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FEED
MANUFACTURING IN
THE 21st CENTURY
21世纪的饲料制造业
By
Fred J. Fairchild, P. E.
Professor
Department of Grain Science & Industry
Kansas State University
Manhattan, Kansas USA
CHANGE
IS
INEVETABLE
变化是必然的
SOCIAL AND ECONOMIC
ISSUES, AS ALWAYS,
WILL CONTINUE TO
DRIVE CHANGE
社会与经济因素仍将引发
变革
FACTORS BRINGING ABOUT
CHANGE
带动变革的因素
Environmental Concerns
环境关切
* Air Pollution空气污染
*Water Pollution 水污染
*Animal Waste Disposal 动物粪便处理
*Odor Control 臭气控制
FACTORS BRINGING ABOUT
CHANGE
带动变革的因素
Public Safety, Laws and Regulations
公共安全与法律法规
Food Safety-Microbiological
食品安全-微生物
Feed Additives/Growth Promotants
饲料添加剂/促生长物
Pesticide and Chemical residues
杀虫剂与化学物残留
FACTORS BRINGING ABOUT
CHANGE 带动变革的因素
Microbiological Contamination
微生物污染
Current Regulations on Meat and Bone Meal
目前针对肉骨粉的法规
Heat Sterilization Policies of the EEC
EEC对热消毒处理政策
HACCP Programs that include Feedmills
包括饲料厂的HACCP方案
FACTORS BRINGING ABOUT
CHANGE带动变革的因素
Process Control and Automation
过程控制与自动化
* Complex Process-e.g. Expanders 复杂工
艺-如膨胀器
* Labor Replaced by Automation 自动化代
替人工
* Feed Quality/Consistency 饲料质量/均匀
* Information Management 信息管理
"We live in an age where
我们生活在这样一个时代
CONSUMER POWER
消费者的力量
frequently outweighs
往往大于
SCIENTIFIC PERSUASION".
科学的主张
Feedstuffs 72:3, 1999
FACTORS BRINGING ABOUT
CHANGE 带动变革的因素
Feed Industry Structure
饲料产业结构
* New Equipment Availability 可用的新设备
* Mergers, Acquisitions and Divestments 合并
,兼并与撤资
* International Ownership 外资拥有
* Marketing Structure 市场结构
* Vertical Integration 纵向一体化
THE FUTURE!
未来
INGREDIENTS
原料
Current Global Population of 6.0 Billion+
目前全球已超过60亿人
"87 Million People Added Annually"
每年增加8700万人
"Conventional technology alone will notallow
food, feed, and fiber production to be
increased sufficiently to meet the needs of the
10 billion global population of the 21st
century"
仅靠传统科技不能提高食品,饲料与纤维生
产来满足21世纪100亿人的需要.
Biotechnology is the only Significant
Means to Increase Food, Feed, and Fiber
Production
生物技术是提高食品,饲料及纤维产
品的唯一重要的手段
|Currently 5 billion tons of food is produced
annually.目前每年生产50亿吨食品
|30% (1.5 billion tons) is lost to pests
30%(15亿吨)失于虫害
|Loss of cultivable land (0.44 ha/capita in
1961; only 0.26 ha in 1997). 耕地的损失(
1961年6.6亩/人,1997年3.9亩/人)
Number of Transgenic Crop Field Trial Sites in
the USA 1987-1997
1987-1997年美国转基因作物的田间试验数
44%
4%1%11%
3%
11%
4%
2%
8%
12%
Corn玉米
Sugar beat 甜菜
Tomato番茄
Cotton棉花
Canola菜籽
Melon/squash
瓜类
Potato土豆
Others
其它
Soybean
大豆
THE FUTURE! 未来
INGREDIENTS 原料
Genetically Modified Organisms (GMO's)
基因改良物
Must be Identity Preserved 必须分开保存
May Have 4 to 6GMO'sPlus Commodity Grains
in a Single Feed Mill 在一家饲料厂中可能除普通
谷物外还有4-6种转基因粮
Bin Space, Grinding, Inventory, and QA 仓容,
粉碎,储存,质量保证
THE FUTURE! 未来
RECEIVING AND STORAGE
收储
* High-Speed Unloading 高速卸料
* Ingredient Segregation 原料分级
* Inbound Analysis and QC 厂内质检
High Speed Infrared Instrument 高速远红外仪
THE FUTURE! 未来
GRINDING OPERATIONS
粉碎工段
* Hammer Design and Metallurgy
锤片设计与冶炼加工
* Air Assist System Design 风助设计
* Noise Control 噪音控制
* Automation and Routing 自动化与程序化
* Quick-Change Screens 快速换筛
* Quick-Change Hammer Gangs 快速换锤片
THE FUTURE! 前景
GRINDING OPERATIONS
粉碎工段
* Vertical Shaft Hammermills
立轴式锤片粉碎机
-European Designs now available
欧洲设计,已出品
-Air-Assist not recommended
不建议用风助
THE FUTURE!前景
GRINDING OPERATIONS
粉碎工段
* AUTOMATION 自动化
-The One System That Clearly Should Be
Automated!! 很应自动化的系统
-Start-up/Shut-Down, Routing and
Ingredient Changes启动/停机,编程及换料
-Lights Out Operations 快跑的工段
THE FUTURE!未来
Proportioning Systems
配料系统
* On-line Reformulation 在线更改配方
* Weighing Accuracy 称量精度
Loss-in-WeightSystems 减重系统
* Short Cycle Batching 短周期配料
1.0-1.5 Min. Cycles 1.0-1.5分钟周期重量的误差分布,超过200%的放在200类(最大的
记录误差为440%)
THE FUTURE! 未来
Mixing and Mixing Equipment
混合与混合设备
* Trend is Toward Large
(12-16 Ton) Mixers.
趋势是用大混合机(12-16吨)
Concern with Uniformity!关注均匀度
* Smaller, Short-Cycle Mixers
小型短周期混合机
-1.0 to 1.5 Min.Mixing Cycles
1.0-1.5分钟混合周期
-High Flexibility 高灵活度IMPROVED RIBBON DESIGN 改良螺带
IMPROVED PADDLE DESIGN 改良桨片
H&S
TR Mixer
混合机
Pelleting 制粒
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
Pelleting Will NotGo
Away!!!
