames, and each layer frame is laid in parallel from bottom to top.
  • the rear end of the lowermost shelf of the first stirring shaft and the second stirring shaft in the receiving trough is located above the receiving trough; the hoist has at least one The feeding hopper that moves between the receiving trough and the receiving hopper.
  • a circular conveying path is formed between the moving track of the hoist and the multi-layered crawler, so as to realize the circulating material turning, the agitator shaft fully agitates the material, and the leveler flattens the material, which accelerates the mass and heat transfer, greatly Improve the balance and efficiency of fermentation.
  • the hoist has an endless conveyor belt
  • the feeding hopper is arranged outside the endless transmission belt
  • one end of the endless conveyor belt extends into the receiving groove
  • the other end of the endless conveyor belt is connected with the receiving hopper.
  • the fermentation tank is also provided with a temperature monitoring unit and/or a humidity monitoring unit and/or a pH value monitoring unit composed of conventional sensors And/or O 2 concentration monitoring unit and/or CO 2 concentration monitoring unit and/or pressure monitoring unit and/or shelf transmission speed monitoring unit; each monitoring unit is electrically connected to the controller.
  • the controller is used to monitor the temperature, humidity, PH value, O 2 concentration, CO 2 concentration, pressure, rack transmission speed and other parameters to realize intelligently controlled precise fermentation.
  • the material disinfection and sterilization conveying tank includes a special-shaped sandwich sterilization pot.
  • the sterilization pot is provided with a material input port and a bacteria input port, and the bottom of the sterilization tank is provided with a spiral stirring
  • the outlet of the screw agitator can be connected to the feed inlet.
  • the materials after the materials are disinfected and sterilized, they can be connected to the fermentation tank through the screw agitator and automatically sent into the fermentation tank to avoid contamination by bacteria.
  • the material sterilization conveying tank can be used for multiple fermentation tanks.
  • the equipped material disinfection and sterilization conveying tank can also produce high-pressure steam for the sterilization and sterilization of the fermentation tank, and the produced high-temperature sterilized water can be used for fermentation and humidification.
  • One machine has multiple uses, energy saving and economical.
  • the fermentation tank body is assembled by multiple panels to form a strictly sealed tank body.
  • Single or multiple disinfection and sterilization of ultraviolet light, olfactory oxygen (olfactory oxygen amount ⁇ 40mg/m 3 ) and high-pressure steam are carried out in the cabinet to ensure The inside of the box is thoroughly disinfected and sterilized.
  • the size of the fermentation tank can be designed and manufactured according to needs to meet the needs of different production plants, and it is convenient to install, disassemble and transport.
  • an air supply and circulation system which includes an air purification and delivery device and an exhaust device such as air filtration, purification, heating, and humidity control.
  • the number of layers of the crawler type shelf is an even number.
  • the number of layers of the crawler-type shelf is even, so that the rear end of the lowest layer is convenient for docking with the receiving trough.
  • the present invention also configures a CIP cleaning system (cleaning in place) on the fermentation tank for cleaning and disinfecting equipment in the fermentation tank.
  • the CIP cleaning system includes several cleaning liquid nozzles and cleaning scrapers (or cleaning brushes), the cleaning liquid nozzles are preferably arranged at the front end of the endless conveyor belt, and the cleaning scrapers (or cleaning brushes) are arranged Below the circulating crawler, in the specific implementation process of the present invention, when the cleaning liquid nozzle sprays the disinfectant, the conveyor belt is activated for disinfection and sterilization with the assistance of the cleaning scraper (or cleaning brush).
  • the present invention also provides a solid-state fermentation method, which adopts the tier-frame circulating crawler-type solid-state fermentation equipment, including the following steps:
  • Step A1 the inoculum enters the receiving trough in the fermentation tank from the feed port;
  • Step A2 the hoist is running, and the feeding hopper transports the inoculum in the receiving trough to the receiving hopper;
  • Step A3 the inoculum enters the front end of the uppermost shelf from the receiving hopper;
  • Step A4 each shelf moves, and when the inoculum material reaches the rear end of the upper shelf, it falls into the front end of the adjacent lower shelf until the inoculation material reaches the rear end of the lowest shelf;
  • Step A5 the inoculum material falls into the receiving trough from the rear end of the lowest shelf
  • Step A6 repeat steps A2 to A5 until the fermentation of the inoculum is completed
  • Step A7 the fermented material in the receiving tank is sent out of the fermentation tank from the discharge port.
  • one or more of the temperature and/or humidity, pH value, CO 2 concentration, O 2 concentration, pressure and rack transmission speed of the fermentation tank are monitored. among them:
  • Shelf gear speed monitoring process comprises: a feedback controller adjusting ⁇ 7 by the temperature difference between the temperature of the material inside the space within the control of the fermentation 0.5 °C, O 2 concentration in the control box and the fermentation material within 1% difference between the O 2 concentration of the .
  • the difference between ⁇ PV 1(n) and the difference between the O 2 concentration in the fermentation tank and the O 2 concentration of the material ⁇ PO 1(n) is processed to synthesize e(n) as the input, and the motor running speed PID control signal u for controlling the transmission speed of the shelf (n) as output.
  • the material disinfection and sterilization conveying tank includes a special-shaped sandwich sterilization pot.
  • the sterilization pot is provided with a material input port and a bacteria input port, and the bottom of the sterilization tank is provided with a spiral stirring
  • the outlet of the screw agitator can be connected to the inlet;
  • the process of obtaining the inoculum in the fermentation tank includes the following steps:
  • Step B1 Put the fermentation material into the sterilization pot from the material input port;
  • Step B2 the fermentation material is sterilized in the sterilization pot
  • Step B3 cooling the material sterilization and conveying tank
  • Step B4 under aseptic conditions, connect the outlet of the screw agitator to the feed inlet of the fermentation tank;
  • Step B5 Put the strain from the strain input port into the sterilization pot
  • Step B6 the spiral stirrer works, and the inoculum in the sterilization pot is fed into the fermentation tank through the feed port.
  • it also includes using the material sterilization and sterilization conveying tank to generate steam for sterilization and sterilization of the fermentation tank, and the generated high-temperature sterilized water is used for fermentation and humidification of the material.
  • the present invention also provides an alternative solution for replacing the lifting circulating crawler with the spiral circulating crawler, which is specifically as follows:
  • the said layer frame circulating crawler type solid state fermentation equipment includes a fermentation tank, a plurality of fermentation bed frames are installed in the tank body of the fermentation tank, and two adjacent fermentation bed frames are connected through corresponding connecting bed frames; the fermentation One of the bed frames is connected to the feed receiving hopper;
  • Each fermentation bed frame and the connecting bed frame are equipped with one or several layers of conveyor belts as the fermentation bed, and the conveyor belts are arranged horizontally or obliquely; the feeding end of each layer of the conveyor belt of the fermentation bed frame is installed A flattener, a mixer is installed at the discharge end of the conveyor belt of the fermentation bed frame;
  • the rotating drum of the conveyor belt and the agitator are driven by a driving device.
  • the inclination angle of the conveyor belt of the fermentation bed frame is ⁇ 30° relative to the horizontal plane.
  • the two fermentation bed frames and the two connecting bed frames are connected up and down correspondingly, forming a spiral shape, so that the materials can be conveyed from the front end of the lowermost layer of the first fermentation bed frame to the second
  • the rear end of the uppermost layer of the second fermentation bed frame slides down to the feed receiving hopper through a sliding trough; the conveyor belt connecting the bed frame is in a refractive shape or a straight shape.
  • the driving device is a motor installed outside the box, and the drive shaft of the motor extends into the box and drives the drum of the conveyor belt and the agitator to rotate.
  • one motor drives the first conveyor belt of the first fermentation bed frame, the first conveyor belt of the first connection bed frame, and the agitator to operate, and at the same time, it runs through a chain and gear Connect to drive the conveyor belts and agitators of other layers to run;
  • another motor drives the first conveyor belt of the second fermentation bed frame, the first conveyor belt of the second connection bed frame and the agitator, and are connected with gears through a chain Drive other conveyor belts and mixers to run.
  • an air circulation system is provided in the tank. More preferably, the air circulation system includes an air supply and temperature control device and an exhaust system connected to the box; the air supply and temperature control device communicates with the inside of the box; an air outlet is opened on the top of the box, and the outlet The air outlet is provided with a humidifying device for adjusting the internal humidity of the box; the air exhaust system includes an air outlet provided on the top of the box, and an exhaust fan connected to the exhaust pipe is installed on the air outlet; One end extends to the bottom of the box. Therefore, the temperature and humidity can be adjusted conveniently, and the ventilation effect can be ensured, thereby facilitating fermentation.
  • a feeding window is opened on the side of the box body, and the position of the feeding window corresponds to the position of the feeding receiving hopper; the feeding window is provided with a feeding port, A discharge port is opened obliquely below the window.
  • an atomizer and a heating device are arranged in the box.
  • the inclination angles of the two adjacent fermentation bed frames and the two conveyor belts connecting the bed frames are opposite, and the refraction shape of the conveyor belt connecting the bed frames is more suitable than the straight shape.
  • the lifting type fermentation bed hoist is combined with the layer frame circulating crawler type fermentation bed, which is compact in structure, circulates the material, and runs smoothly; the spiral type fermentation bed and the connecting bed All crawlers can be used as fermentation beds, with high effective space utilization and relatively low manufacturing costs;
  • the control algorithm optimizes the control parameters, optimizes the environment, and realizes precise fermentation, which greatly improves the fermentation efficiency and product quality;
  • the equipped material sterilization and sterilization conveying tank has the functions of sterilization, inoculation and stirring, and mobile conveying (one device can (For multiple fermentation tanks); at the same time, it can produce high-pressure steam for sterilization and sterilization of the fermentation tank at the same time as the materials are sterilized, and the generated high-temperature sterilized water is used for material fermentation and humidification, that is, one machine has multiple functions; (4) Circul
  • Figures 1-12 are related drawings of the tier-frame circulating crawler solid-state fermentation equipment in Example 1, in which:
  • Figure 1 is a schematic diagram of the appearance of the fermentation tank
  • Figure 2 is the front view of the fermentation bed and hoist
  • Figure 3 is a top view of the fermentation bed and hoist
  • FIG. 4 is a schematic diagram of the drive system of the present invention.
  • Figure 5 is a front view of a fermentation tank with a fermentation bed
  • Figure 6 is a top view of a fermentation tank with a double row fermentation bed (with the top plate removed);
  • Figure 7 is a top view of a fermentation tank with a single-row fermentation bed (with the top plate removed);
  • Figure 8 is the front view of the air supply box system
  • Figure 9 is the appearance view of the material sterilization conveying tank
  • Figure 10 is a cross-sectional view of the material disinfection and sterilization transport tank
  • FIG. 11 is a block diagram of the electrical control part of the present invention.
  • Figure 12 is a block diagram of the speed control system of the shelf
  • 1 is the fermentation tank
  • 101 is the feed port
  • 102 is the drive motor
  • 103 is the door
  • 104 is the observation window and sampling port
  • 105 is the exhaust port
  • 106 is the discharge port
  • 107 is the valve
  • Valve 108 is the discharging trough
  • 2 is the fermentation bed
  • 201 is the shelf
  • 202 is the stopper
  • 203 is the leveler
  • 3 is the elevator
  • 301 is the feeding hopper
  • 302 is the endless conveyor belt
  • 4 is the receiving hopper
  • 5 is the receiving tank
  • 501 is the first stirring shaft
  • 502 is the second stirring shaft
  • 6 is the controller
  • 601 is the temperature monitoring unit
  • 602 is the humidity monitoring unit
  • 603 is the pH monitoring unit
  • 604 is the O 2 concentration monitoring Unit
  • 605 is the CO 2 concentration monitoring unit
  • 606 is the pressure monitoring unit
  • 607 is the transmission speed monitoring unit of the shelf
  • 608 is the touch screen human-machine interface
  • 804 is an air filter
  • 805 is a blower
  • 806 is a bag-type air filter
  • 807 is a heat sterilizer
  • 808 is an air supply pipe
  • 809 is a high-efficiency air filter
  • 810 is an air outlet
  • 9 is a honeycomb humidity control device
  • 10 is the control cabinet
  • 11 is the exhaust fan.
  • Figure 13 is a front view of a fermentation tank with a fermentation bed in the layer frame circulating crawler solid state fermentation equipment in Example 3, where C is a CIP nozzle and D is a cleaning scraper or cleaning brush;
  • Figures 14-15 are related drawings of the tier-frame circulating crawler solid-state fermentation equipment in embodiment 4, in which:
  • Fig. 14 is a schematic diagram of the driving connection device for the fermentation bed
  • Figure 15 is a partial enlarged view of B in Figure 14;
  • Fig. 16 is a partial enlarged view of A in Fig. 14;
  • Figure 17 is a schematic diagram of the paver described in Example 4; where a) is a front view and b) is a left view;
  • Figure 18 is a schematic diagram of the agitator described in Example 4.
