RU2740018C1 - Combined production line of flocculated flakes production for starter and pre-starter feedstuffs for young stock of farm animals with usage of purified biogas - Google Patents

Abstract

FIELD: agriculture.

SUBSTANCE: invention relates to production of flocculated flakes for starter and pre-starter feedstuffs for young stock of farm animals due to use of biogas, can be used in feedstuff industry. Combined technological production line includes bins connected directly or by means of transport devices, auger feeder, magnetic separator, humidification machine, steaming conditioner, crimping machine, drier-cooler and hopper. Line is additionally equipped with a system for cleaning and conditioning biogas consisting of a column for purifying from hydrogen sulphide. Besides it is equipped with a refrigerator, a water vapour purification column, a condensate collector, a fan, a steam generator and a heat exchanger. Cleaned biogas (biomethane) is directed to the burners of the steam generator, and the produced steam - to the conditioner-stirrer and to the steam heater of the drier-cooler.

EFFECT: invention provides implementation of energy-saving technology of production of starter and pre-starter feedstuffs based on flocculated flakes using biogas obtained from livestock complex wastes, reduced specific energy consumption, saving of energy resources and improvement of ecological situation due to processing of livestock complex wastes.

1 cl, 2 dwg

Description

The invention relates to lines for the production of flocked flakes for starter and prestarter feeds for young farm animals through the use of biogas obtained by utilizing organic waste of livestock complexes and can be used in the feed industry.

A known method for purifying biogas (US Patent US 20180221817), which includes the following steps: pre-cooling the waste stream of biogas, to reduce the content of siloxanes, volatile organic compounds and remove water; adsorption of siloxanes, which significantly reduce the amount of siloxanes from the biogas stream; then adding hydrogen gas to the biogas stream; catalytic combustion of the mixed hydrogen with the remaining oxygen, so that oxygen is removed from the biogas and the biogas stream is heated; then the sulfur is hydrogenated to hydrogen sulfide and at the same time chlorine is hydrogenated to hydrogen chloride; then hydrogen chloride is adsorbed; then, hydrogen sulfides are adsorbed using a sulfuric adsorbent; then further adsorption of the remaining hydrogen sulfides; regulating the flow and temperature of the hot biogas returned to the economizer heat exchanger to maintain the biogas temperature downstream of the deoxidizer catalyst bed in the range of 250 ° C to 400 ° C, so that clean biogas fuel is provided.

The known method and installation of separation of carbon dioxide from biogas (Pat. No. EP 2822673 European Patent Office. Method and installation for separation of carbon dioxide from biogas / Gunter Lothar - application No. 13718778, app. 03/08/2013, publ. 01/14/2015), consisting to significantly reduce the methane content in precipitated CO ₂ and improve the overall energy balance of the process. For this rinse solution, loaded on the first desorption stage is treated in a separate step by means of stripping, is separated from that of CO ₂ and completely regenerated washing solution is supplied to the second stage washing and separates contained therein CO ₂ with the regenerated washing solution. This method can significantly reduce methane consumption and improve the overall energy balance.

So-called "amine washers" are used to separate CO ₂ . After purification, the amine solution charged with CO ₂ must then be regenerated for reuse. To obtain methane, biogas is treated with an amine washing solution, and for biogas purification, at least two successive absorption stages, and for regeneration of the loaded washing solution, at least two regeneration stages.

The closest in its technical essence and the achieved effect is the method of combined purification of biogas (Patent No. 2013100384 RF), in which the pre-compressed initial biogas with a carbon dioxide content of 30 ÷ 50% and saturated with moisture is fed into the absorber, where, as a result of excess pressure and flushing of biogas water dissolves carbon dioxide in water. By means of excess pressure, water with dissolved carbon dioxide enters the recuperative heat exchanger, then into the water heater, where it is heated to the temperature required for water regeneration, and is sprayed in the desorber. The pressure in the stripper is maintained at the level of 3 ÷ 11 kPa. Desorption of carbon dioxide from water occurs under the influence of pressure and temperature differences. Further, deep cleaning and drying of carbon dioxide is carried out in two adsorbers operating alternately. Regenerated water is pumped into a recuperative heat exchanger, then into a heat exchanger, where the water is cooled to 15 ÷ 20 ° C and sent to an intermediate tank, from where the cooled water is pumped into the absorber. The biogas purified from carbon dioxide in the absorber is fed to the separator, where, as a result of throttling, partial condensation of moisture occurs, thus reducing the load for the adsorbers. After the separator, biogas is fed for deep cleaning and drying to the state of biomethane (90 ÷ 97% methane) in adsorbers, which work alternately.