将来也要制粒
THE FUTURE!未来
PELLETING-CONDITIONING
制粒与调质
Conditioning Time Control
调质时间控制
-Variable Shaft Speed 变轴速
-Pick Angle Control 控制角度
-Steam Block Panels 蒸汽挡板
-Conditioner Angle 调质器角度
THE FUTURE!未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
On-Line Moisture Control
在线水分控制
"MOISTURE MANAGEMENT"
水分管理
The Effect of Precise Moisture
Control on Pelleting Operations
水分精确控制对制粒工段的影响
Incoming
进料
Target
目标
Actual
实际
Conditioned
调质后
(%)(%)(%)(%)
11.412.012.215.1
11.013.013.015.9
10.914.014.016.8
10.714.514.717.0
11.115.015.118.5
Moisture and Conditioning Results
水分与调质结果批模式
水分传感器
流量泵
水表
电磁水阀手动水阀
重量模拟
信号
72
74
76
78
80
82
84
86
88
90
12131414.515
PDI(%)
Effect of Added Moisture on Pellet Quality
加水对制粒质量的影响
PDI%
Starting Mash Moisture (%) 开始时水分
颗粒持久
性指数
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
EXPANDERS
膨胀器
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
COMPACTOR
压缩机
Compactor
Roll
Assembly
压缩机之压
轴组件
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
UNIVERSAL PELLET COOKER
通用制粒蒸煮机
The "UPC"
from
Wenger Manufacturing
料仓
进料器
2-3分钟驻留时间
制粒头
切刀
14-18%
水分的
颗粒料
加液体
加蒸汽电机
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
PRESSURE PELLETING
加压制粒PRESSURIZED CONDITIONING
PCI, Inc. Wichita, Ks.
加压调质
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
"ON-LINE"
ROLL ADJUSTMENT
"在线"压辊调节
Remote Roll Adjust 远程压辊调节
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
Formulating for Pellet
Quality !!给颗粒质量做配方
Is It Possible 可能吗
THE FUTURE!未来
COOLERS AND COOLER DESIGN
冷却机及其设计
Counter Flow Coolers
Are Here To Stay!
逆流式冷却机使用良好
THE FUTURE! 未来
COOLERS AND COOLER DESIGN
冷却机及其设计
Future Designs Will
Include Drying Capability
未来的设计将包括干燥能力
THE FUTURE! 未来
Post Pellet Additive Application
制粒后添加
*Low Inclusion Liquids
低含量液体
-Enzymes 酶
-Drugs 药物
-Vitamins 微生物
-Biologicals 生物品
THE FUTURE! 未来
Load Out System Design
出料系统设计
* Finished Feed Blending
成品料混合
Can Create an Infinite number of
Feeds to Match Stage of Growth
为配合生长阶段能造出无数种饲料
SUMMARY 结语
*Consider the Economics
虑及经济性
* Consider the Alternatives
考虑其它可选方案
*Make Logical, Rational Decisions
做出合理决策
*Watch Related Developments
关注相应进展
DRY MATERIAL HANDLING
EQUIPMENT SELECTION
干物料输送设备的选择
by
Fred J. Fairchild, P. E.
Professor
Department of Grain Science and Industry
Kansas State University
Manhattan, Kansas
DRY MATERIAL
HANDLING
干物料的输送
Definition定义:
"The movement of a material from one
location to another while insuring its
arrival in proper condition." 将物料从一
处运到另一处,并在适当条件下保证其
到达.
MATERIAL HANDLING
物料输送
High Speed
高速
Self Cleaning
自清
Minimum Interchanges
交换少
Eliminate Void Areas
消除无用空间
Material Handling
物料输送
Handling Methods:输送方法
Manual 手工
Gravity 重力
Mechanical 机械
Pneumatics 气动
Material Characteristics Affecting
Equipment Selection
物料特性影响设备的选择
Size 大小
-Fine, Granular, Lumpy
细,颗粒,块状
Flowability 流动性
-Very Free Flowing, Free Flowing, Sluggish
很易自流,易自流,缓流
Friction 摩擦
-Abrasiveness, Stickiness
磨蚀性,粘性
Material Characteristics Affecting
Equipment Selection
物料特性影响设备的选择
Hydroscopic吸湿性
Corrosive 腐蚀性
Fumes or Dust 烟尘
Degradability 降解性
Particle Separation 颗粒分散
Contamination 污染
Fluidity 液体
Packing or Pressure 成团或压力
Temperature 温度
Age 年龄
Factors Affecting Equipment
Selection
影响设备选择的因素
The characteristics and behavior of the
material(s) to be handled is the most
important consideration in handling
equipment selection.
物料的特性及其在输运时的表现是选择
输送设备时应考虑的重要因素.
Types Handling Equipment
输送设备的类型
Gravity Spouting, Valves and Distributors 重力
喷管,闸门和分配器
Screw Conveyors 螺旋输送机
Drag Conveyors 刮板输送机
En-Masse Conveyors 整体输送机
Belt Conveyors 皮带输送机
Pneumatic Conveyors 气动输送机
Oscillating / Vibratory Conveyors 震动输送机
Bucket Elevators 斗式提升机
Gravity Conveying
重力输送
Gravity Conveying重力输送
Valves 闸门
Flip/Flop Type 翻板式
"A"Style
A型
"K" or "Y" Style
K 或Y型
Gravity Conveying重力输送
Valves闸门
Flip/Flop Type翻板式
"A"Style
A型
"K" or "Y"Style
K 或Y型
Gravity Conveying重力输送
Valves闸门
Bucket Type 斗状
"A"Style
A型
"K" or "Y"Style
K 或Y型
Gravity Conveying重力输送
Valves闸门
Bucket Type斗状
"A"Style
A型
"K" or "Y"Style
K 或Y型
Gravity Conveying重力输送
带仓管转头式分配器系统
Gravity Conveying重力输送
Requires no energy to move materials. 输送物料不
需能源
Minimal mechanical components to maintain.