  • Figure 19 is an outline view of the box of the embodiment 4.
  • Figure 20 is a perspective view of the box body of Embodiment 4.
  • Figure 21 shows the refracting conveyor belt bed frame in embodiment 5: 3'is the refracting conveyor belt, C is the CIP nozzle, and D is the cleaning scraper or cleaning brush under the belt.
  • the layer frame circulating crawler solid state fermentation equipment of this embodiment includes: fermentation tank 1, layer frame crawler fermentation bed 2, disinfection system, air supply system, parameter detection and control system, material sterilization and transportation, etc., with complete configuration and structure Compact, coordinated and applicable.
  • Fermentation tank 1 is made of heat-preserving, temperature-resistant and corrosion-resistant materials, and is assembled by 6 large (or small pieces assembled into large pieces) panels, that is, 4 walls: door 103 at both ends, middle and lower parts on one side Purified air inlet (behind the air purifying and feeding device 8), one side is provided with an inlet 101, a transmission motor 102 (mechanical sealing hole of the motor shaft), a steam inlet, an observation window and a sampling port 104, and an outlet on the other side Feed port 106; 2 upper and lower top plates and bottom plates: the top plate is equipped with a valve valve 107 and an exhaust port 105 with a fan, and an ultraviolet lamp and an oxygen generator are installed inside; the bottom plate is equipped with a bed frame fixing device and a closed pipe hole for sewage drainage; each The board connection is fixed with hard materials and screws, which is easy to combine and install, and it is convenient to disassemble and transport. See Figure 1 and Figure 5.
  • Layer-frame crawler fermentation bed 2 is composed of double layers (4 or 6 layers), which is made of corrosion-resistant and high-temperature food-grade materials (PVC, PU, EP, silica gel, nylon, It is composed of a synchronous conveyor belt made of stainless steel, etc. and a stainless steel bracket. Each layer is equipped with 5-20cm high baffle plates.
  • the front end of the uppermost shelf 201 is equipped with a hopper 4, followed by a stirring and leveling device (shaft). Root or multiple roots; the running directions of each adjacent 2 layers are opposite, connected by gears and chains, driven by motors outside the box (see Figure 2, Figure 4).
  • the fermentation bed 2 includes at least two crawler-type shelves 201, and each layer shelf 201 is laid out sequentially from bottom to top, and the moving directions of adjacent layer shelves 201 are opposite.
  • the blanking place is provided with a blocking groove 202, and the fermentation tank 1 A receiving trough 5 located below the feed opening 101 is provided inside, and the rear end of the lowermost shelf 201 is located above the receiving trough 5.
  • Each box is equipped with 1 set (single row) or 2 sets (double row) of fermentation bed frame.
  • Lifting device It includes two parts, the melon hoist 3 and the receiving trough 5.
  • the hoist 3 has at least one feeding hopper 301 that can move between the receiving trough 5 and the receiving hopper 4.
  • the hoist 3 has an endless conveyor belt 302, the feeding hopper 301 is arranged on the outer side of the endless transmission belt, and the shape of the feeding hopper 301 is melon-shaped.
  • One end of the endless conveyor belt 302 is set in the receiving groove 5, and the other end of the endless conveyor belt 302 is connected with the receiving hopper 4.
  • the elevator 3 is a material lifting device (see Figure 3) composed of a melon scoop with a bottom (crawler) fixed on a stainless steel chain; the lifting device is installed on a bar-shaped (side view) bracket and driven by a motor outside the box.
  • the receiving trough 5 is in the shape of a long strip, and is placed at the head of the first layer of the fermentation bed frame below the elevator 3 to receive the fermentation materials from the initial input material outside the fermentation tank 1 and the conveyor belt of the fermentation bed 2 for the elevator 3 Lifting;
  • the second stirring shaft 502 is a toothed stirring shaft at the proximal end of the fermentation bed 2, which is mainly responsible for stirring the falling materials from the conveyor belt.
  • a closable baffle is provided at one end of the receiving trough, and the baffle is connected with the discharging trough 108.
  • the material is fed into the material receiving tank 5 at the lower end of the elevator 3 through the feed pipe outside the fermentation tank 1, and the material is stirred and spread by the stirring shaft in the material receiving tank 5, and the material is lifted to the uppermost shelf 201 by the elevator 3 (from bottom to bottom).
  • the receiving hopper 4 of the fourth layer from the top is stirred and spread by the third stirring shaft 204, and then the material is conveyed backward by the fermentation bed belt, and falls into the front end of the third layer shelf 201; the third layer shelf 201 is backward Turning in the direction, the material will be transported and dropped into the front end of the second layer shelf 201; the second layer shelf 201 will run backward again, and the material will be transported and dropped into the front end of the first layer shelf 201; the first layer shelf 201 will move backward, The material is transferred to the receiving tank 5 at the lower part of the elevator 3, and then the material is lifted by the elevator 3 to the receiving hopper 4 at the upper part of the fermentation bed 2, and enters the next transfer cycle (see Figure 2). In order to ensure that the materials of the upper shelf 201 accurately fall into the lower shelf 201, the front end of the other shelf 201 except for the uppermost shelf 201 is provided with a blocking groove 202.
  • the fermented material is pushed to one end by the stirring shaft in the receiving trough 5 under the elevator 3 (clutch disengaged and stopped) (movable baffle is lowered), and passed out of the box through the moving chute from the discharge port 106 ( Single row bed frame) or from the door of the box end (double row bed frame).
  • Solid-state fermentation equipment also includes:
  • Air purification and conveying device set up an air purification and feeding device 8 outside the fermentation tank 1, including a wind box body 801, which is divided into a main box 802 and a sub box 803.
  • the main box 802 is equipped with a blower 805,
  • the air inlet of the box 802 is provided with an air pre-filter 804, the main box 802 and the auxiliary box 803 are connected with a secondary bag-type air filter 806, followed by a heater 807, the auxiliary box 803 and the air supply pipe 808 are connected, and the air supply pipe
  • a three-stage high-efficiency air filter 810 is provided in the outlet 809 of the pipe extending into the fermentation tank 1.
  • the air is filtered, purified, heated and sterilized for three times and sent into the fermentation tank 1 to ensure the sterility and proper temperature of the inlet air. See Figure 8.
  • Heating device A heating device is also installed on both sides of the box, which is mainly used for initial heating and auxiliary heating.
  • Humidification device 9 The honeycomb humidification device 9 made of water-absorbing material is installed at the air outlet of the purified air ( Figure 6 and Figure 7) to humidify the dry air that is blown in. At the same time, an ultrasonic atomizer is installed in the fermentation tank 1. Humidity.
  • pH adjustment device set up an acid bottle and a lye bottle (connected with the atomizer by a hose) in the fermentation tank 1, respectively containing weak acid solution (carbonic acid, organic acid, etc.) and weak alkali solution (ammonia, soda water) Wait).
  • weak acid solution carbonic acid, organic acid, etc.
  • weak alkali solution ammonia, soda water
  • Exhaust air and cooling device Exhaust fans 11 are provided at the air outlets 502 at the four corners of the top of the fermentation tank 1. Fresh purified air enters the box from the bottom of the box or the center of the top of the box, and is discharged from the air outlet after the diffusion cycle to achieve rapid air exchange, cooling and dehumidification.
  • Pressure adjustment device a valve 107 is installed in the center of the top of the fermentation tank 1 for pressure adjustment in the tank.
  • a control cabinet 10 is fixed outside the fermentation tank 1, and a controller 6 is arranged in the control cabinet 10.
  • the controller 6 is a PLC or a single-chip microcomputer, and performs human-machine interaction with the controller 6 through a touch screen man-machine interface 608.
  • the fermentation tank 1 is also provided with a temperature monitoring unit 601, a humidity monitoring unit 602, a pH value monitoring unit 603, an O 2 concentration monitoring unit 604, a CO 2 concentration monitoring unit 605, a pressure monitoring unit 606, and a rack transmission speed monitoring unit 607; temperature monitoring unit 601, humidity monitoring unit 602, PH value monitoring unit 603, O 2 concentration monitoring unit 604, CO 2 concentration monitoring unit 605, pressure monitoring unit 606 and shelf transmission speed monitoring unit 607 are all connected to the controller 6 Connect (see Figure 11).
  • the PLC or single-chip microcomputer and temperature sensor, control electric heater, air supply box heating device, space humidity sensor, material moisture content (water activity) sensor, air inlet humidifier, atomization device, pH sensor, Weak acid-base regulator, pressure sensor, exhaust valve, O 2 sensor, CO 2 sensor, air supply box blower, exhaust fan, bed belt motor speed controller, etc. are connected.
  • the solid-state fermentation equipment also includes a mobile (or fixed) material disinfection and sterilization conveying tank 7.
  • the material disinfection and sterilization conveying tank 7 includes a special-shaped sandwich autoclave 701.
  • the sterilization tank 701 is provided with a material input port 702 and bacteria For the input port 703, a spiral stirrer 704 is provided at the bottom of the sterilization pot 701 (see FIG. 9 and FIG. 10).
  • the material disinfection and sterilization conveying tank 7 is equipped with brackets and wheels, which is movable and convenient for feeding.
  • the temperature is quickly cooled (replacing the interlayer hot water to cold water), and the material sterilization and sterilization conveying tank 7 is pushed to the fermentation tank 1, and then the screw is stirred under aseptic conditions (on the flame)
  • the outlet of the device 704 is docked with the feed inlet 101 of the fermentation tank 1 to connect the bacteria, and the screw agitating shaft is turned on to mix the bacteria and materials into the fermentation tank 1.
  • the material disinfection and sterilization conveying tank 7 is provided with an air outlet pipe 705 with a valve on the top of the tank, which is used to supply air and sterilize the fermentation tank 1; there is also an outlet pipe valve 706 at the lower side of the material disinfection and sterilization conveying tank 7 for Supply sterile water.
  • one of the following two disinfection methods or a combination of two methods is selected for enhanced disinfection and sterilization according to the conditions;
  • an olfactory oxygen generator is arranged outside the box, and the olfactory oxygen is generated and passed into the box for disinfection.
  • the method for solid-state fermentation by adopting the tier-frame circulating crawler solid-state fermentation equipment includes:
  • Step A1 the inoculum enters the receiving trough 5 in the fermentation tank 1 from the feed port 101;
  • Step A2 the hoist 3 runs, and the hopper 301 transports the inoculum in the receiving trough 5 to the receiving hopper 4;
  • Step A3 the inoculum enters the front end of the uppermost shelf 201 from the receiving hopper 4;
  • Step A4 each shelf 201 moves, and when the inoculum material reaches the rear end of the upper shelf 201, it falls into the front end of the adjacent lower shelf 201 until the inoculation material reaches the rear end of the lower shelf 201;
  • Step A5 the inoculum material falls into the receiving trough 5 from the rear end of the lowermost shelf 201;
  • Step A6 repeat steps A2 to A5 until the fermentation of the inoculum is completed
  • Step A7 the fermented material in the receiving tank 5 is sent out of the fermentation tank 1 from the discharge port 106 through the discharge tank 108.
  • Temperature monitoring temperature control input and output configuration composed of temperature sensor, electric heater, hot air device, and exhaust fan, using existing mature closed loop PID (proportion, integral, derivative) controller 6 Carry out control and make certain appropriate parameter adjustments according to the characteristics of the fermentation equipment to achieve the advantages of control accuracy and high energy saving.
  • PID proportion, integral, derivative
  • the controller 6 is based on the existing PID control algorithm based on genetic algorithm and uses the advance function to set the value of the temperature control ratio.
  • the specific parameter adjustment methods are as follows:
  • SV 1 (n) is the set temperature control value of fermentation tank 1
  • PV 1 (n) is the actual temperature value of fermentation tank 1
  • ⁇ 1 is the temperature deviation amplification factor, and the difference limit value is assumed to be ⁇ 1 , 0 ⁇ 1 ⁇ 0.05.
  • the value of ⁇ 1 is inversely proportional to ⁇ 1 , and the smaller ⁇ 1 is, the temperature deviation amplification factor increases.
  • the closed loop controller continuously feeds back and adjusts ⁇ 1 , so that the temperature of the fermentation tank 1 is between 20°C and 45°C.
  • Humidity monitoring the input and output configuration of humidity control is composed of space humidity and material water content (or water activity) sensors, humidifier, and atomization device, and the existing PID control algorithm based on genetic algorithm is used for fermentation tank 1 Real-time regulation of internal humidity. Use the advance function to set the value of the humidity control ratio.
