A complete set of equipment for processing 500 tons of corn embryos per day, reducing 25-30% of the equipment investment in the production link.Among them, the crushing process can be saved 100%, the fermentation process can save 30% investment, the distillation process can save 25% investment, and the distiller's grains can save 30-40% investment.
After the germ is removed, the germ cake is thrown back to the production line for fermentation with no loss of starch and DDGS feed.The energy cost can be reduced by 20% and high quality protein powder can be obtained when DDGS protein feed is produced by evaporation and concentration.Remove the germ and alcohol equipment pipe cleaning, the maintenance cost of the whole equipment can be saved by more than 90%, the steam consumption is greatly reduced, and the sewage discharge is less;
Corn germ, the by-product of corn germ oil, is the core raw material of corn germ oil, which has high market value and can increase the economic benefit of enterprises.
The dry alcohol embryo extraction process is a patented technology of Henan Cereals Engineering Technology Research and Development Center, which has been successfully applied to many alcohol enterprises.
Process introduction: this design scheme is divided into cleaning, embryo removal, powder lifting, including medium pressure air network, high pressure air network, mechanical conveying, PLC automatic control system.The whole production process is monitored by the industrial computer (PLC) in the main control room.
Cleaning section: the process of "one screen, one stone removal, one magnetic separation and one measurement" is adopted.
Raw grain cleaning: the use of cleaning - magnetic separation - stone - metering process.Efficient vibrating screen for cleaning food may also contain large miscellaneous, small miscellaneous, with a vertical suction duct, clean up the dust in food and other light miscellaneous.Magnetic separator selection of permanent magnet cylinder, easy maintenance, can remove the grain may contain iron scraps, screws and other magnetic impurities, can play a protective role in high-speed rotating equipment deembryos.Stone removing machine is used to remove the heavy impurities that may contain stones and other gravity than corn in the grain. Stone removing machine is equipped with medium pressure wind net, which can remove the light impurities of some dust and other light gravity in the grain.Flow scale is used to measure the amount of grain processing, convenient for production and operation management.The dust removal air network is used to remove dust, light impurities and other impurities in the grain, to ensure that the dust content of the air discharged into the atmosphere does not exceed the standard, and to protect the atmospheric environment.
Conditioning section: the cleaned grain is added with water (1-2%) into the tempering chamber for 8 hours, with the purpose of softening the germ, ensuring that the germ is not broken in the process of embryo removal and embryo lifting, and improving the yield of the germ.
Deembryogenesis and embryo extraction section: the process of deembryogenesis -- grading -- rolling embryos -- sieving -- depowdering and embryogenesis -- sieving is adopted.The degerminating machine processes the clean grain from the cleaning section to separate the maize endosperm from the germ.High-square flat screen is used to classify materials processed by deembryoing machine. The materials containing germ go through the blender rolling machine and then enter the next high-square sieve sieve classification to separate materials containing germ. The materials containing germ are processed by depowdering blender, and then screened by high-efficiency vibrating screen and sucked by vertical air duct to separate pure germ.The material without germ produced in the process of sieving and pulverizing and embryo-beating is transported to the hoist by wringing horizontally, and then into the pulverizing powder by vertical conveying.
Medium pressure air network system: this plan sets up a total of 3 sets of medium pressure air network, two sets of stone-removing machine air network, and one set of grading screen air network.To stone need medium voltage wind auxiliary machine work, enables the material on the stone machine screen is in a state of suspension, the proportion of large stones and the proportion of smaller corn formed certain stratification, the proportion of large stone by stone machine screen upward momentum and upward movement, the proportion of smaller corn under the action of wind downward movement, realize the separation of stones with corn.In the working process of stone removing machine, under the action of wind, a part of dust and light impurities are separated.The classification screen in the process of processing can be achieved with the help of wind power larger material and slight leather and miscellaneous separation, to achieve the corresponding process requirements.The hoist, winch and vibrating screen are easy to produce dust in the process of work. This scheme can avoid dust spillovers by setting dust removal air network, ensure the workshop environment, and benefit the quality of finished products and the health of staff.
High pressure air network system: this project adopts a group of high pressure air network.In the whole processing process, part of the section, part of the equipment need to use the wind to transport, choose TY series of high efficiency and high pressure fan, with material strong negative pressure air suction cyclone discharge, wind shutters push down the principle of material to achieve the purpose of wind transport and no dust, so that the production workshop clean.
Mechanical conveying system: part of the material conveying scheme adopts bucket elevator and winch conveying.The vertical direction of material conveying adopts bucket elevator, the horizontal direction of material conveying adopts the dragonnet.
Process characteristics:
1. The water system adopts the new full process water measurement and control system, which is a special equipment for water measurement in the corn processing production line. The system can realize the automation of water regulation in the process of corn processing, such as measuring the water of corn, measuring the flow of corn and adding the flow of water.Automatic adjustment of water valve to achieve water regulation, to grain water, grain water stop, when the flow of corn increases, the water increase automatically, at the same time according to the set of water automatic adjustment to achieve control accuracy, automatic recording.The system uses curve display to provide historical records.Cumulative value of corn flow and water flow can be provided.The system provides alarm for corn flow exceeding standard, alarm for water exceeding standard, and alarm for abnormal water adding.
2, the use of special equipment to roll the embryo grinding, improve the yield of germ, broken embryo does not lose.After increasing the yield, the oil yield can be increased by at least 1-3 thousand points.
3. Rubbing and degerminating machine introduces improved Italian technology, using material swimming degerminating from top to bottom.The machine has high output, small power, no broken germ, high particle size.
4, screening classification equipment because of the material humidity, all 304 stainless steel screen frame and screen mesh, screen frame is not deformation, no blocking screen, to ensure continuous operation, and improve the service life.