需维护的机械部件很少
Requires large vertical heights. 需要较高垂直高度
Slope must exceed angle of static friction. 倾斜要大
过静流角
High wear at contact points. 接触磨损严重
Can break up materials being conveyed. 有可能将
输送的物料打碎
Advantages优点:
Disadvantages缺点:
Screw Conveyor 螺旋输送器
Screw
Conveyor
螺旋输送器
特殊输送螺旋
Screw
Conveyor
螺旋输送器
特殊输送螺旋
Screw Conveyor 螺旋输送器
15% Loading 装料15%
Very abrasive, Fine particles/irregular shapes
Mineral powders 用于非常高磨蚀性
30% Loading 装料30%
Mildly/moderately abrasive 中等磨蚀性
Most soft feed ingredients 多数软饲料原料
45% Loading 装料45%
Mildly/abrasive, Free flowing中等磨蚀性,易流动
Whole grains, pelleted feed 全谷物,颗粒料
100% Loading 装料100%
Screw feeders 螺旋进料器
Volumetric metering 体积计量器
Screw
Feeder
螺旋进料器
MAJOR
INGREDIENTS
主原料
MINOR
INGREDIENTS
次原料
LIQUIDS
液体
MICRO
INGREDIENTS
微量原料
GROUND
GRAINS
已粉碎谷物
SCALE
称#1
SCALE
称#2
SCALE
称#3LIQUID
SCALE 液体称
MIXER 混合机
SURGE BIN 缓冲仓
Multiple Feeders & Conveyors
多进料器及输送机
Screw Conveyor
螺旋输送机
Low initial cost. 初装成本低
Can be used in horizontal, inclined or vertical
position. 可为卧式,斜式或立式
Continuous rate of discharge. 连续卸料
Can combine conveying and mixing. 可同时输送
和混合
Convey widely varying materials.可输送变化范围
很大的原料
Multiple inlets and outlets. 多进口和出口
Reasonably low maintenance. 维护成本相对较低
Advantages 优点:
Screw Conveyor
螺旋输送机
Not self-cleaning. 不能自清
Low efficiency. 效率低
Can break or damage materials being
conveyed. 可能破损所送物料
Can only be installed in a straight line. 只
能直线安装
Subject to material buildup at
intermediate outlets. 中间出口可能积料
Disadvantages 缺点:
Drag Conveyor
刮板输送机
Round Bottom
Style
圆底式
Drag
Conveyor
刮板输送机
Flat
Bottom
Style
平底式
Drag Conveyor
Side Wall Return Style
'侧壁回弯'式刮板输送机
Drag
Conveyor
刮板输送机Side
Wall Return
Style
'侧壁回弯'式刮
板输送机
Drag Conveyor
刮板输送机
圆底侧弯
平底
Drag Conveyor
刮板输送机
Moderate initial cost. 中等初装成本
Can convey both horizontal and vertical in
some models. 某些型号可同时平输和立输
Can turn corners in some models. 某些型号
可转角
Reasonably self-cleaning.适度自清
Minimum material breakage or damage. 很
少物料破损
Advantages 优点:
Drag Conveyor
刮板输送机
Usually low efficiency.
Dense ingredients difficult to convey.
Paddle wear.
Material carryover.
Disadvantages:
En-Masse
Conveyors
平底整体式输送机
En-Masse Conveyors
整体式输送机
More efficient. 更高效
Conveys large volumes of material. 输送大量物料
Self-Cleaning. 自清
Conveys free-flowing granular materials well.很好地输
送易流动的颗粒
Some material carryover. 有些残余料
Loses capacity quickly on incline. 内嵌式对输送能力损
失很快
Won't convey fine or fluffy materials 不能输送细粉或
蓬松的物料
Advantages 优点:
Disadvantages 缺点:
Belt Conveyors
皮带输送机
封闭辊式皮带输送机
Belt
Conveyors
皮带输送机
Belt Conveyors皮带输送机
High efficiency, low power requirements. 高效
,低能耗
Large capacity over long distances. 长距离,高
能
Practically self-cleaning.实际自清
Gentle material handling. 轻缓送料
Low maintenance. 低维护
Sometimes difficult to enclose. 有时难封闭
Not made for easy intermediate discharge
points. 难设中间卸料口
Advantages 优点:
Disadvantages:
Pneumatic Conveyors
气动输送
Positive Systems 正压
正低气压输送机
Pneumatic Conveyors
气动输送
Positive Systems正压
Pneumatic Conveyors
气动输送
Positive Systems正压
Pneumatic Conveyors
气动输送
Positive Systems正压
Can be discharged to multiple locations.
可在不同位点卸料
Most efficient use of air for conveying. 运
用输送气流效率高
Can operate at high pressure and dense
loading. 可在高压下运转,提装料强度
No special filtration required for intake
air. 入气无需特别过滤
Advantages优点:
Pneumatic Conveyors
气动输送
Positive Systems正压
Difficult to use multiple pickup points. 难用做多点
取料
Heat build-up in air due to compressing air at
pump. 因气泵压缩,气温上升
Drying affect on materials.使物料干燥
High velocity can cause material breakup. 高速可
导致物料破损
High wear potential for system components. 可能磨
损系统配件
High energy use. 能耗多
Disadvantages 缺点:
Pneumatic Conveyors 气动输送
Negative Systems 负压系统
Pneumatic Conveyors 气动输送
Negative Systems 负压系统
Can pickup materials from multiple sources. 可
在多点取料
Operates at negative pressure and controls dust
emissions. 负压操作,控制尘漏
Can handle heat sensitive materials. 可输送怕
热的物料
Advantages 优点:
Conveyors 气动输送
Negative Systems 负压系统
Single discharge point. 单卸料点
Low efficiency, high energy requirements. 低效,高能
耗
Low material to air ratio. 料,气比低
Drying effect on materials handled. 对所送物料有干燥
作用
Must protect blower/fan from materials. 须防止物料到
吹气扇上
Higher energy use. 高能耗
High maintenance. 高维护
Disadvantages 缺点:
Oscillating/Vibratory
Conveyors 震动输送机
Oscillating/Vibratory
Conveyors 震动输送机
Convey hot, abrasive or corrosive materials. 输送高温
,磨蚀腐蚀性的物料
Self-cleaning. 自清
With screen bottoms can be a screener.