  • the specific parameter adjustment methods are as follows:
  • SH 1 (n) is the set humidity control value of fermentation tank 1
  • PH 1 (n) is the actual humidity value of fermentation tank 1;
  • ⁇ 2 is the humidity deviation amplification factor, and the difference limit value is assumed to be ⁇ 2 , 0 ⁇ 2 ⁇ 0.1.
  • the value of ⁇ 2 is inversely proportional to ⁇ 2 , and the smaller ⁇ 2 is, the temperature deviation amplification factor increases.
  • the closed loop controller continuously feeds back and adjusts ⁇ 2 , so that the humidity of the fermentation tank 1 is between 70% and 85%.
  • PH is composed of a pH sensor (additional drip head to ensure that the material at the measurement site contains a certain amount of water) and a weak acid-base solution (carbonic acid, organic acid, ammonia, soda water, etc.) adjustment device (implemented through an atomizer)
  • the input and output configuration of value control adopts the existing PID control algorithm based on genetic algorithm to realize real-time regulation of the PH value in the fermentation tank 1.
  • the advance function is used to set the value of the PH value control ratio, and the specific parameter adjustment methods are as follows:
  • SPH 1 (n) is the set PH value control value of fermentation tank 1
  • PPH 1 (n) is the actual PH value of fermentation tank 1;
  • ⁇ 3 is the pH deviation amplification factor, and the difference limit value is assumed to be ⁇ 3 , 0 ⁇ 3 ⁇ 0.05.
  • the value of ⁇ 3 is inversely proportional to ⁇ 3 , and the smaller ⁇ 3 is, the PH value deviation amplification factor increases.
  • EPH 2 (n) is the actual PH value control of fermentation tank 1 at time n value
  • the closed loop controller continuously feeds back and adjusts ⁇ 3 , so that the PH value of the fermentation tank 1 is 6-8.
  • Pressure monitoring The input and output configuration of pressure control is composed of a pressure sensor and an exhaust valve, and the pressure value in the fermentation tank 1 is controlled in real time based on the existing PID control algorithm based on genetic algorithm.
  • Use the advance function to set the value of the pressure value control ratio, and the specific parameter adjustment methods are as follows:
  • SF 1 (n) is the set pressure control value of fermentation tank 1
  • PF 1 (n) is the actual pressure value of fermentation tank 1;
  • ⁇ 6 is the temperature deviation amplification coefficient, and the difference limit value is assumed to be ⁇ 6 , 0 ⁇ 6 ⁇ 0.01.
  • the value of ⁇ 6 is inversely proportional to ⁇ 6 , and the smaller ⁇ 6 is, the pressure deviation amplification factor increases.
  • SF 2 (n) is the actual pressure control value of the fermentation tank 1 at time n :
  • the closed loop controller continuously feeds back and adjusts ⁇ 6 , so that the pressure jitter range of the fermentation tank 1 is -0.01Mpa ⁇ 0.01Mpa.
  • Gas concentration monitoring control input and output configuration composed of O 2 , CO 2 sensors, intake blower flow, and exhaust blower flow.
  • the existing PID control algorithm based on genetic algorithm is used to control the O 2 .
  • the CO 2 concentration value can be adjusted in real time.
  • Use the advance function to set the O 2 , CO 2 concentration value control ratio, the specific parameter adjustment method (taking O 2 concentration control as an example) is as follows:
  • SO 1 (n) is the set O 2 concentration control value of fermentation tank 1
  • PO 1 (n) is the actual O 2 concentration value of fermentation tank 1
  • ⁇ 4 is the O 2 concentration deviation amplification factor
  • the difference limit value is assumed to be ⁇ 4 , 0 ⁇ 4 ⁇ 0.05.
  • the value of ⁇ 4 is inversely proportional to ⁇ 4 , and the smaller ⁇ 4 is, the larger the coefficient of O 2 concentration deviation increases.
  • the closed loop controller continuously feeds back and adjusts ⁇ 4 so that the O 2 concentration of the fermentation tank 1 is between 5% and 25%.
  • Shelf transmission monitoring the difference between the space temperature in the fermentation tank 1 and the material temperature, the difference between the O 2 concentration in the fermentation tank 1 and the material O 2 concentration as the input, and the motor running speed that controls the transmission speed of the 201 as the output , input and output composed of the input-output configuration, the temperature difference between the inner space 1 and the material temperatures within the control of the fermentation tank 0.5 °C, control of the fermentation tank 1 O O 2 concentration with the material difference in concentration of 1% 2.
  • the speed control system of the shelf 201 is composed of four parts: a computer, a PID control module, an AC servo system, and a sensor detection unit.
  • the computer is connected to the encoder of the PID control module through the ISA bus, and can send speed or position commands, set PID adjustment parameters, and perform digital-to-analog (D/A) conversion through the ISA bus.
  • the converted analog signal is amplified by the AC servo amplifier to drive the AC motor.
  • the shaft end of the motor is equipped with an incremental photoelectric encoder.
  • the feedback signal is provided through the encoder.
  • the counting card accumulates the number of feedback pulses.
  • the speed feedback of the servo system is formed after comparison with the command pulse representing a given speed, forming a closed loop system.
  • the corresponding PID parameter setting is adopted according to the deviation range, and the speed control signal is converted into analog control voltage through digital-to-analog conversion, and output to the servo amplifier to adjust the motor Running speed to complete the desired speed control requirements.
  • the block diagram of the closed-loop control system is shown in Figure 12.
  • the PID controller can adjust the loop output to make the system stable.
  • the output of the PID controller is:
  • the transfer function of the PID regulator is:
  • the continuous function needs to be discretized, and the differential equation describing the continuous-time PID algorithm is changed to the differential equation describing the discrete-time PID, and the different output values at time n and n-1 are obtained respectively:
  • ⁇ U(n) is the increment corresponding to the control quantity at the nth moment
  • ⁇ is the switching coefficient of the integral term.
  • the integral separation PID control algorithm needs to set the integral separation threshold ⁇ . When
  • the process of obtaining the inoculum in the fermentation tank 1 includes the following steps:
  • Step B1 Put the fermentation material into the sterilization pot 701 from the material input port 702;
  • Step B2 the fermentation material is sterilized in the sterilization pot 701;
  • Step B3 cooling the material sterilization and conveying tank 7;
  • Step B4 under aseptic conditions, connect the outlet of the screw agitator 704 to the feed inlet 101 of the fermentation tank 1;
  • Step B5 Put the strain into the sterilization pot 701 from the strain input port 703;
  • step B6 the screw agitator 704 works to mix the sterilized material in the sterilization pot 701 with the access bacteria and send it into the fermentation tank 1 through the feed port 101.
  • This embodiment also includes using the material sterilization and sterilization conveying tank 7 to generate steam for the sterilization and sterilization of the fermentation tank 1, and the generated high-temperature sterilized water (interlayer water) is used for fermentation and humidification.
  • the material sterilization and sterilization conveying tank 7 to generate steam for the sterilization and sterilization of the fermentation tank 1, and the generated high-temperature sterilized water (interlayer water) is used for fermentation and humidification.
  • This embodiment combines the shallow pan loading of the shallow pan fermenter and the turning of dynamic solid fermentation equipment such as the disc fermenter, and the design is relatively complete automatic control, supporting material sterilization and sterilization conveying equipment and air purification heating
  • the gas supply equipment can carry out the full automatic solid aerobic fermentation, especially suitable for fungal fermentation.
  • the material circulation uses the melon-type elevator 3 and the layered crawler fermentation bed 2 to combine, and other types of elevators 3 and the layered crawler fermentation bed 2 can also be used; in this embodiment, blast air supply is used, and it can also be used Aseptic air conditioner; in this embodiment, a PLC controller system is used, and a control system composed of intelligent controllers such as PAC and DCS and various professional instruments, sensors and networks can also be used to realize automatic control of the entire process of industrial production.
  • the structure of the tier-frame circulating crawler solid-state fermentation equipment of this embodiment is the same as that of the first embodiment.
  • one of the following two disinfection methods or a combination of two methods is selected for enhanced disinfection and sterilization according to the conditions;
  • an olfactory oxygen generator is arranged outside the box, and the olfactory oxygen is generated and passed into the box for disinfection.
  • the disinfection and cleaning system equipped with CIP cleaning equipment outside the box, and a cleaning fluid spray head at the front end of the endless belt.
  • spray the disinfectant and open the endless belt at the same time with the assistance of the cleaning scraper (cleaning brush) , Disinfect and sterilize.
  • Example 1 The following is an application example of applying the equipment in Example 1 to a directional fermented fungal feed additive of traditional Chinese medicine residue in a health oral liquid.
  • Adopt intelligent double-row layer frame circulating crawler fermentation equipment fermentation bed 2 area: 1.5m ⁇ 5m ⁇ 4 layers ⁇ 2 rows, material disinfection and sterilization transportation tank 7 volume: 500L.
  • the first fermentation inoculate the liquid Candida utilis strain into the autoclaved Chinese medicine residue culture medium at 5%, and send it to the fermenter 1 (material thickness 5.0CM), and incubate at 30°C for 2 days until The medium is covered with white bacteria.
  • Second fermentation the first cultured traditional Chinese medicine residue fungus is inoculated with 10% liquid tiger milk mushroom strains through the feed port 101 of the incubator, cultured at 28°C for 2-3 days, until white hyphae grow ; 60 °C drying, crushing, packaging.
  • Determination of polysaccharide content sulfuric acid-phenol method combined with DNS colorimetric method to determine polysaccharide content.
  • UV method for total soap vanillin-perchloric acid colorimetric method
  • Yeast and large fungi can grow normally in their culture medium and environment in both fermentations (see Table 1).
  • Routine nutrient content determination after the second fermentation of the medicine residue, the protein increased by 48.75%; it also has certain changes (see Table 4).
  • a type of solid fermentation tank with a layer frame circulating conveyor belt the tank body is made of heat-insulating, temperature-resistant and corrosion-resistant materials, as shown in Figures 19 and 20, composed of 6 large blocks (or small blocks assembled into large blocks), that is, 4 walls
  • the body, the top plate, the floor, and the joints of each plate are fixed with hard materials and screws, which is easy to combine and install, and is convenient to disassemble and transport.
  • the two ends of the fermentation tank body are provided with doors 21, the sides are provided with a feed port 20, a discharge port 22, a mechanical seal hole 25 of the motor shaft, an observation window 17 is provided on both sides and both ends, and an air inlet 23 is provided on the top plate.
  • the exhaust vent 24 a UV lamp is installed inside.
  • the floor is equipped with bed frame fixing devices, heating devices and closed pipe holes for sewage drainage.
  • Layer frame circulating conveyor belt type fermentation bed Connect the layer frame conveyor belt, and set the two ends of the two-layer frame fermentation bed conveyor belt (set appropriate slope, slope ⁇ 30 degrees), so that the two layers are connected, as shown in Figure 13. , Forming a circulating conveying: feed window ⁇ the front end of the first shelf of the first fermentation bed frame (set with the feed receiving hopper 6 and agitator) ⁇ the rear end of the first shelf of the first fermentation bed frame ⁇ the first connecting shelf
  • the first layer ⁇ the rear end of the first shelf of the second fermentation bed frame ⁇ the front end of the first shelf of the second fermentation bed frame ⁇ the first layer of the second connecting shelf ⁇ the second shelf of the first fermentation bed frame
  • conveyor belt type fermentation beds are organically linked, and the material is circulated and turned smoothly.
  • Material turning and leveling As shown in Figure 14 and Figure 15, a flattener 9 with a strip is installed at the front end of each layer of each shelf. If necessary, the middle of the conveyor belt can also be installed and flattened. Device. A toothed drum agitator 8 is installed at the discharge point at the rear end of each layer of each layer.
  • a drive motor 12 is installed on each side of the box body, preferably a circulating conveyor belt drive motor.
  • the two motor shafts respectively extend into the lower layer of the first fermentation bed in the box body through corresponding mechanical seal holes 25 In the drum of the conveyor belt, the conveyor belt and the agitator 8 are driven, and then the conveyor belt and the agitator in other layers are driven by the chain and gear connection 7.
  • a steering gear 10 or a gear box is installed to drive the lower conveyor belt of the first connecting shelf 3 where the motor shaft extends to the intersection of the fermentation bed frame and the connecting bed frame, and then a chain and gear are connected to drive the conveyor belts of other layers of the connecting frame.
  • another motor is used to drive the second fermentation bed frame 2 and the conveyor belt and agitator connected to the second bed frame 4.
  • Two fermentation bed frames and two connecting layer frames can also be driven by four motors respectively.
  • a basic heating device 26 is installed at the bottom of the box, which is mainly used for auxiliary heating at the beginning and when the temperature is too low.
  • An air supply and temperature adjustment device 11 (such as a hot air blower) is installed at the air inlet of the ventilation system. , Air conditioning, etc.).
  • the air outlet is provided with a honeycomb-shaped humidity control device 14 made of water-absorbing material, and an atomizer 15 is also provided in the box for auxiliary humidity control.