Known line for the production of mixed feed from cereal flakes (Patent RU No. 2539151. Line for the production of mixed feed from cereal flakes. Afanasyev VA, Trutneva LA В02С 4/00, A23K 1/00. Patent holders: Ministry of Agriculture of the Russian Federation (RU ), Open Joint Stock Company All-Russian Research Institute of the Feed Industry (JSC VNIIKP) (RU) - No. 2013123295/13, Appl. 05/21/2013, Publ. 01/10/2015. Bull. No. 1), which includes the combined bunkers, feeders, magnetic separators, screening machines, stone separator, crusher, weighing batchers, mixers between themselves directly or with the help of transport devices. Additionally, the line contains an air conditioner-steamer, into which steam and grain of cereals or legumes are simultaneously fed. After the conditioner-steamer, a two-roll flaking machine is installed to produce cereal flakes, from which the cereal flakes are fed to the dryer-cooler and then to the hopper. The hopper is installed in front of the multi-component weighing batcher for introducing the main components of the compound feed.

The main disadvantages of the known line are:

- the impossibility of implementing energy-saving technology for the production and use of biogas obtained from waste of livestock complexes;

- does not solve the problem of saving energy resources and improving the ecological situation in non-gasified regions of the country.

The technical result of the invention consists in the implementation of energy-saving technology for the production of starter and pre-starter feeds based on flocked flakes using biogas obtained from the waste of livestock complexes, reducing the specific energy consumption, saving energy resources and improving the environmental situation through processing waste from livestock farms.

The task is achieved by the fact that in a combined technological line for the production of flocked flakes for starter and prestarter feeds for young farm animals using purified biogas, which includes bunkers connected directly or by means of transport devices, a screw feeder, a magnetic separator, a humidifying machine, an air conditioner. a steamer, a flattening machine, a dryer-cooler and a hopper, new is that the line is additionally equipped with a system for purifying and conditioning biogas, consisting of a column for purifying hydrogen sulfide; a refrigerator, a column for cleaning water vapor, a condensate collector, a fan, a steam generator and a heat exchanger, and the line is configured to direct the purified biogas (biomethane) to the burners of the steam generator, and the resulting steam to the air conditioner-steamer and the steam heater of the dryer-cooler.

FIG. 1 shows a planar view of a combined technological line for the production of flocked flakes for starter and prestarter feed for young farm animals using purified biogas, and FIG. 2 - volumetric-plan view of a combined technological line for the production of flocked flakes for starter and prestarter feed for young farm animals using purified biogas.

The combined technological line for the production of flocked grains for starter and prestarter feed for young farm animals using purified biogas includes the following equipment: grain bin 1; screw feeder 2; magnetic separator 3; dampening machine 4; a bunker for detoxifying grain (detoxifying agent) 5; unit for moisture-heat treatment of grain 6; flattening machine 7; dryer-cooler 8; bunker of processed grain 9; column 10 for cleaning from H ₂ S; refrigerator 11; column 12 cleaning from water vapor; condensate collector 13; fan 14; steam generator 15 and heat exchanger 16.