如有筛底可做筛用
Limited capacity.产能有限
Capacity varies with materials. 不同物料不同产能
Conveys in straight line only. 只能直线输送
Advantages 优点:
Disadvantages 缺点:
Bucket
Elevators
斗式提升机
Bucket Elevators斗式提升机
Self-Cleaning
Elevator Boot
自清式斗式提升机
Bucket Elevators斗式提升机
Lowest power for vertical conveying. 垂直输送
能耗低
Positive movement of materials.物料正移动
Carries most types of materials. 可送多数原料
Can be slowed down for gentle handling. 可调
慢以便轻缓运料
Advantages 优点:
Bucket Elevators斗式提升机
Conveys only vertically. 只能垂直输送
Can emit dust unless attached to dust system.
不装除尘系统便会排尘
Potential for dust explosions. 有粉尘爆炸的可
能
Requires regular maintenance. 需要经常维护
Disadvantages 缺点:
SUMMARY 结语
Know the characteristics of the material
conveyed. 了解要送物料的特性
Select the proper equipment for the
application. 按用途选择设备
Material handling equipment handles material
by volume, not weight. 输送设备是按体积运料
并非重量
Select conveying equipment to minimize
damage to conveyed material(s). 选择合适的设
备防止损伤物料
SUMMARY 结语
Do not overfill/overload the conveying
equipment. 不要给输送机超量
Choose conveying equipment that requires the
least amount of energy to do the job. 选择用能
量少的输送设备
As density changes, so do energy requirements
to power the equipment. 容重变化,设备用能
力变化
Consider the needed useful life of the
equipment. 考虑设备的使用寿命
GRINDING
PARTICLE SIZING
粉碎粒度确定
By
Fred J. Fairchild, P. E.
Professor
Department of Grain Science &
Industry
Kansas State University
Manhattan, Kansas, USA
WHY DO WE GRIND
为什么要粉碎
IMPROVED ANIMAL
PERFORMANCE 动物性能
INCREASED MIX UNIFORMITY
混合
IMPROVED PELLETING制粒
MEASURING PARTICLE
SIZE 测粒度
PARTICLE SIZE TEST
(ASAE STANDARD -S319)
测粒度
This method involves using a sieve stack
to determine the geometric mean particle
size (dgw) and the geometric standard
deviation (sgw).
Results can be obtained either
graphically or through calculations.
Ro-tap Sifter
with
Sieve Stack
摇筛机与套筛
A Quick Method for Estimating
PARTICLE SIZE
快速法评定粒度
No. 14 Sieve
A Quick Method for Estimating
PARTICLE SIZE 快速粒度估测法
100050-60%
90060-70%
80065-75%
70070-80%
60080-90%
50090-95%
Particle Size
粒度(Microns)
Minus 14 Mesh
14目下(%)
METHODS OF GRINDING
粉碎方法
Impact 撞击
Compression 挤压
Shear 剪切
Attrition 研磨
HAMMERMILLS 锤片式
受锤片末端速度影响
ADVANTAGES 优点
Ability to grind a wide variety of
materials原料范围广
Ease of maintenance, less maintenance
cost 易维护
Versatility 多功能
Less complicated to operate 易操作
Less initial cost 初价低
DISADVANTAGES 缺点
Energy consumption
耗能
Produces a greater Sgw
标准差大
Noise and dust pollution
吵,粉尘
Heat generation and moisture loss
产热,失水
AIR ASSIST SYSTEM
风助系统
AIR ASSIST SYSTEM
风助系统
AIR ASSIST SYSTEM
风助系统
ROLLER
MILLS
压辊式粉
碎机
ADVANTAGES 好处
Electrical efficiency
电效高
Particle size uniformity
粒度一致
Less maintenance
少维护
Less dust pollution
少粉尘
DISADVANTAGES 缺点
Higher initial cost 初价高
When maintenance is needed it is
expensive 维护成本高
Can not effectively grind fibrous
materials 不适宜纤维粉碎
Reduced throughput at small particle
sizes 粒度小时产量低
粉碎玉米时的效率对比
ENERGY COST
COMPARISON 辊式与锤片式能耗对比
Roller Mills vsHammermills
.05
.35
.47
.65
1.31
1.56
Energy
Cost
($/ton)
861,813Roller Mill
2,040Hammermill
28709Roller Mill
718Hammermill
辊式
16432Roller Mill
399Hammermill
锤式
Savings
(%)
Particle
Size
(microns)
Grinder
Type
GRINDING
SYSTEMS
粉碎系统
PRE-GRINDING SYSTEM
前粉碎
Advantages 好处
Longer grinding time a t full motor load 电
机满负荷时,粉碎时间长
Gives a buffer for down time or maintenance
on the grinder 留出了维护和停机时间
Disadvantage 缺点
Requires more storage bins for both ground
and raw ingredients 需要更多的料仓来存放
已粉碎及原料
POST GRIND SYSTEM
后粉碎
Advantages 优点
Accommodates material changes易应付原料
变化
Does not require as many storage bins 不要
太多料仓
Disadvantages 缺点
Less energy efficient 能量利用率低
Directly affects the capacity of the facility 直
接影响设施产能
需粉碎原料去混合机原料
称
喂料
锤片粉
碎机
混合
FINE GRINDING
EQUIPMENT
微粉碎设备
BURR MILL 强压磨粉机
Fine Grinder 微粉机
FitzMill
Air Swept Pulverizer
风扫研磨机
Direct Cooled Grinding System
直冷粉碎系统
INNOVATIONS
IN
GRINDING
粉碎创新
THE FUTURE! 前景
GRINDING OPERATIONS
粉碎操作
* Hammer Design and Metallurgy
锤片设计与冶炼加工
* Air Assist System Design 风助设计
* Noise Control 噪音控制
* Automation and Routing 自动化与程序化
* Quick-Change Screens 快速换筛
* Quick-Change Hammer Gangs 快速换锤片
THE FUTURE! 前景
GRINDING OPERATIONS
粉碎工段
* Vertical Shaft Hammermills
立轴式锤片粉碎机
-European Designs now available
欧洲设计,已出品
-Air-Assist not recommended
不建议用风助
VERTICAL
SHAFT
HAMMERMILL
立轴锤片粉碎机
THE FUTURE! 前景
GRINDING OPERATIONS
粉碎工段
* AUTOMATION 自动化
-The One System That Clearly Should Be
Automated!! 很应自动化的系统
-Start-up/Shut-Down, Routing and
Ingredient Changes启动/停机,编程及换料
-Lights Out Operations 快跑的工段
LIQUIDS:
New Ingredients, New
Applications
液体:新原料,新用法
by
Fred J. Fairchild, P. E.