  • the fan uses a motor speed regulator to control the speed and control the air intake, so as to achieve rapid heating and controllable ventilation, temperature and humidity, and ensure a suitable fermentation environment.
  • the water for the humidifier and atomizer in the box is sterilized and then input through the pipeline. Ensure that the fermentation process is pollution-free.
  • the structure of the layer frame circulating conveyor belt type solid fermentation tank in this embodiment is the same as that of the embodiment 4, except that the CIP system is set and the bed frame conveyor belt is connected to a refraction shape, and the details are shown in FIG. 21.

Abstract

本发明提供了一种层架循环履带式固态发酵设备及固态发酵方法，该固态发酵设备包括发酵箱以及发酵箱内部设置的循环履带，该循环履带的循环方式为以提升机提料的提升式循环或者输送带盘旋式循环；该层架循环履带式固态发酵设备结构紧凑，安装、拆卸与运输方便，相对制造成本低，空间利用率高；循环翻料，运行顺畅，无菌控制，发酵条件优化，可精准发酵，大大提高发酵效率与产品质量，可实行规模化的高效固体有氧发酵。该固态发酵方法包括：步骤A1，接种物料从进料口进入发酵箱内的接料槽；步骤A2，提升机运转，送料斗将接料槽内的接种物料运送至接料斗；步骤A3，接种物料从接料斗进入最上层层架的前端；步骤A4，各层架移动，接种物料到达上层层架后端时，经挡料槽落入下层相邻的层架前端，直到接种物料到达最下层层架的后端；步骤A5，接种物料从最下层层架的后端落入接料槽；步骤A6，重复步骤A2至A5直至接种物料发酵完成；步骤A7，接料槽内的发酵好的物料从出料口送出发酵箱。

Description

一种智能型层架循环履带式固态发酵设备及有氧固态发酵方法
本申请要求于2019年05月23日提交中国专利局、申请号为201910433292.0、发明名称为“一种层架循环履带式固态发酵设备及固态发酵方法”的中国专利申请的优先权；本申请还要求于2019年05月14日提交中国专利局、申请号为201920682385.2，名称为“一种固体发酵箱”中国实用新型专利的优先权，上述两个专利的全部内容通过引用结合在本申请中。
技术领域
本发明涉及固态发酵技术领域，特别涉及一种层架循环履带式固态发酵设备及固态发酵方法。
背景技术
生物发酵根据氧气的供给情况分为有(需)氧发酵和无(厌)氧发酵两类。厌氧发酵主要是厌氧细菌发酵起作用，包括分解纤维素、糖类和蛋白质水解，产生醇、酸和甲烷(沼气)等，适用于废物废水生物处理、酒和醋等食品生产，过程缓慢；有氧发酵是需氧菌(细菌、真菌、放线菌)在有氧条件下进行有机物的分解与转化，在人为控制下可产生人们所需要的物质，发酵过程较快，应用于医药、饲料、食品和废物处理等工业生产中。生物发酵根据形态分为固态和液态发酵两种，目前一般可控的精准发酵多为液态发酵；固态发酵多为粗放型发酵，广泛应用于生产、生活中。与液态发酵相比，固态发酵，尤其是有氧固态发酵，具有显著的特征与优势：原料来源广，发酵量大，效率高，生产成本低，适用性广等。因此，在生物医药、生物食品、生物饲料与兽药、生物农药与肥料、生物化工及环境净化等领域广泛应用。
发酵设备是发酵工业的基础，随着发酵技术水平的提高，要求可控的精准发酵，对设备的要求也越来越高。目前只有液体发酵设备(发酵罐系统)研究早，技术先进完备，能适应各种工业化生产的要求；而固态发酵设备的研究创新滞后，至今没有条件可控的固态发酵设备能满足工业化生产的需要，这严重制约着固态发酵工艺的研究与应用。
现有固态发酵设备除传统的厌氧发酵桶和发酵池外，有氧固态发酵设备有浅盘发酵反应器(传质传热速率低，造成高污染风险和托盘利用率低)、流化床发酵反应器(反应器容积率低)、转鼓式发酵反应器(物料结块和粘壁、反应器容积率低的问题)、圆盘式发酵反应器(不能无菌操作)、搅拌式发酵反应器(只适用于小规模发酵)、压力脉动固态发酵反应器(设备要求高，物料配制难等)；各种固态反应器(固态发酵设备)中，在工业上已得到应用的还只有浅盘式、转鼓式及搅拌式反应器，国内对其它形式的固态反应器的研制还刚刚萌发。2004年曾报道一种箱式固态物料发酵设备(专利申请号为200420026272.0)，为阶梯输送带式，占地面积大而长，适应性差。蒋勤等2011年报道KRH-Ⅱ型智能固态微生物递进成套装置的研究(《农机化研究》2011年第4期)，其装置为层架式发酵箱系统，解决物料混合、消毒、进料、铺料及发酵过程控制，但发酵过程不能翻料，且体积小(500L)，只适用于小规模试验和菌种生产；且物料消毒罐与发酵箱组装，物料消毒罐置于发酵箱上，设备制造成本高，操作不便。肖毅等2015年报道一种层架循还履带式发酵箱(ZL 201510388026.2)，并撰文“10m 2层架循还履带式发酵箱的制作与性能测定”和“发酵糟粕生产高活性高营养饲料的设备与工艺的效果分析”，发表于《湖南农业科学》2017年第10期和《饲料工业》2018.11期；该设备为双层架输送带，结构较复杂，欠紧凑，占地面积大，物料传送不顺；缺乏配套的物料处理(消毒等)输送设备，易造成过程中物料污染。
固态发酵是一种自然状态的发酵，与液态深层发酵有许多不同，其中最显著的特征是水分活度低，传质和传热性差，发酵不均匀。菌体的生长、对营养物质的吸收和代谢产物的分泌在各处也不均匀，使得发酵参数的检测和控制比较困难，许多液态发酵的生物传感器也无法应用于固态发酵。迄今为止，固态发酵检测或调控的参数有培养基含水量(水活度)、pH值、空气湿度、CO 2和O 2的含量、温度和菌体生长量等，但在文献中还没有见到较为完善的关于固态发酵的数学模型，虽然有些关于固态发酵的动力学研究报道，但都是以图纸的形式出现，更无成熟的固态发酵参数检测与调控的系统。2010和2011报道的“固体发酵过程参数检测与优化控制”也主要是运用模糊数学方法分析发酵过程不同方位不同时间的参数差异，在理论上研究发酵过程最佳控制参数(温度、湿度和pH值)；而关键的检测与调节方法不清。其实对生物发酵，不是寻找发酵环境各处的差异，而是设法消除差异，如有效地搅拌翻料，空间内空气循环等。肖毅等2018报道的10M 2层架循环履带式发酵箱(动态)也只是温度与湿度简单调控，未能智能化。
固态发酵物料的消毒与输送是保障发酵过程无杂菌污染，确保发酵产品质量的关键，而大多数固态发酵装置(箱、罐等)不能直接高压高温消毒灭菌，而是先将发酵装置用化学(臭氧、消毒剂等)或物理(蒸汽、紫外线等)灭菌，再用另外的物料消毒装置将物料消毒灭菌后以人工或机械方式输入发酵装置内，进行接种发酵，这样易于造成第二次污染，发酵失败。蒋勤等2011报道在发酵箱的上位安装一个消毒灭菌罐，将物料高温灭菌后，借助重力作用将物料落下输入发酵箱内接种发酵。这虽然解决了物料灭菌输送问题，但大大增加了设备成本(一个小型发酵箱配套一个高压灭菌罐)，且在发酵箱的上位安装消毒灭菌罐，位置高，生产操作极不方便。
以上现有固态发酵设备，均存在各自的缺陷，尤其是对大型真菌的发酵不适应，因大型真菌发酵除要求温度、湿度稳定，供氧充足和无杂菌等条件外，还需较浅的发酵物料和适度的温和翻动及较长的发酵时间(易受杂菌污染)；以上设备中只有浅盘发酵反应器、圆盘式发酵反应器以及流化床发酵反应器能勉强应用，但均难严格满足发酵要求，不能实行规模化的安全(无污染)生产。可见，研究开发新型智能化的大型固态发酵设备是解决当今制约固态发酵业发展瓶颈的关键。
发明内容
针对上述现有技术的不足，本发明的目的在于提供一种层架循环履带式固态发酵设备及固态发酵方法；解决了现有技术中固态发酵设备无法充分搅拌、不能循环翻料等使物料传质传热难及发酵过程控制难的技术问题，同时也解决了现有发酵设备占地面积大，空间利用低下的问题。
为了实现上述发明目的，本发明提供以下技术方案：
一种层架循环履带式固态发酵设备，包括发酵箱，发酵箱上开设进料口和出料口，所述发酵箱内设有提升式床架循环履带发酵床或盘旋式床架循环履带发酵床，
所述提升式床架循环履带发酵床至少一个发酵床，还包括提升机，所述发酵床包括至少两层履带式层架，各层架由下而上依次平行铺设，各层架上各设有一铺平器；相邻层架的移动方向相反，最上层层架的前端设有接料斗，除最上层层架外的其余层架的前端设有斜置的挡料槽；发酵箱内设有位于进料口下方的接料槽，所述接料槽内设有第一搅拌轴和第二搅拌轴最下层层架的后端位于接料槽上方；所述提升机具有至少一个可在接料槽与接料斗之间移动的送料斗。
借由上述结构，提升机与多层层架履带的运动轨迹之间形成循环输送道，从而可实现循环翻料，搅拌轴充分搅拌，铺平器铺平物料，使传质传热加速，大大提高发酵的均衡性和发酵效率。
作为一种优选方式，所述提升机具有环形传送带，所述送料斗设于环形传动带的外侧，环形传送带的一端伸至接料槽内，环形传送带的另一端与接料斗衔接。
借由上述结构，物料提升顺畅，不易阻料撒料，空间利用率高。
为解决现有技术中固态发酵设备在发酵过程中不具备完备的参数监控功能的技术问题，本发明所采用的技术方案是：
进一步地，还包括控制器，所述发酵箱内基于无高温高压的特点并经适当的技术改进，还设有由常规传感器组成的温度监控单元和/或湿度监控单元和/或PH值监控单元和/或O 2浓度监控单元和/或CO 2浓度监控单元和/或压力监控单元和/或层架传动速度监控单元；所述各监控单元与控制器电连接。
借由上述结构，利用控制器对温度、湿度、PH值、O 2浓度、CO 2浓度、压力、层架传动速度等参数进行监控，实现智能化控制的精准发酵。
为解决现有技术中固态发酵设备难以保证无菌环境的技术问题，本发明所采用的技术方案是：
进一步地，还包括物料消毒灭菌输送罐，所述物料消毒灭菌输送罐包括异形夹层灭菌锅，灭菌锅上开设物料投入口及菌种投入口，灭菌锅内底部设有螺旋搅拌器，螺旋搅拌器的出口可与所述进料口相对接。
借由上述结构，物料消毒灭菌后，可通过螺旋搅拌器对接发酵箱，自动送入发酵箱内，避免杂菌污染。同时，物料消毒杀菌输送罐可供多个发酵箱使用。此外，配备的物料消毒杀菌输送罐还可以生产高压蒸汽供发酵箱消毒灭菌，产生的高温灭菌水可供发酵加湿，一机多用，节能经济。
进一步地，所述发酵箱箱体由多块面板拼装形成严格密封的箱体，箱内进行紫外线、嗅氧(嗅氧量≥40mg/m 3)和高压蒸汽的单一或多重消毒灭菌，保障箱内彻底消毒灭菌。发酵箱的大小可根据需要设计制造，满足不同生产工厂的需要，安装、拆卸与运输方便。
进一步地，还包括供气与循环系统，所述供气与循环系统包括空气过滤净化、加温、调湿等的空气净化送入装置和排风装置。
借由上述结构，保障为发酵过程供给无菌、温度与湿度稳定的空气，并在箱内有效循环与排放。
作为一种优选方式，所述履带式层架的层数为偶数。
履带式层架的层数为偶数，从而方便最下层的层架后端与接料槽对接。