The combined technological scheme of the line for the production of flocked grains for starter and pre-starter compound feed for young farm animals using purified biogas (Fig. 1) includes the following technological operations:

- performance control for the original product by means of a screw feeder 2, installed at the exit from the grain bin 1;

- cleaning grain from metal-magnetic impurities in the magnetic separator 3;

- grain moistening in a humidifying machine 4;

- uniform distribution of moisture throughout the volume of the supplied grain in the decorator 5;

- steaming grain in apparatus 6 for moisture-heat treatment;

- obtaining grain flakes in a flattening machine 7;

- drying of crimped flakes and their cooling in a dryer-cooler 8;

- storage of processed grain in the bunker 9;

- purification of initial biogas from hydrogen sulfide in column 10;

- cooling of biogas purified from hydrogen sulfide in refrigerator 11;

- removal of water vapor in column 12;

- blowing of the purified biogas by the fan 14 into the steam generator 15;

- obtaining a drying agent in the heat exchanger 16 due to the heat of the combustion products in the steam generator 15.

Livestock farms located in remote, non-gasified areas are in dire need of additional energy sources. In the prime cost of compound feed, a significant part (20-35%) is energy consumption. Therefore, it is advisable to provide for an autonomous power supply of feed production at the expense of biofuel resources. The production and use of biogas obtained from the waste of pig farms almost completely covers their energy needs.

The approximate composition of the biogas produced in the fermenter: methane - up to 60%; carbon dioxide - 35%; other gaseous substances (including hydrogen sulfide, oxygen; nitrogen; hydrogen) up to 5%. In addition, the biogas leaving the fermenter is 100% saturated with water vapor.

Research on purification of biogas from impurities, carried out at the All-Russian Research Institute of the Feed Industry, showed the need to prepare it for subsequent use in steam generator burners to the following composition: methane up to 60%, H ₂ S - up to 20 mg / m ³ , H ₂ O vapors more than 9 mg / m ³ , CO ₂ - up to 36%.

The combined technological line for the production of flocked flakes for starter and prestarter feed for young farm animals using purified biogas (Fig. 1) works as follows.

The original grain is accumulated in the production hopper 1. Depending on the capacity of the line, the feeder 2 through the magnetic separator 3 feeds the grain into the humidifying machine 4 until the moisture content reaches 23-35%. The moistened grain is kept in a decorating device 5 for uniform moisture distribution throughout the entire grain mass.

The moistened grain is fed to the conditioner-steamer 6, where it is processed with steam, and then aged to evenly distribute moisture throughout the grain. The conditioner-steamer 6 is made in the form of three interconnected cylinders, each with a screw inside, driven by an electric motor. Due to steaming and short-term conditioning, the grain is softened for crushing.

In the apparatus for moisture-heat treatment 6, the grain is steamed for 12-14 minutes at an elevated temperature (up to 95 ° C), which makes it possible to increase the digestibility of feed to 85-88%.

The steaming method processes not only grain of cereals (corn, wheat, shelled barley, shelled oats, rye, triticale), but also legumes (peas, soybeans, rapeseed). The specially processed grain is used in the production of pre-starter and starter compound feed. In the process of steaming, water molecules that form saturated or superheated steam have a large reserve of kinetic energy and freely overcome the moisture-retaining layers of the grain. As a result of steaming, the grain is moistened and swells much faster than when treated with water.

Changes in the physicomechanical and biochemical properties of grain have been noted. So, the temperature of the grain after steaming rises to 85-90 ° C, the bulk density decreases. With an increase in the duration of steaming, the degree of gelatinization of grain starch increases and conditions are created for the conversion of starch into dextrins.

The steamed grain is preheated for 3-5 minutes, and then subjected to flattening on a flattening machine 7 with a gap between rollers of 0.40-0.55 mm and cereal flakes are obtained. The flaking machine 7 has a system for regulating the speed of the rolls and the pressure of the roll pressure, which ensures the production of flakes of various thicknesses. The rolls are pressed and the required clearance is maintained by a hydraulic device. The uniformity of grain supply and its distribution along the length of the rollers of the flattening machine is carried out by means of a roller feeder with an adjustable speed.