Professor
Department of Grain Science and Industry
Kansas State University
Manhattan, Kansas
Chronology of Liquid
Addition液体添加史
Molasses糖蜜 1850
Animal Fat 动物脂 1954
Liquid Methionine1977
液体蛋氨酸
Chronology of Liquid Addition
液体添加史-1990's
Amino Acids 氨基酸
Vitamins 维生素
Pigments 着色素
Mold Inhibitors 防霉剂
Flavorings 调味剂
Enzymes 酶
Liquids Used in Feeds
Fats & Oils
用于饲料的液体油脂
Liquid 液体Addition Point(s) 添加点Maximum 最大量Remarks 备注
Animal 动物Mixer, 混合机6%Heated storage/dispensing
Conditioner, die, coater 12%加热储存/添加
调制器, 压模, 喷涂机
Fatty Acids 脂肪酸Mixer, die, coater6%Heated storage/dispensing
混合机, 压模, 喷涂机加热储存/添加
Palm Oil 棕榈油Mixer, die, coater6%Heated storage/dispensing
混合机, 压模, 喷涂机加热储存/添加
Lethicin Mixer, die, coater2%Heated storage/dispensing
混合机, 压模, 喷涂机Difficult to pump 难以泵送
Liquids Used in Feeds
Molasses
用于饲料中的液体糖蜜
LiquidAddition Point(s)MaximumRemarks
液体添加点最大量备注
BeetMixer 混合机4%Some heating required
甜菜 Conditioner, Loadout/Bag10%需要一些加热
调制器, 装车/包袋
CaneMixer 混合机4%Some heating required
甘蔗 Conditioner, Loadout/Bag14%需要一些加热
调制器, 装车/包袋
Liquids Used in Feeds
Amino Acids
用于饲料中的液体氨基酸
LiquidAddition Point(s)MaximumRemarks
液体添加点最大量备注
Lysine 28%Mixer2%Heating reqd., Corrosive
赖氨酸混合机需加热,腐蚀性
Lysine 50%Mixer1%Corrosive
赖氨酸混合机需加热,腐蚀性
Methionene Mixer1%Corrosive
蛋氨酸混合机需加热,腐蚀性
Liquids Used in Feeds
Other Liquids
用于饲料中的液体其它液体
Liquid 液体Addition Point(s) 添加点MaximumRemarks 备注
Pro-Vitamin 维生素类最大量
Choline 胆碱Mixer 混合机1%Corrosive 腐蚀性
Enzymes 酶
Phytase 植酸酶Coater 喷涂机0.02%Heat sensitive 热敏感
B-Gluconase 葡聚糖Coater 喷涂机0.10%Heat sensitive 热敏感
Acids 酸
Proprionic 丙酸Mixer 混合机1%Corrosive 腐蚀性
Formic 甲酸Mixer 混合机1%Corrosive 腐蚀性
Positive Displacement Meter
正位移计
Accuracy Affected by:
精度受以下因素影响
Temperature 温度
Pressure 压力
Voids 空间
Viscosity粘度
Measures by Volume
体积定量
Mass Flow Meter
质量/容积流量计
Measures by
Mass of Liquid
质量定量
Compensates
for:补偿以下方面
Temperature温度
Pressure 压力
Voids 空间
Viscosity 粘度
Strainer 滤器
Meter 表
Spray Nozzle
喷嘴
1.Direct Liquid Addition System
直接液体添加系统
Pump 泵
Liquid
Tank
液体罐Strainer 滤器
2. Batch Liquid Addition System
分批液体添加系统
Pump泵
Liquid
Tank
液体罐
Liquid
Weigh
Hopper
称量斗
To Mixer/Coater
至混合机/喷涂机
3. Batch Liquid Addition -Fixed Rate Application
分批液体添加-固定量添加
Strainer
滤器
Pump泵
Liquid
Tank
液体罐
Liquid
Weigh
Hopper
称量斗
Metering
Pump计量泵
Spray Nozzle
喷嘴
4. Direct Liquid Addition System-
Controlled/Variable Flow Rate
直接液体添加系统-可控/变速流量
Strainer
滤器
Spray Nozzle
喷嘴
Liquid
Tank
液体罐
Variable Speed
Positive Pump
变速主动泵
Dry Flow Rate Sensor
干流量传感器
Mass
Flow
Meter
质量表
5. Batch Liquid Addition -
Controlled Rate Application
分批液体添加-可控流量添加
Strainer
滤器
Pump泵Liquid
Tank
液体罐
Liquid
Weigh
Hopper
称量斗
Spray Nozzle
喷嘴
Dry Flow Rate Sensor
干流量传感器
Mass
Flow
Meter
质量表Variable Speed
Positive Pump
变速主动泵
LIQUID APPLICATION
SYSTEMS
液体添加系统
Point 位置Type 种类System 系统Dry Ingredient 干原料Remarks 备注
Mixer 混合机Batch 分批1, 2, 3Weighed Batch 称重配料
Mixer 混合机Continuous 连续4, 5Weighed Rate 称重率Cont. Monitoring 连续监控
Conditioner 调质器Continuous 连续4, 5Weighed Rate 称重率Cont. Monitoring 连续监控
Pellet Die 压模Continuous 连续1*, 3Volumetric Rate 体积率*Metering Pump 计量泵
Pellet Die 压模Continuous 连续4, 5Weighed Rate 称重率Cont. Monitoring 连续监控
Coater 喷涂机Continuous 连续4, 5Weighed Rate 称重率Cont. Monitoring 连续监控
Vacuum Coater真空喷涂机分批Batch 分批3Weighed Batch 称重配料
Dry Product Weighing
Accuracy
干品称量精度
Weighing Equipment 称量设备Accuracry* 精度System 系统
Volumetric Metering 体积计5%Continuous 继续
Impact Plate 冲击板5%Continuous 继续
Drag/Screw Conveyor on Scale System3%Continuous 继续
称量系统的螺旋输送器
Loss-In-Weight 重量损失1%Continuous 继续
Scale Hopper 称量斗0.1 - 0.2%Batch 分批
*Accuracy based on plus or minus % variation applied to scale system including weight of equipment.