进一步的，本发明还在所述发酵箱上配置CIP清洗系统(cleaning in place)供发酵箱内设备清洗消毒。在本发明中，所述CIP清洗系统包括若干清洗液喷头和清洗刮板(或清洗刷)，所述清洗液喷头优选的设置在所述环形传送带的前端，清洗刮板(或清洗刷)设置在循环履带下方，在本发明具体实施过程中，当所述清洗液喷头喷消毒液的同时开打传送带在清洗刮板(或清洗刷)的辅助作用下进行消毒灭菌。
基于同一个发明构思，本发明还提供了一种固态发酵方法，采用所述的层架循环履带式固态发酵设备，包括以下步骤：
步骤A1，接种物料从进料口进入发酵箱内的接料槽；
步骤A2，提升机运转，送料斗将接料槽内的接种物料运送至接料斗；
步骤A3，接种物料从接料斗进入最上层层架的前端；
步骤A4，各层架移动，接种物料到达上层层架后端时，落入下层相邻的层架前端，直到接种物料到达最下层层架的后端；
步骤A5，接种物料从最下层层架的后端落入接料槽；
步骤A6，重复步骤A2至A5直至接种物料发酵完成；
步骤A7，接料槽内的发酵好的物料从出料口送出发酵箱。
作为一种优选方式，在接种物料发酵过程中，对发酵箱的温度和/或湿度、PH值、CO 2浓度、O 2浓度、压力和层架传动速度中的一种或几种进行监控，其中：
温度监控过程包括：通过控制器反馈调整β1，使得发酵箱的温度在20℃～45℃，其中，β1满足条件SV2(n)＝(1+β1*EV 1(n))SV 1(n)，SV 2(n)是n时刻发酵箱实际温度控制值，SV 1(n)是发酵箱设定温度控制值，PV 1(n)是发酵箱实际温度值；
湿度监控过程包括：通过控制器反馈调整β2，使得发酵箱的湿度在70％～85％，其中，β2满足条件SH 2(n)＝(1+β2*EH 1(n))SH 1(n)，SH 2(n)是n时刻发酵箱实际湿度控制值，SH 1(n)是发酵箱设定湿度控制值，PH 1(n) 是发酵箱实际湿度值；
PH值监控过程包括：通过控制器反馈调整β3，使得发酵箱的PH值在6～8，其中，β3满足条件SPH 2(n)＝(1+β3*EPH 1(n))SPH 1(n)，SPH 2(n)是n时刻发酵箱实际PH值控制值，SPH 1(n)是发酵箱设定PH值控制值，PPH 1(n)是发酵箱实际PH值；
O 2浓度监控过程包括：通过控制器反馈调整β4，使得发酵箱的O 2浓度在5％～25％，其中，β4满足条件SO2(n)＝(1+β4*EO 1(n))SO 1(n)，SO2(n)是n时刻发酵箱实际O 2浓度控制值，SO 1(n)是发酵箱设定O 2浓度控制值，PO 1(n)是发酵箱实际O 2浓度值；
CO 2浓度监控过程包括：通过控制器反馈调整β5，使得发酵箱的CO 2浓度在300ppm～400ppm，其中，β5满足条件SCO 2(n)＝(1+β5*ECO 1(n))SCO 1(n)，SCO 2(n)是n时刻发酵箱实际CO 2浓度控制值，SCO 1(n)是发酵箱设定CO 2浓度控制值，PCO 1(n)是发酵箱实际CO 2浓度值；
压力监控过程包括：通过控制器反馈调整β6，使得发酵箱的压力抖动范围为-0.01Mpa～0.01Mpa，其中，β6满足条件SF 2(n)＝(1+β6*EF 1(n))SF 1(n)，SF 2(n)是n时刻发酵箱实际压力控制值，SF 1(n)是发酵箱设定压力控制值，PF 1(n)是发酵箱实际压力值；
层架传动速度监控过程包括：通过控制器反馈调整β7，使控制发酵箱内空间温度与物料温度之差在0.5℃内，控制发酵箱内O 2浓度与物料O 2浓度之差在1％内。β7满足的条件u(n)＝u(n-1)-Δu(n)，u(n)为PID回路的输出，Δu(n)是第n时刻控制量的增量，Δu(n)＝KP[e(n)-e(n-1)]+β7KIe(n)+KD[e(n)-2e(n-1)+e(n-2)]，发酵箱内空间温度与物料温度之差ΔPV 1(n)和发酵箱内O 2浓度与物料O 2浓度之差ΔPO 1(n)经处理合成e(n)作为输入量，控制层架传动速度的电机运行速度PID控制信号u(n)作为输出量。
进一步地，还包括物料消毒灭菌输送罐，所述物料消毒灭菌输送罐包括异形夹层灭菌锅，灭菌锅上开设物料投入口及菌种投入口，灭菌锅内底部设有螺旋搅拌器，螺旋搅拌器的出口可与所述进料口相对接；
发酵箱内接种物料的获得过程包括以下步骤：
步骤B1，将发酵物料从物料投入口投入灭菌锅；
步骤B2，发酵物料在灭菌锅内消毒灭菌；
步骤B3，对物料消毒灭菌输送罐降温；
步骤B4，在无菌条件下，将螺旋搅拌器的出口与发酵箱的进料口相对接；
步骤B5，将菌种从菌种投入口投入灭菌锅；
步骤B6，螺旋搅拌器工作，将灭菌锅内的接种物料通过进料口送入发酵箱。
进一步地，还包括利用物料消毒灭菌输送罐产生蒸汽供发酵箱消毒灭菌，产生的高温灭菌水供物料发酵加湿。
对于所述层架循环履带式固态发酵设备，本发明还提供了将提升式循环履带替换为盘旋式循环履带的替代方案，具体如下：
所述层架循环履带式固态发酵设备，包括发酵箱，所述发酵箱的箱体内装有多个发酵床架，相邻两个发酵床架之间通过相应的连接床架连通；所述发酵床架中的一台与进料接受斗连通；
每个发酵床架和连接床架上均装有一层或数层输送带作为发酵床，所述输送带水平或倾斜设置；在所述发酵床架的每一层输送带的进料端安装有铺平器，所述发酵床架的输送带的出料端安装有搅拌器；
所述输送带的转鼓与所述搅拌器通过驱动装置驱动。
为了利于物料发酵，所述发酵床架的输送带的倾斜角度为相对水平面≤30°。
优选的，所述发酵床架有两台，两台发酵床架与两台连接床架首尾对应上下重叠连接，整体形成盘旋状，使得物料可从第一发酵床架的最下层前端传送至第二发酵床架的最上层的后端，再经下滑槽下滑至进料接受斗；所述连接床架的输送带为折射形或平直形。
优选地，所述驱动装置为装在箱体外的电机，该电机的驱动轴伸入箱体内并驱动所述输送带的转鼓和所述搅拌器转动。
所述电机有两台，两台电机中，一台电机驱动第一发酵床架的第一层输送带、第一连接床架的第一层输送带、及搅拌器运转，同时通过链条与齿轮连接驱动其它层输送带及搅拌器运转；另一台电机驱动第二发酵床架的第一层输送带、第二连接床架的第一层输送带及搅拌器运转，同时通过链条与齿轮连接驱动其它层输送带及搅拌器运转。
为了保证箱体内的温度与湿度等参数条件易于控制，从而实现均衡高效地发酵，所述箱体内设有空气循环系统。更优选地，所述空气循环系统包括供气调温装置和与箱体内连通的抽风系统；所述供气调温装置与所述箱体内部连通；所述箱体顶部开设出风口，该出风口处设置有用于调节箱体内部湿度的加湿装置；所述抽风系统包括设置在箱体顶部的排风口，该排风口上安装有与排风管连通的抽风机；所述排风管的一端延伸至箱体底部。由此可以方便调温调湿度，同时保证通风效果，从而便于发酵。
为了方便进料和出料，所述箱体的侧面开设有进料窗，该进料窗位置与所述进料接受斗位置对应；所述进料窗处设有进料口，在进料窗的斜下方开设有出料口。
为了更加方便地调节箱内湿度和温度，所述箱体内设有雾化器和加热装置。
为了降低高度，减少占用空间，有利连接与物料循环，相邻两台发酵床架和两台连接床架的输送带的倾斜角度相反，连接床架输送带以折射形比平直形更为合适。
与现有技术相比，本发明具有以下有益效果：(1)提升形发酵床提升机与层架循环履带式发酵床结合，结构紧凑，循环翻料，运行顺畅；盘旋形发酵床与连接床均为履带，都可作发酵床，有效空间利用率高，相对制造成本低；(2)根据发酵箱环境条件并适当技术改进，配备由常规传感器组成的智能化控制系统，用遗传算法的PID控 制算法优化调控参数，优化环境，实现精准发酵，大大提高发酵效率与产品质量；(3)配备的物料消毒灭菌输送罐，具有消毒灭菌、接种搅拌、移动输料功能(一台设备可供多个发酵箱用)；同时可在物料消毒的同时，产生高压蒸汽供发酵箱消毒灭菌，产生的高温灭菌水供作物料发酵加湿，即一机多用；(4)配制供气与循环系统，系统设置空气三级净化过滤器、加热杀菌器和加湿器，保障通入空气无菌、温度湿度适宜，箱内循环有效；(5)完全控制无菌，操作方便，可实行规模化的高效固体有氧发酵，特别适用于发酵周期长的真菌，尤其是药食用真菌菌丝的发酵，可供中药材、药渣、糟粕等农副产品及其它物料的发酵；(6)发酵箱箱体由多块定型制作的面板拼装形成，安装、拆卸与运输方便，设备大小可根据需要设计制作，适应不同生产工厂的需要。(7)配置CIP清洗系统保障箱内设备清洗消毒。
说明书附图
图1～图12为实施例1中的层架循环履带式固态发酵设备的相关附图，其中：
图1为发酵箱外观示意图；
图2为发酵床与提升机主视图；
图3为发酵床与提升机俯视图；
图4为本发明的驱动系统示意图；
图5为带发酵床的发酵箱主视图；
图6为带双列发酵床的发酵箱俯视图(去掉顶板)；
图7为带单列发酵床的发酵箱俯视图(去掉顶板)；
图8为供气箱系统主视图；
图9为物料消毒灭菌输送罐外观图；
图10为物料消毒灭菌输送罐的剖面图；
图11为本发明电气控制部分方框图；
图12为层架速度控制系统框图；
图1～图12中，1为发酵箱，101为进料口，102为传动电机，103为门，104为观察窗与取样口，105为排风口，106为出料口，107为气门阀，108为出料槽，2为发酵床，201为层架，202为挡料槽，203为铺平器，3为提升机，301为送料斗，302为环形传送带，4为接料斗，5为接料槽，501为第一搅拌轴，502为第二搅拌轴，6为控制器，601为温度监控单元，602为湿度监控单元，603为PH值监控单元，604为O 2浓度监控单元，605为CO 2浓度监控单元，606为压力监控单元，607为层架传动速度监控单元，608为触摸屏人机界面，7为物料消毒灭菌输送罐，701为灭菌锅，702为物料投入口，703为菌种投入口，704为螺旋搅拌器，705为出气管，706为出水管阀，8为空气净化送入装置，801为风箱体，802为主箱，803为副箱，804为空气过滤器，805为鼓风机，806为袋式空气过滤器，807为加热杀菌器，808为送风管，809为高效空气过滤器，810为出风口，9为蜂窝状调湿装置，10为控制柜，11为排风机。
图13是实施例3中的层架循环履带式固态发酵设备中带发酵床的发酵箱主视图，其中C为CIP喷头，D为清洗刮板或清洗刷；
图14～图15为实施例4中的层架循环履带式固态发酵设备的相关附图，其中：
图14为所述的发酵床驱动连接装置示意图；
图15为图14的B处局部放大图；
图16为图14的A处局部放大图；
图17为实施例4中所述的铺平器示意图；其中a)为正视图，b)为左视图；
图18为实施例4所述的搅拌器示意图；
图19是实施例4的箱体外形图；
图20是实施例4的箱体内的透视图；
在图中
1、2-发酵床架；3、4-连接床架；5-下料槽；6-进料接受斗；7-驱动连接齿轮与链条；8-搅拌器，9-铺平器；10-转向齿轮；11-供气调温装置；12电机，13-抽风机；14-调湿装置；15-雾化器；16-控制柜；17-观察窗；18-进料口；19-排风管；20-出料口，21-门，22-进料窗，23-进风口，24-排风口，25-机械密封孔；26-加热器。
图21为实施例5中折射形输送带床架：其中3’为折射形输送带，C为CIP喷头，D为带下清洗刮板或清洗刷。
具体实施方式
下面结合实施例和附图对本发明进一步说明。
实施例1
本实施例的层架循环履带式固态发酵设备包括：发酵箱1、层架履带发酵床2、消毒系统、供气系统、参数检测调控系统、物料灭菌输送等几个部分，配置齐全、结构紧凑、协调适用。
发酵箱1：发酵箱1箱体由保温耐温耐腐蚀材料制作，由6大块(或小块拼装大块)面板拼装形成，即4块墙体：两端开门103，一侧中下部设净化空气进入口(空气净化送入装置8后面)，一侧设进料口101、传动电机102(电机轴机械密封孔)、蒸汽通入孔、观察窗与取样口104，另一侧设出料口106；2块上下顶板底板：顶板设气门阀107与带风机的排风口105，内安装紫外灯、嗅氧发生器；底板设床架固定装置和污水排泄可关闭的管孔；各板连接处用硬质材料加螺丝固定，易于组合安装，拆卸运输方便。见图1与图5。