When the steamed grain is flattened between the rolls, the structure of the swollen starch grains is mechanically destroyed - destruction, which, together with the action of heat, moisture and pressure, leads to gelatinization of starch, determined by the rupture of the starch granule shells. With a decrease in the gap between the rollers, the degree of gelatinization increases. Compared with the original barley, the rate of digestibility of the starch of steamed barley flakes with a high degree of gelatinization increases 2.0-3.5 times.

It has been established that for steamed barley under the same conditions, it is possible to obtain a different degree of starch gelatinization, depending on the size of the gap between the rollers of the flaking machine, that is, on the thickness of the flakes. In this regard, flakes of different thicknesses can have different nutritional value. As the results of our research have shown, the amount of glucose formed during the hydrolysis of the starch of barley flakes increases with a decrease in their thickness, that is, with a decrease in the gap between the rolls in the process of flattening.

The crimped flakes coming out of the crimping machine 7 are sent to the dryer-cooler 8, which is made in a single housing and is divided into two zones: a drying zone and a cooling zone. In the dryer-cooler 8, cereal flakes are dried at a temperature of 80-90 ° C and a drying agent speed of 0.4-0.7 m / s with a decrease in humidity to 8-9%. The air entering the drying zone is heated in a steam heater. Cooling is carried out with air taken from the room. Drying and cooling of the product takes place in a vibro-boiling bed, obtained by vibration of the sieve surface of the dryer-cooler and the air flow supplied by two medium pressure fans. In the cooling zone of the dryer-cooler, the temperature of the dried crimped grains is reduced to ambient temperature with atmospheric air. Dried and cooled flakes are sent to the overdosing bin 9.

Steaming, conditioning, and crushing the peas resulted in a decrease in anti-nutrients such as trypsin inhibitors. In addition, there is an improvement in the microbiological background of the grain after steaming with subsequent crushing. That is, steaming, conditioning, and crushing of grain provides a decrease in the content of anti-nutrients, increases the feed value, and improves microbiological characteristics.

To implement the processes of steaming and drying, biogas is purified to a hydrogen sulfide content of 0.005%, carbon dioxide 50-40%, moisture content 3-5%.

The initial biogas is fed into the column 10 for purification from hydrogen sulfide, the gas purified from hydrogen sulfide is cooled in the refrigerator 11, after which it is supplied to the burners of the steam generator 15 in the column 12 for purification from H ₂ O using the fan 14.

In the steam generator 15, by means of recuperative heat exchange between the combustion products of biogas and water, steam is prepared for steaming in an apparatus for moisture-heat treatment and heating of a drying agent (air) in a heat exchanger 16 for drying crimped grain in a dryer-cooler, followed by its cooling to ambient temperature. The condensate formed in columns 10 and 12 for cleaning from H ₂ S and H ₂ O is discharged into a condensate collector 13.

The proposed combined technological line for the production of flocked flakes for starter and prestarter feed for young farm animals using purified biogas obtained from the processing of waste from livestock complexes has the following advantages:

- allows you to effectively produce flocked flakes for their further use in the production of starter and pre-starter feeds for young farm animals using purified biogas obtained from the waste of livestock complexes;

- technology for the production of flocked flakes due to the combustion of purified biogas in a steam generator, provides for the production of highly efficient feed in non-gasified areas;

- flocking will increase the feed value of flakes by increasing the digestibility of starch, changing the protein complex of the grain, inactivating inhibitors of the digestive tract and the formation of aromatic substances that improve the taste of grain.

Claims (1)

Combined technological line for the production of flocked flakes for starter and prestarter feed for young farm animals using purified biogas, including bunkers connected directly or by means of transport devices, a screw feeder, a magnetic separator, a humidifier, an air conditioner-steamer, a flattening machine, a dryer - a cooler and a bunker, characterized in that the line is additionally equipped with a system for purification and conditioning of biogas, consisting of a column for purification from hydrogen sulfide; a refrigerator, a column for cleaning water vapor, a condensate collector, a fan, a steam generator and a heat exchanger, and the line is configured to direct the purified biogas (biomethane) to the burners of the steam generator, and the resulting steam to the air conditioner-steamer and the steam heater of the dryer-cooler.

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