精度基于称量系统,包括设备重量的变异+, -的%Liquid Application at the Mixer
混合机上的液体添加装置
重量
喂料斗
中的重
量损失
制粒机
调质器
失重
喂料系统
低重量填料点
Liquid Application at the Pellet Die
制粒机上的液体添加设备
Post Process Coating
加工后喷涂
Accurate dry mass rate flow
精确干料流动
Uniform distribution of dry material
干料整齐分散
Accurate measurement of liquid application rate
液体添加精准
Proper droplet size of applied liquid
液滴大小合适
Post Process Coating
加工后喷涂
Proper temperature of dry material and
liquid(s)
干料,液体温度合适
Uniform distribution of liquid(s) (atomization)
液体分布整齐(自动)
Adequate mixing
混合充分
Adequate retention time
停留时间充分
Post Processing
Post Process Liquid Application
after Pelleting
制粒后的液体添加
Loadout
Post Process Liquid Application
at Loadout/Bagging
卸料/打包口处的液体添加系统
Enzyme Addition Flow
酶制剂添加
Metering Pumps
计量泵
Flow Meters
流量计
Controller
控制器
Liquid Tank
液体罐
Enzyme/Water Metering (BASF)
酶/水计量/(BASF)
ProMinet
Liquid
Addition
Cabinet
液体添加柜
ProMinet
Liquid
Addition
Scale
液体添加称
ProMinet4 Enzyme Addition System
ProMinet4 酶剂添加系统
ProMinet4 Water Addition System
ProMinet4 添加加水系统
ProMinet4 Liquid Mixing System
ProMinet4 液体混合系统
Micro Fluid System Coater
(Sprout Matador)
微量液体系统喷涂
Weigh Table
Spray Chamber
Individual
NozzlesVolumetric
Feeder
Micro Fluid System Coater
(Sprout Matador)
微量液体系统喷涂
Liquid Addition Accuracy > 98%
液体添加精度
CV's < 10%
Xylanase 500g./ton
木聚糖酶
Apply Up To 8 Liquids Simultaneously
同时可添加多达8种/液体
Micro Fluid System Diagram
微量液体添加流程图
Mistcoater (APEC)
雾状喷涂
Spinning Disk -Dry Product
旋转碟-干料
Spinning Disks -Liquid
旋转碟 -液体
Mixing Chamber
混合室
Mistcoater(APEC)
雾状喷涂
No pressurizing or spraying of liquid
无液体压力或喷雾
Disk speeds vary by application
碟盘速度可变
Will handle anyflowableliquid
适于任何流体
Auto-Koter (Hayes & Stolz)
Surge Hopper
缓冲料斗
Metering Conveyor
on Load Cells
装料室的计量输送器
Spray Chamber
喷雾室
Mixing Conveyor
混合输送器
Auto-Koter(Hayes &Stolz)
Fat addition accuracy = 2-5%
油脂添加精度
At 5% addition rate = 4.9 -5.1 % fat
added
添加5%时=加了4.9 -5.1 %
Enzyme addition with water and air
added for atomization
酶与水,气共同添加可自动化
MicroCoater(Beta Raven)
Conveyor Belt
"S" Shaped
Spray Chamber
Mass Flow Meter
MicroCoater
(Beta Raven)
Liquid Application
Point #1
Product Stream
Liquid Application
Point #2
Momentum Meter
MicroCoater(Beta Raven)
"S" Shaped chamber prevents product damage.
S 型状料室防止产品损伤
Thin curtain of product = consistent coating.
薄料层= 连续喷涂
Normally no additional mixing required after
chamber. 料室外不需再混合
99.1% Accuracy 99.1%精度
Average Cv is 7.8 for phytase applied at rate of
0.1 pounds per ton. (diluted 8:1)
每2000磅加0.1磅加植的酶的变异系数Cv为
7.8(8:1稀释)
Vacuum Core Coater (Dinnissen)
真空中心喷涂
Vacuum Core Coater System
真空中心喷涂系统
Vacuum Coating -Incoming Product
真空喷涂 -进料
料中含0-10%脂肪
Vacuum Coating -Incoming Product
真空喷涂-进料
Fissures & Pores
裂缝与气孔
Vacuum Coating -Incoming Product
真空喷涂-进料
空气
Vacuum Coating -Air Removal
真空喷涂-去气
真空
Vacuum Coating -Liquid Application
真空喷涂-加液体
维生素
真空
涂料
油/脂
Vacuum Coating -Liquid Penetration
真空喷涂-液体渗透
加压后
空气
回复正常
Vacuum Coating -Surface Application
真空喷涂-表面添加
Vacuum Coating -Finished Product
真空喷涂-成品
成品
Summary 结论
More ingredients in liquid form.
液态原料越来越少
Proper liquid storage/handling
systems. 需要合适的储藏/处理系统
Properly designed dispensing.