层架履带式发酵床2与提升装置：
(1)层架履带式发酵床2：层架履带发酵床2由双层(4层或6层)组成，系由耐腐蚀耐高温的食品级材料(PVC、PU、EP、硅胶、尼龙、不锈钢等)制造的同步输送带和不锈钢支架组成，每层两边设5-20cm高的挡料板，最上层层架201的前端设有接料斗4，其后设搅拌铺平器(轴)一根或多根；各相邻2层的运转方向相反，由齿轮与链条连接，通过箱外电机驱动(见图2，图4)。
所述发酵床2包括至少两层履带式层架201，各层架201由下而上依次平铺，相邻层架201的移动方向相反，落料处设有挡料槽202，发酵箱1内设有位于进料口101下方的接料槽5，最下层层架201的后端位于接料槽5上方。
每箱内设置发酵床架1套(单列式)或2套(双列式)。
(2)提升装置：包括瓜瓢式提升机3和接料槽5两部分。所述提升机3具有至少一个可在接料槽5与接料斗4之间移动的送料斗301。所述提升机3具有环形传送带302，所述送料斗301设于环形传动带的外侧，所述送料斗301的形状为瓜瓤状。环形传送带302的一端设于接料槽5内，环形传送带302的另一端与接料斗4衔接。
提升机3由带垫底(履带)的瓜瓢固定在不锈钢链条上，组成的物料提升装置(见图3)；再将提升装置安装在条形(侧面观)支架上，经箱外电机驱动。接料槽5呈长条形，置提升机3下方发酵床架一层的首端，接受经发酵箱1箱外初次输入物料与发酵床2输送带运行传来的发酵物料，供提升机3提升；接料槽5内设有2根搅拌轴，第一搅拌轴501在发酵床2的远端，呈间断式螺旋形，主要负责发酵箱1箱外输入物料的在接，料槽内的混合与铺展，及发酵完成后物料的传出；第二搅拌轴502在发酵床2的近端，为带齿的搅拌轴，主要负责输送带落下物料的搅拌。接料槽一端设可关闭的挡板，挡板处与出料槽108相连。
物料经发酵箱1外进料管输入提升机3下端的接料槽5，由接料槽5内搅拌轴将物料搅拌铺展，由提升机3将物料提升至最上层层架201(由下而上数第四层)的接料斗4，经第三搅拌轴204搅拌铺开，再由发酵床带将物料向后传送，落入第三层层架201前端；第三层层架201向后方向运转，将物料输送落入第二层层架201前端；第二层层架201又向后运转，将物料传送落入第一层层架201前端；第一层层架201向后运转，将物料传送到提升机3下部的接料槽5，再由提升机3将物料提升到发酵床2上部的接料斗4，进入下一个传送周期(见图2)。为确保上层层架201的物料准确落入下层层架201，除最上层层架201外的其它层架201前端设有挡料槽202。
发酵好的物料由提升机3(离合器分离，停止运转)下的接料槽5内搅拌轴将料推至一端(活动挡板放下)，经移动滑槽从出料口106传出箱外(单列床架)或从箱端大门传出(双列床架)。
(3)驱动系统：一组床架发酵床2与一提升机系统由一台电机驱动，以齿轮加链条连接；提升机3传动安装离合器，在出料时离开，中断料的提升，使料从出料口106输出(见图3)，也可用两台电机分别驱动。
固态发酵设备还包括：
(1)空气净化输送装置：在发酵箱1外侧设立空气净化送入装置8，包括风箱体801，风箱体801分隔为主箱802和副箱803，主箱802内设鼓风机805，主箱802进风口设空气初滤器804、主箱802与副箱803连接处设二级袋式空气过滤器806，其后设加热器807，副箱803和送风管808相连接，送风管伸入发酵箱1的管道出口809内设三级高效空气过滤器810。空气经3次过滤净化与加热并杀菌送入发酵箱1内，保障进风无菌与适温。见图8。
(2)加热装置：在箱内两侧还安装加热装置，主要用于起始加热和辅助加热。
(3)加湿装置：净化空气出风口处设吸水材料制作的蜂窝状调湿装置9(图6和图7)，为吹进的干燥空气加湿，同时在发酵箱1内设超声波雾化器辅助调湿。
(4)pH调节装置：在发酵箱1定设酸液瓶和碱液瓶(用胶管与雾化器连接)，分别盛弱酸溶液(碳酸、有机酸等)和弱碱溶液(氨水、苏打水等)。
(5)排风与降温装置：在发酵箱1顶部四角出风口502设排风机11。新鲜净化空气由箱底部或箱顶中央进入箱内，经扩散循环后由出风口排出，实现快速换气、降温、除湿。
(6)压力调节装置：在发酵箱1顶中央安装气门阀107，供箱内压力调节。
为实现智能控制，在发酵箱1外固定控制柜10，控制柜10内设有控制器6，所述控制器6为PLC或单片机，通过触摸屏人机界面608与控制器6进行人机交互。所述发酵箱1内还设有温度监控单元601、湿度监控单元602、PH值监控单元603、O 2浓度监控单元604、CO 2浓度监控单元605、压力监控单元606和层架传动速度监控单元607；温度监控单元601、湿度监控单元602、PH值监控单元603、O 2浓度监控单元604、CO 2浓度监控单元605、压力监控单元606和层架传动速度监控单元607均与控制器6电连接(见图11)。具体地，所述PLC或单片机与温度传感器、调控电加热器、供气箱加热装置、空间湿度传感器、物料含水量(水活度)传感器、进气调湿器、雾化装置、酸碱度传感器、弱酸碱调节装置、压力传感器、排气阀门、O 2传感器、CO 2传感器、供气箱鼓风机、排风机、床带电机调速器等连接。
固态发酵设备还包括移动式(或固定式)物料消毒灭菌输送罐7，所述物料消毒灭菌输送罐7包括异形夹层高压灭菌锅701，灭菌锅701上开设物料投入口702及菌种投入口703，灭菌锅701内底部设有螺旋搅拌器704(见图9，图10)，螺旋搅拌器704的出口可与所述进料口101相对接。物料消毒灭菌输送罐7配备支架和车轮，可移动，方便送料。即待发酵物料经蒸汽高压消毒灭菌后，快速降温(更换夹层热水为冷水)，将物料消毒灭菌输送罐7推至发酵箱1，在无菌条件下(焰上)再将螺旋搅拌器704的出口与发酵箱1进料口101对接，接入菌种，开启螺旋搅拌轴，使菌种与物料混合送入发酵箱1。物料消毒灭菌输送罐7罐顶上设有带阀门的出气管705，用于为发酵箱1供气消毒；在物料消毒灭菌输送罐7的侧面下部还设有一出水管阀706，用于供给无菌水。
消毒系统：
在发酵箱1内顶面安装紫外线灯杀菌的基础上，根据条件选用下列两种消毒方法之一或两种组合进行强化消毒灭菌；
一，蒸汽消毒，利用工厂现有高压蒸汽或本实施例的物料消毒灭菌输送罐7产生蒸汽，通入发酵箱1内进行高压蒸汽消毒灭菌；
二，嗅氧消毒，在箱外配置嗅氧发生器，产生嗅氧通入箱内消毒，嗅氧量≥40mg/m 3，达100级C＝20ppm以上。
采用所述层架循环履带式固态发酵设备进行固态发酵的方法包括：
步骤A1，接种物料从进料口101进入发酵箱1内的接料槽5；
步骤A2，提升机3运转，送料斗301将接料槽5内的接种物料运送至接料斗4；
步骤A3，接种物料从接料斗4进入最上层层架201的前端；
步骤A4，各层架201移动，接种物料到达上层层架201后端时，落入下层相邻的层架201前端，直到接种物料到达最下层层架201的后端；
步骤A5，接种物料从最下层层架201的后端落入接料槽5；
步骤A6，重复步骤A2至A5直至接种物料发酵完成；
步骤A7，接料槽5内的发酵好的物料从出料口106经出料槽108送出发酵箱1。
在接种物料发酵过程中，对发酵箱1的温度、湿度、PH值、CO 2浓度、O 2浓度、压力和层架传动速度进行监控，其中：
温度监控：由温度传感器和电加热器、热风装置、排风机组成温度控制的输入输出组态，采用现有的成熟闭环PID(比例(proportion)、积分(integral)、导数(derivative))控制器6进行控制，并针对本发酵设备自身特征做一定的适当参数调整，以达到控制精度和高节约能耗等优点。
本控制器6以已有基于遗传算法的PID控制算法为基础，使用先行函数设定了温度控制比例的值，具体参数调整方式如下：
SV 1(n)是发酵箱1设定温度控制值，PV 1(n)是发酵箱1实际温度值，
Figure PCTCN2020090179-appb-000001
Figure PCTCN2020090179-appb-000002
β 1是温度偏差放大系数，差值限制值假设为α 1，0＜α 1≤0.05。α 1的值与β 1成反比，α 1越小则温度偏差放大系数增加。
如-α 1≤EV 1(n)≤α 1，则误差放大：
EV 2(n)＝β 1*EV 1(n)   (2)
给EV 2(n)设定范围：|EV 2(n)|≤0.05，即允许温度误差在±5％，公式(3)中SV 2(n)是n时刻实际的温度控制值：
SV 2(n)＝(1+β 1*EV 1(n))SV 1(n)   (3)
通过闭环控制器不断反馈和调整β 1，使得发酵箱1的温度在20℃～45℃。
湿度监控：由空间湿度和物料含水量(或水活度)传感器和调湿器、雾化装置组成湿度控制的输入输出组态，采用已有基于遗传算法的PID控制算法为基础对发酵箱1体内湿度实现实时调控。使用先行函数设定了湿度控制比例的值，具体参数调整方式如下：
SH 1(n)是发酵箱1设定湿度控制值，PH 1(n)是发酵箱1实际湿度值；
Figure PCTCN2020090179-appb-000003
β 2是湿度偏差放大系数，差值限制值假设为α 2，0＜α 2≤0.1。α 2的值与β 2成反比，α 2越小则温度偏差放大系数增加。
如-α 2≤EH 1(n)≤α 2，则误差放大：
EH 2(n)＝β 2*EH 1(n)    (5)
给EH 2(n)设定范围：|EH 2(n)|≤0.1，即允许湿度误差在±10％，公式(6)中SH 2(n)是n时刻发酵箱1实际湿度控制值：
SH 2(n)＝(1+β 2*EH 1(n))SH 1(n)   (6)
通过闭环控制器不断反馈和调整β 2，使得发酵箱1的湿度在70％～85％。
PH值监控：由酸碱度传感器(附加滴水头，保障测定部位物料含一定量的水)和弱酸碱液(碳酸、有机酸、氨水、苏打水等)调节装置(通过雾化器实施)组成PH值控制的输入输出组态，采用已有基于遗传算法的PID控制算法为基础对发酵箱1体内PH值实现实时调控。使用先行函数设定了PH值控制比例的值，具体参数调整方式如下：
SPH 1(n)是发酵箱1设定PH值控制值，PPH 1(n)是发酵箱1实际PH值；
Figure PCTCN2020090179-appb-000004
β 3是PH值偏差放大系数，差值限制值假设为α 3，0＜α 3≤0.05。α 3的值与β 3成反比，α 3越小则PH值偏差放大系数增加。
如-α 3≤EPV 1(n)≤α 3，则误差放大：
EPH 2(n)＝β 3*EPH 1(n)    (8)
给EPH 2(n)设定范围：|EPH 2(n)|≤0.05，即允许PH值误差在±5％，公式(9)中SPH 2(n)是n时刻发酵箱1实际PH值控制值
SPH 2(n)＝(1+β 3*EPH 1(n))SPH 1(n)   (9)
通过闭环控制器不断反馈和调整β 3，使得发酵箱1的PH值在6～8。
压力监控：由压力传感器和排气阀门组成压力控制的输入输出组态，采用已有基于遗传算法的PID控制算法为基础对发酵箱1体内压力值实现实时调控。使用先行函数设定了压力值控制比例的值，具体参数调整方式如下：
SF 1(n)是发酵箱1设定压力控制值，PF 1(n)是发酵箱1实际压力值；
Figure PCTCN2020090179-appb-000005
β 6是温度偏差放大系数，差值限制值假设为α 6，0＜α 6≤0.01。α 6的值与β 6成反比，α 6越小则压力偏差放大系数增加。
如-α 6≤EF 1(n)≤α 6，则误差放大：
EF 2(n)＝β 6*EF 1(n)   (11)
给EF 2(n)设定范围：|EF 2(n)|≤0.01，即允许压力值误差在±1％，公式(12)中SF 2(n)是n时刻发酵箱1实际压力控制值：
SF 2(n)＝(1+β 6*EF 1(n))SF 1(n)   (12)
通过闭环控制器不断反馈和调整β 6，使得发酵箱1的压力抖动范围为-0.01Mpa～0.01Mpa。