合理设计分散装置
Dry/liquid flow rate accuracy
固/液流量精度
Liquid droplet size 液滴大小
Summary 结论
Proper distribution patterns
合适的分送方式
Proper incorporation/mixing
适当混合
Adequate retention time
充分的存留时间
Proper equipment selection
选取适当设备
Proper system design 适当的系统设计
System interfaces/controls
系统控制/面板
Preventative Maintenance
for
Feed Processing Plants
饲料加工车间的预防性维修
By
Fred J. Fairchild, P.E.
Professor
Department of Grain Science
Kansas State University
Manhattan, Kansas USA
Maintenance
维护
Keeping facilities and equipment in
good operating condition to avoid
unexpected failures and unplanned
production losses. 使设施/设备保持良好
的操作状态,以避免未预计的失误及未
计划的生产损失.
Types of Maintenance
维护的类型
Routine
例常
Emergency
紧急
Outside
外聘
Preventative
预防
Types of Maintenance
维护的类型
Routine Maintenance:例常维修
" Servicing equipment on a regular basis."
定期经常给设备做维护
Draining Air Lines 抽空空气管道
HammermillScreen Replacement更换筛片
Checking Oil Levels 查油位
Tightening Belt Drives 紧皮带
Types of Maintenance
维护的类型
Emergency Maintenance:紧急维修
" Immediate reaction to unscheduled
breakdowns." 对未预料的停机的及时反应
Broken Shafts 断轴
Torn Belts 断皮带
Burned Out Motors 烧电机
Jammed Equipment 堵塞设备
Types of Maintenance
维护的类型
Outside Maintenance:外聘维修
"Requires calling in outside help."需要请外人帮
忙
Repair Expertise Not in Plant 维修专家不在厂内
Need Special Repair Equipment 需要特殊维修设备
Need Outside Services 需要外部服务
Types of Maintenance
维护的类型
Preventative Maintenance:预防性维修
"Keeping Equipment in Working Order."
让设备保持可工作状态
Repair / Replace Equipment Before Failure在
失误前即修理/更换设备
Scheduled Inspections 有安排的巡视
Scheduled Repairs / Replacement 有安排的修
理/更换
Preventative Maintenance
预防性维修
"For every unit of cost spent on
preventative maintenance, at
least 5 times that cost will be
saved in subsequent expenses."在
预防性维修上的一块钱,可在后
果的花费上省出至少5块钱.
Developing A Preventative
Maintenance Program
制订预防性维修方案
"Requires collecting good information and
organizing it into a useful format."
"需要收集好的信息并编成有用的格式"
Equipment Identification 设备号
Equipment Information 设备信息
Equipment Maintenance Requirements设备维
修要求
Proper Parts Inventory 合理备件/库存
Maintenance Records 维修记录
Developing A Preventative
Maintenance Program
制订预防性维修方案
Equipment Identification:设备编号
All Equipment Needs Maintenance at Some
Point.所有的设备到时都需要维修
Tracking Maintenance Type and Cost
Necessary.跟踪维修方式及其必要成本
Separate Identifying Number for Each Piece
of Equipment. 每件设备均需分别编号
Developing A Preventative
Maintenance Program
制订预防性维修方案
Equipment Information:设备信息
Part Numbers 零件号
Assembly Drawings 组件图
Operating Manuals 操作手册
Purchase Records and Supplier Information
购买记录及供应商资料
Supplier Codes 供应商号
Developing A Preventative Maintenance
Program
制订预防性维修方案
Maintenance Requirements: 维修要求
Required Inspections 必要查看
Lubrication Requirements 润滑要求
Recommended Servicing 建议维护
Recommended Servicing Intervals建议维护
间隔
Developing A Preventative
Maintenance Program
制订预防性维修方案
Proper Parts Inventory:零件的合理库存
Recommended Spare Parts 建议备件
Availability of Parts零件可获得性
Critical Parts 关键零件
Cost of Inventory 库存成本
Location of Parts 零件位置
Developing A Preventative
Maintenance Program
制订预防性维修方案
Maintenance Records 维修记录
Work Performed 已做工作
Who Did the Work 谁做
Parts Used 所用零件
Cost of Parts 零件
Cost of Labor 人工零件
Frequency of Repairs 修理频率
Types of Repairs 修理类型
Developing A Preventative
Maintenance Program
制订预防性维修方案
Maintenance Records 维修记录
Set Preventative Maintenance Schedule 制订预防维修计划
Determine Inspection and Replacement Schedule 确定检查
及更换计划
Indicate Potential Trouble Spots 指出可能出错的位点
Indicate Continuing Trouble Spots指明正出错的位点
Indicate Parts Needs and Frequency指明需要的零件及频
率
Guide Repair/Replacement/Elimination Decisions 指导修
理/更换/清除决策
Process Flow Diagram 流程图
Chart 1
Equipment
List
设备表
Equipment
List
设备表
Rail Receiving Conveyor Grain Screener w/ Aspiraion
Truck Receiving Conveyor Two-Way Valve
Magnet Grain Cleaner
Receiving Elevator Crimped Grain Elevator
Two-Way Valve Transfer Conveyor
Transfer Conveyor Two-Way Valve
TurnheadDistributor Ingredient BinScrew Feeders
Corn Storage Bin Main Ingredient Scale
Milo Storage Bin Mineral Ingredient Scale
Alfalfa Storage Bin ScaleAir Gate
Receiving Scalper ScaleAir Gate
Receiving Distributor Batch Mixer
Storage Bin Feeders Surge Bin
Grain Transfer Conveyor Surge Conveyor
Grain Transfer Conveyor Mixing Elevator
Two-Way Valve Magnet
= Surge Bin and Level Control Mash Cleaner
HammermillFeeder OversRegrinder
Hammermill Mash Distributor
HammerrmillDischarge Conveyor Mash Transfer Conveyor
HammermillAir System Mash Distributor
Grinding Elevator Slide Gates
Grinding Distributor SurgeBin
Pneumatic Receiving Pipes Pellet Mill
Chart 2
Equipment
Information
设备信息
Equipment
Information
设备信息
Chart 3
Supplier
List
供应商表
Supplier
List
供应商表
A-1
Acme Electric Co.