气体浓度监控：由O 2、CO 2传感器和进气鼓风机流量、排气风机流量组成控制的输入输出组态，采用已有基于遗传算法的PID控制算法为基础对发酵箱1箱体内O 2、CO 2浓度值实现实时调控。使用先行函数设定了O 2、CO 2浓度值控制比例的值，具体参数调整方式(以O 2浓度控制为例)如下：
SO 1(n)是发酵箱1设定O 2浓度控制值，PO 1(n)是发酵箱1实际O 2浓度值；
Figure PCTCN2020090179-appb-000006
β 4是O 2浓度偏差放大系数，差值限制值假设为α 4，0＜α 4≤0.05。α 4的值与β 4成反比，α 4越小则O 2浓度偏差放大系数增加。
如-α 4≤EO 1(n)≤α 4，则误差放大：
EO 2(n)＝β 4*EO 1(n)   (14)
给EO 2(n)设定范围：|EO 2(n)|≤0.05，即允许O 2浓度误差在±5％，公式(15)中SO 2(n)是n时刻发酵箱1实际O 2浓度控制值：
SO 2(n)＝(1+β 4*EO 1(n))SO 1(n)   (15)
通过闭环控制器不断反馈和调整β 4，使得发酵箱1的O 2浓度在5％～25％。
同理，CO 2浓度监控过程包括：通过控制器反馈调整β 5，使得发酵箱1的CO 2浓度在300ppm～400ppm，其中，β 5满足条件SCO 2(n)＝(1+β 5*ECO 1(n))SCO 1(n)，SCO 2(n)是n时刻发酵箱1实际CO 2浓度控制值，
Figure PCTCN2020090179-appb-000007
SCO 1(n)是发酵箱1设定CO 2浓度控制值，PCO 1(n)是发酵箱1实际CO 2浓度值。
层架传动监控：以发酵箱1内空间温度与物料温度之差，发酵箱1内O 2浓度与物料O 2浓度之差作为输入量，以控制层架201传动速度的电机运行速度作为输出量，输入量与输出量组成输入输出组态，控制发酵箱1内空间温度与物料温度之差在0.5℃内，控制发酵箱1内O 2浓度与物料O 2浓度之差在1％内。
传统的用模拟量作为速度反馈参数的系统，由于受非线性、温度变化和元件老化等因素的影响,很难满足控制过程的快速性和准确性的要求。因此应考虑采用高性能的以数字量完成反馈的方式并结合传统的PID控制算法实现高速、高精度控制。
层架201速度控制系统由计算机、PID控制模块、交流伺服系统、传感器检测单元4个部分组成。计算机通过ISA总线与PID控制模块的编码器相连,可以通过ISA总线发送速度或位置命令、设定PID调节参数、并进行数模(D/A)转换。转换后的模拟信号经过交流伺服放大器放大后驱动交流电动机。电机轴端装有增量式光电编码器，通过编码器提供反馈信号，计数卡累计反馈脉冲数，与代表给定速度的指令脉冲比较后形成伺服系统的速度反馈，组成一个闭环系统。计算机给定速度与实际速度(即反馈到的速度)的偏差后，根据偏差范围采取相应的PID参数设置，将速度控制信号经数模转换变成模拟控制电压，并输出给伺服放大器，调节电机运行速度，完成期望的速度控制要求。闭环控制系统框图如图12所示。
如图12所示，PID控制器可调节回路输出，使系统达到稳定状态。偏差e和输入量r、输出量c的关系，其中的n为通过传感器监测到的箱体内温度值t及氧气含量值O 2的某一时刻：
e(n)＝r(n)-c(n)   (16)
PID控制器的输出为：
Figure PCTCN2020090179-appb-000008
式(17)中，u(n)为PID回路的输出；K P为比例放大系数；T i为积分时间；T d为微分时间。
PID调节器的传输函数为：
Figure PCTCN2020090179-appb-000009
为便于计算机处理此函数关系式，需将连续函数离散化，将描述连续时间PID算法的微分方程变为描述离散时间PID的差分方程，分别得到n时刻和n-1时刻的不同输出值：
Figure PCTCN2020090179-appb-000010
Figure PCTCN2020090179-appb-000011
为消除过程的开始、结束或大幅增减设定值时，短时间内系统输出产生的偏差导致的积分积累，避免系统较大的超调甚至振荡，减小电机在运行过程中积分校正对控制系统动态性能的影响，采用积分分离PID控制算法。将方程修正为基于时刻的控制量增量方程：
u(n)＝u(n-1)-Δu(n)   (21)
Δu(n)＝K P[e(n)-e(n-1)]+βK Ie(n)+K D[e(n)-2e(n-1)+e(n-2)]  (22)
式中，ΔU(n)是对应于第n时刻控制量的增量，β为积分项的开关系数。积分分离PID控制算法需设定积分分离阀值ε。当|e(n)|>ε时，即偏差值较大时，采用PID控制。减少超调量，使伺服系统有较快响应；当|e(n)|≤ε时,即 偏差值比较小时，采用PID控制以保证伺服电机的速度控制精度。
发酵箱1内接种物料的获得过程包括以下步骤：
步骤B1，将发酵物料从物料投入口702投入灭菌锅701；
步骤B2，发酵物料在灭菌锅701内消毒灭菌；
步骤B3，对物料消毒灭菌输送罐7降温；
步骤B4，在无菌条件下，将螺旋搅拌器704的出口与发酵箱1的进料口101相对接；
步骤B5，将菌种从菌种投入口703投入灭菌锅701；
步骤B6，螺旋搅拌器704工作，将灭菌锅701内的灭菌物料与接入菌种混合并通过进料口101送入发酵箱1。
本实施例还包括利用物料消毒灭菌输送罐7产生蒸汽供发酵箱1消毒灭菌，产生的高温灭菌水(夹层水)供发酵加湿。
本实施例结合了浅盘发酵器的浅盘装料和圆盘式发酵器等动态固体发酵设备的翻料，且设计较完备的自动化控制，配套的物料消毒灭菌输送设备和空气净化加热的供气设备，可进行全程自动化的固体有氧发酵，特别适用于真菌发酵。
本实施例中物料循环用瓜瓢式提升机3与层架履带发酵床2组合，也可用其它类型的提升机3与层架履带发酵床2；本实施例中采用鼓风供气，也可用无菌空调机；本实施例中采用PLC控制器系统，也可采用PAC、DCS等智能控制器及各类专业仪表、传感器及网络组成的控制系统，实现工业生产全过程的自动化控制。
实施例2
本实施例的层架循环履带式固态发酵设备除了设置CIP系统外，其余结构与实施例1相同。
本实施例中的清洗与消毒系统：
在发酵箱1内顶面安装紫外线灯杀菌的基础上，根据条件选用下列两种消毒方法之一或两种组合进行强化消毒灭菌；
一，蒸汽消毒，利用工厂现有高压蒸汽或本实施例的物料消毒灭菌输送罐7产生蒸汽，通入发酵箱1内进行高压蒸汽消毒灭菌；
二，嗅氧消毒，在箱外配置嗅氧发生器，产生嗅氧通入箱内消毒，嗅氧量≥40mg/m 3，达100级C＝20ppm以上。
三，消毒清洗系统，在箱外配置CIP清洗设备，在环形传动带的前端设清洗液喷头，在以上消毒前，喷消毒液的同时开打环形传动带，在清洗刮板(清洗刷)的辅助作用下，进行消毒灭菌。
实施例3
下面给出实施例1中的设备应用在一种保健口服液中药渣定向发酵菌质饲料添加剂的应用实例。
1、发酵设备：
采用智能型双列层架循环履带式发酵设备：发酵床2面积：1.5m×5m×4层×2列，物料消毒灭菌输送罐7容积：500L。
2、药渣原料与试验方法：
2.1培养基料配制：采自王中华保健食品公司的新鲜药渣，60-70℃烘干、粉碎，加20％营养基料(玉米粉：麦麸：豆粕粉＝4:3:3)和适量水配制培养基料，经121℃高温消毒灭菌，备用。
2.2发酵方法
第一次发酵：将液态产朊假丝酵母菌种按5％的量接种到高压灭菌的中药渣培养基中，送入发酵箱1(物料厚度5.0CM)，30℃恒温培养2d，至培养基布满白色菌体。
第二次发酵：将第一次培养好的中药渣菌质，经培养箱进料口101接种10％的液体虎奶菇菌种，28℃恒温培养，2-3d，至长满白色菌丝；60℃烘干，粉碎，包装。
2.3检测分析
(1)理化性质检测：测定颜色、气味、PH值(水浸出液)等理化性质。
(2)主要功能成分检测：
多糖含量测定：硫酸-苯酚法结合DNS比色法，测定多糖含量。
总皂苷含量测定：紫外法测总皂(香草醛-高氯酸比色法)。
(3)营养成分测定：按常规方法测定蛋白、纤维素、脂肪、能量、氨基酸和矿物元素等。
(4)抑菌力测定：样品加酸性蛋白酶水解，提取滤液，超滤除菌，牛津杯法测定抑菌效果。
3、试验结果
3.1菌的生长情况
酵母菌和大型真菌在两次发酵中均能在其培养基及其环境中正常生长(见表1)。
表1菌在保健口服液药渣培养基中的生长情况
Figure PCTCN2020090179-appb-000012
Figure PCTCN2020090179-appb-000013
注：“+”少量可见菌，“++”多量散状菌落/丝，“+++”成片菌落/丝，“++++”菌体长满。
3.2主要成分测定
(1)功能成分与物理性状测定：二次发酵后，多糖和皂苷提取量大幅度增加；pH值降低，细腻、芳香、有光泽(见表2)。
表2二次发酵药渣菌质多糖、皂苷含量与理化性状测定结果(3次平均值)
Figure PCTCN2020090179-appb-000014
(2)抗菌活性测定：发酵后的药渣菌质提取液，对5种菌，除链球菌外，均有较强的抑菌力，见表3。
表3二次发酵药渣菌质浸提液的抑菌试验结果(单位：cm)
Figure PCTCN2020090179-appb-000015
(3)营养成分测定：
常规营养含量测定：药渣二次发酵后，蛋白质增长48.75％；其也有一定的变化(见表4)。
表4药渣和二次发酵中药渣的常规营养成分含量(％)
Figure PCTCN2020090179-appb-000016
氨基酸含量测定：药渣发酵后各类氨基酸均呈上涨趋势，总氨基酸含量提高52.8％，其中芳香族氨基酸提高98.7％、支链氨基酸提高55.7％、直链氨基酸提高32.7％、酸性氨基酸提高45.45％、碱性氨基酸提高61.6％、羟基氨基酸提高56.4％(见表5)。
表5药渣和二次发酵中药渣的氨基酸含量(％)
Figure PCTCN2020090179-appb-000017
实施例4
一种层架循环输送带式固体发酵箱，其箱体由保温耐温耐腐蚀材料制作，如图19和20所示，由6大块(或小块拼装大块)组成，即4块墙体和顶板、地板，各板连接处用硬质材料加螺丝固定，易于组合安装，拆卸运输方便。其中发酵箱箱体的两端设有门21，侧面设进料口20、出料口22，电机轴的机械密封孔25，两侧和两端均设有观察窗17，顶板设进风口23与排风口24，内安装紫外灯。地板设床架固定装置、加热装置和污水排泄可关闭的管孔。
层架循环输送带式发酵床：连接层架输送带，置两层架发酵床输送带(设适当坡度，斜坡≤30度)的两端，使二者层层相衔接，如图13所示，形成循环输送：进料窗→第一发酵床架的第一层架前端(设进料接受斗6与搅拌器)→第一发酵床架的第一层架后端→第一连接层架的第一层→第二发酵床架的第一层架后端→第二发酵床架的第一层架前端→第二连接层架的第一层→第一发酵床架的第二层架前端→第一发酵床架的第二层架后端→第一连接床架的第二层→第二发酵床架的第二层后端→第二发酵床架的第二层前端→第二连接床架第二层→第一发酵床架的第三层前端→第一发酵床架的第三层后端→第一连接床架第三层→第二发酵床架的第三层后端→第二发酵 床架的第三层前端→下料槽5→第一发酵床架的第一层架前端→进入下一轮循环。
四台床架(两台发酵床架，两台连接床架)输送带式发酵床有机的链接，平稳地物料循环与翻动。
物料翻耙与铺平：如图14与图15所示，每一层架的每一层前端接料处后均安装带片的铺平器9，必要时输送带的中部也可安装铺平器。每一层架的每一层后端的出料处均安装有带齿的滚筒式搅拌器8。
驱动连接：如图20所示，箱体外两侧各安装一台驱动电机12，优选为循环输送带驱动电机，两电机轴分别经对应的机械密封孔25伸入箱体内第一发酵床下层输送带的转鼓内，驱动其输送带及搅拌器8，再以链条与齿轮连接7驱动其它层输送带及搅拌器。同时在电机轴伸入至发酵床架与连接床架交叉处安装转向齿轮10或齿轮箱驱动第一连接层架3的下层输送带，再用链条与齿轮连接驱动连接架其它层输送带。同样，用另一台电机驱动第二发酵床架2和第二连接床架4的输送带及搅拌器。两台发酵床架和两台连接层架也可分别用四台电机驱动。
调温调湿：如图19所示，在箱底设基础加热装置26，主要用于起始和气温过低时辅助加热，在通风系统的进风处设供气调温装置11(如热风机、空调等)。出风口处设吸水材料制作的蜂窝状的调湿装置14，箱体内还设雾化器15用于辅助调湿。风机用电机调速器控制转速控制进风量，实现快速升温和通风、调温、调湿可控，保障适宜的发酵环境。
消毒灭菌：箱体内消毒用高压蒸汽或紫外线和嗅氧量(≥40mg/m 3,达100级C＝20ppm以上)，保障灭菌效果。通风系统的进风至出风设有三级空气净化，保障通入空气无菌。箱体内调湿器和雾化器的用水均经灭菌后经管道输入。保障发酵过程无污染。
实施例5
本实施例中的层架循环输送带式固体发酵箱的结构除了设置CIP系统以及连接床架输送带为折射形以外，其余结构与实施例4中的相同，具体如图21所示。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (19)

  1. 一种层架循环履带式固态发酵设备，包括发酵箱(1)，发酵箱(1)上开设进料口(101)和出料口(106)，所述发酵箱(1)内设有至少一个发酵床(2)，其特征在于，还包括提升机(3)，所述发酵床(2)包括至少两层履带式层架(201)，各层架(201)由下而上依次平行铺设，各层架(201)上各安装一铺平器(203)，相邻层架(201)的移动方向相反，最上层层架(201)的前端设有接料斗(4)，除最上层层架(201)外的其它层架(201)前端设有挡料槽(202)，发酵箱(1)内设有位于进料口(101)下方的接料槽(5)，所述接料槽(5)内设有第一搅拌轴(501)和第二搅拌轴(502)；最下层层架(201)的后端位于接料槽(5)上方；所述提升机(3)具有至少一个可在接料槽(5)与接料斗(4)之间移动的送料斗(301)。
  2. 如权利要求1所述的层架循环履带式固态发酵设备，其特征在于，所述提升机(3)具有环形传送带(302)，所述送料斗(301)设于环形传动带的外侧，环形传送带(302)的一端伸至接料槽(5)内，环形传送带(302)的另一端与接料斗(4)衔接。
  3. 如权利要求1所述的层架循环履带式固态发酵设备，其特征在于，还包括控制器(6)，所述发酵箱(1)内还设有温度监控单元(601)和/或湿度监控单元(602)和/或PH值监控单元(603)和/或O 2浓度监控单元(604)和/或CO 2浓度监控单元(605)和/或压力监控单元(606)和/或层架传动速度监控单元(607)；所述各监控单元与控制器(6)电连接。
  4. 如权利要求1所述的层架循环履带式固态发酵设备，其特征在于，还包括物料消毒灭菌输送罐(7)，所述物料消毒灭菌输送罐(7)包括灭菌锅(701)，灭菌锅(701)上开设物料投入口(702)及菌种投入口(703)，灭菌锅(701)内底部设有螺旋搅拌器(704)，螺旋搅拌器(704)的出口可与所述进料口(101)相对接。
  5. 如权利要求1所述的层架循环履带式固态发酵设备，其特征在于，还包括供气与循环系统(8)，所述供气与循环系统(8)包括风箱体(801)，主箱(802)，副箱(803)，空气过滤器(804)，鼓风机(805)，袋式空气过滤器(806)，加热器(807)，送风管(808)高效空气过滤器(809)，出风口(810)，加湿器(9)，排风机(11)。
  6. 如权利要求1至5任一项所述的层架循环履带式固态发酵设备，其特征在于，所述发酵箱(1)箱体由多块定型制作的面板拼装形成。
  7. 根据权利要求1所述的层架循环履带式固态发酵设备，其特征在于，在所述发酵箱外配置CIP清洗设备。
  8. 根据权利要求7所述的层架循环履带式固态发酵设备，其特征在于，在所述环形传动带的前端设清洗液喷头，并在每层传动带下方设置清洗刮板或清洗刷。
  9. 一种固态发酵方法，其特征在于，采用如权利要求1～8任一项所述的层架循环履带式固态发酵设备，包括：
    步骤A1，接种物料从进料口(101)进入发酵箱(1)内的接料槽(5)；
    步骤A2，提升机(3)运转，送料斗(301)将接料槽(5)内的接种物料运送至接料斗(4)；
    步骤A3，接种物料从接料斗(4)进入最上层层架(201)的前端；
    步骤A4，各层架(201)移动，接种物料到达上层层架(201)后端时，经挡料槽(202)落入下层相邻的层架(201)前端，直到接种物料到达最下层层架(201)的后端；
    步骤A5，接种物料从最下层层架(201)的后端落入接料槽(5)；
    步骤A6，重复步骤A2至A5直至接种物料发酵完成；
    步骤A7，接料槽(5)内的发酵好的物料从出料口(106)送出发酵箱(1)。
  10. 如权利要求9所述的固态发酵方法，其特征在于，在接种物料发酵过程中，对发酵箱(1)的温度和/或湿度和/或PH值和/或CO 2浓度和/或O 2浓度和/或压力和/或层架传动速度进行监控，其中：
    温度监控过程包括：通过控制器(6)反馈调整β1，使得发酵箱(1)的温度在20℃～45℃，其中，β1满足条件SV2(n)＝(1+β1*EV 1(n))SV 1(n)，SV 2(n)是n时刻发酵箱(1)实际温度控制值，SV 1(n)是发酵箱(1)设定温度控制值，PV 1(n)是发酵箱(1)实际温度值；
    湿度监控过程包括：通过控制器(6)反馈调整β2，使得发酵箱(1)的湿度在70％～85％，其中，β2满足条件SH 2(n)＝(1+β2*EH 1(n))SH 1(n)，SH 2(n)是n时刻发酵箱(1)实际湿度控制值，SH 1(n)是发酵箱(1)设定湿度控制值，PH 1(n)是发酵箱(1)实际湿度值；
    PH值监控过程包括：通过控制器(6)反馈调整β3，使得发酵箱(1)的PH值在6～8，其中，β3满足条件SPH 2(n)＝(1+β3*EPH 1(n))SPH 1(n)，SPH 2(n)是n时刻发酵箱(1)实际PH值控制值，SPH 1(n)是发酵箱(1)设定PH值控制值，PPH 1(n)是发酵箱(1)实际PH值；
    O 2浓度监控过程包括：通过控制器(6)反馈调整β4，使得发酵箱(1)的O 2浓度在5％～25％，其中，β4满足条件SO 2(n)＝(1+β4*EO 1(n))SO 1(n)，SO 2(n)是n时刻发酵箱(1)实际O 2浓度控制值，SO 1(n)是发酵箱(1)设定O 2浓度控制值，PO 1(n)是发酵箱(1)实际O 2浓度值；
    CO 2浓度监控过程包括：通过控制器(6)反馈调整β5，使得发酵箱(1)的CO 2浓度在300ppm～400ppm，其中，β5满足条件SCO 2(n)＝(1+β5*ECO 1(n))SCO 1(n)，SCO 2(n)是n时刻发酵箱(1)实际CO 2浓度控制值，SCO 1(n)是发酵箱(1)设定CO 2浓度控制值，PCO 1(n)是发酵箱(1)实际CO 2浓度值；
    压力监控过程包括：通过控制器(6)反馈调整β6，使得发酵箱(1)的压力抖动范围为-0.01Mpa～0.01Mpa，其中，β6满足条件SF 2(n)＝(1+β6*EF 1(n))SF 1(n)，SF 2(n)是n时刻发酵箱(1)实际压力控制值，SF 1(n)是发酵箱(1)设定压力控制值，PF 1(n)是发酵箱(1)实际压力值；
    层架传动速度监控过程包括：通过控制器(6)反馈调整β7，使控制发酵箱(1)内空间温度与物料温度之差在0.5℃内，控制发酵箱(1)内O 2浓度与物料O 2浓度之差在1％内；β7满足的条件u(n)＝u(n-1)-Δu(n)，u(n)为PID回路的输出，Δu(n)是第n时刻控制量的增量，Δu(n)＝K P[e(n)-e(n-1)]+β7K I e(n)+K D[e(n)-2e(n-1)+e(n-2)]，发酵箱(1)内空间温度与物料温度之差ΔPV 1(n)和发酵箱(1)内O 2浓度与物料O 2浓度之差ΔPO 1(n)经处理合成e(n)作为输入 量，控制层架(201)传动速度的电机运行速度PID控制信号u(n)作为输出量。
  11. 如权利要求9所述的固态发酵方法，其特征在于，还包括物料消毒灭菌输送罐(7)，所述物料消毒灭菌输送罐(7)包括灭菌锅(701)，灭菌锅(701)上开设物料投入口(702)及菌种投入口(703)，灭菌锅(701)内底部设有螺旋搅拌器(704)，螺旋搅拌器(704)的出口可与所述进料口(101)相对接；
    发酵箱(1)内接种物料的获得过程包括以下步骤：
    步骤B1，将发酵物料从物料投入口(702)投入灭菌锅(701)；
    步骤B2，发酵物料在灭菌锅(701)内高温高压消毒灭菌；
    步骤B3，对物料消毒灭菌输送罐(7)降温；
    步骤B4，在无菌条件下，将螺旋搅拌器(704)的出口与发酵箱(1)的进料口(101)相对接；
    步骤B5，将菌种从菌种投入口(703)投入灭菌锅(701)；
    步骤B6，螺旋搅拌器(704)工作，将灭菌锅(701)内的物料与接入菌种混合并通过进料口(101)送入发酵箱(1)。
  12. 如权利要求11所述的固态发酵方法，其特征在于，还包括利用物料消毒灭菌输送罐(7)产生蒸汽供发酵箱(1)消毒灭菌，产生高温灭菌水供发酵箱(1)加湿。
  13. 一种层架循环履带式固态发酵设备，包括箱体，其特征在于，所述箱体内装有多个发酵床架(1,2)，相邻两个发酵床架(1,2)之间通过相应的连接床架(3,4)连通；所述发酵床架(1,2)中的一台与进料接受斗(6)连通；
    每个发酵床架(1,2)和连接床架(3,4)上均装有一层或数层输送带作为发酵床，所述输送带水平或倾斜设置；在所述发酵床架(1,2)的每一层输送带的进料端安装有铺平器(9)，该发酵床架(1,2)的输送带的出料端安装有搅拌器(8)；
    所述输送带的转鼓与所述搅拌器(8)通过驱动装置驱动。
  14. 根据权利要求13所述的层架循环履带式固态发酵设备，其特征在于，所述发酵床架(1,2)的输送带的倾斜角度为相对水平面≤30°。
  15. 根据权利要求13所述的层架循环履带式固态发酵设备，其特征在于，所述发酵床架(1,2)有两台，两台发酵床架(1、2)与两台连接床架(3、4)首尾对应上下重叠连接，整体形成盘旋状，使得物料可从第一发酵床架的最下层前端传送至第二发酵床架的最上层的后端，再经下滑槽下滑至进料接受斗(6)；所述连接床架的输送带为折射形或平直形。
  16. 根据权利要求15所述的层架循环履带式固态发酵设备，其特征在于，所述驱动装置为装在箱体外的电机(12)，该电机(12)的驱动轴伸入箱体内并驱动所述输送带的转鼓和所述搅拌器(8)转动。
  17. 根据权利要求16所述的层架循环履带式固态发酵设备，其特征在于，所述电机有两台，两台电机中，一台电机驱动第一发酵床架的第一层输送带、第一连接床架的第一层输送带、及搅拌器运转，同时通过链条与齿轮连接驱动其它层输送带及搅拌器运转；另一台电机驱动第二发酵床架的第一层输送带、第二连接床架的第一层输送带及搅拌器运转，同时通过链条与齿轮连接驱动其它层输送带及搅拌器运转。
  18. 根据权利要求13所述的层架循环履带式固态发酵设备，其特征在于，在所述发酵箱外配置CIP清洗设备。
  19. 根据权利要求13所述的层架循环履带式固态发酵设备，其特征在于，在每层输送带的前端设清洗液喷头，并在每层输送带下方设置清洗刮板或清洗刷。
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