610 Green Street
Smallton, Kansas
USA
785-555-5555
785-555-1234
785-456-7890
Bill Smith
A-2
Adams Supply Company
1613 Highway 1
Southtown, Kansas
316-444-5555
316-444-1000
316-987-6543
John AdamsChart 4
Maintenance
Schedule
维修计划
Maintenance
Schedule
维修计划
Pellet Mills
Pellet Cooler
Moxer
Augers
60, 61, 102
96',96-A,100
101
Milo Cooler
Boiler
Air Comp.
Fork lifts
Milo Cooler
Fan
Pellet Cooler
Fan
28A-27 B&C
Chem. Pump
Feedes,
Bins 11-22
Rollers 1-2,
Hammermill,
Hammermill
Fan
Leg33-41
Augers 41-
106
Scalper
Pellet Mills
Conditioner
Bins 29 -36
Boiler
Air Comp.
Fork lifts
3-ton Mixer
Scales
Pellet Cooler
Air Lifts
Tractors
Bobcat
Air Comp.
Fork lifts
Air Comp.
Air Comp.
Fork lifts
Manlift
Boiler
Boiler
Boiler
Bins 1-10
Pellet Mills
Pellet Mills
Pellet Mills
Rollers 1-2
Hammermill
Fat Filter
Mol. Filter
Hammermill
Hammermill
Legs 53-54
Hammermill
Leg
Cooler
Leg
DistributorsBagging
Scales
Pellet
Cooler
Hyd. Pump
Mol. Pump
Fat Pump
Tractors
Bobcat
Pellet
Cooler
Mix. Leg
Rec. Leg
Mix. Leg
Rec. Leg
Chart 5
Maintenance
Calendar
维修日历
Maintenance
Calendar
维修日历
Pellet Mills
Pellet Cooler
Moxer
Augers
60, 61, 102
96',96-A,100
101
Milo Cooler
Boiler
Air Comp.
Fork lifts
Milo Cooler
Fan
Pellet Cooler
Fan
28A-27 B&C
Chem. Pump
Feedes,
Bins 11-22
Rollers 1-2,
Hammermill,
Hammermill
Fan
Leg33-41
Augers 41-
106
Scalper
Pellet Mills
Conditioner
Bins 29 -36
Boiler
Air Comp.
Fork lifts
3-ton Mixer
Scales
Pellet Cooler
Air Lifts
Tractors
Bobcat
Air Comp.
Fork lifts
Air Comp.
Air Comp.
Fork lifts
Manlift
Boiler
Boiler
Boiler
Bins 1-10
Pellet Mills
Pellet Mills
Pellet Mills
Rollers 1-2
Hammermill
Fat Filter
Mol. Filter
Hammermill
Hammermill
Legs 53-54
Hammermill
Leg
Cooler
Leg
DistributorsBagging
Scales
Pellet
Cooler
Hyd. Pump
Mol. Pump
Fat Pump
Tractors
Bobcat
Pellet
Cooler
Mix. Leg
Rec. Leg
Mix. Leg
Rec. Leg
Chart 6
Maintenance
Record
维修记录
Maintenance
Record
维修记录
Developing A Preventative
Maintenance Program
制订预防性维修方案 Program Administration:方案管理
Manual Record Keeping 手写记录
Computerized Record Keeping 电脑保存记录
Manual or Computerized Scheduling手工或电
脑排计划
Work Order Generation 开工表制作
Lifecycle Predictions 寿命期预测
Equipment Improvement/Redesign 设备改进/
重新设计
Costs vsRevenue Generation 成本/收入的产生
Preventative Maintenance
预防性维修
A Properly Designed and Used Preventative
Maintenance Program Will More Than Pay
Itself in Prevention of Lost Production
Time.
设计和使用合理的预防性维修计划,在防
止生产时间的损失方面是有超额回报的.
MANUFACTURING IN
THE 21st CENTURY
21世纪的饲料制造业
By
Fred J. Fairchild, P. E.
Professor
Department of Grain Science & Industry
Kansas State University
Manhattan, Kansas USA
CHANGE
IS
INEVETABLE
变化是必然的
SOCIAL AND ECONOMIC
ISSUES, AS ALWAYS,
WILL CONTINUE TO
DRIVE CHANGE
社会与经济因素仍将引发
变革
FACTORS BRINGING ABOUT
CHANGE
带动变革的因素
Environmental Concerns
环境关切
* Air Pollution空气污染
*Water Pollution 水污染
*Animal Waste Disposal 动物粪便处理
*Odor Control 臭气控制
FACTORS BRINGING ABOUT
CHANGE
带动变革的因素
Public Safety, Laws and Regulations
公共安全与法律法规
Food Safety-Microbiological
食品安全-微生物
Feed Additives/Growth Promotants
饲料添加剂/促生长物
Pesticide and Chemical residues
杀虫剂与化学物残留
FACTORS BRINGING ABOUT
CHANGE 带动变革的因素
Microbiological Contamination
微生物污染
Current Regulations on Meat and Bone Meal
目前针对肉骨粉的法规
Heat Sterilization Policies of the EEC
EEC对热消毒处理政策
HACCP Programs that include Feedmills
包括饲料厂的HACCP方案
FACTORS BRINGING ABOUT
CHANGE带动变革的因素
Process Control and Automation
过程控制与自动化
* Complex Process-e.g. Expanders 复杂工
艺-如膨胀器
* Labor Replaced by Automation 自动化代
替人工
* Feed Quality/Consistency 饲料质量/均匀
* Information Management 信息管理
"We live in an age where
我们生活在这样一个时代
CONSUMER POWER
消费者的力量
frequently outweighs
往往大于
SCIENTIFIC PERSUASION".
科学的主张
Feedstuffs 72:3, 1999
FACTORS BRINGING ABOUT
CHANGE 带动变革的因素
Feed Industry Structure
饲料产业结构
* New Equipment Availability 可用的新设备
* Mergers, Acquisitions and Divestments 合并
,兼并与撤资
* International Ownership 外资拥有
* Marketing Structure 市场结构
* Vertical Integration 纵向一体化
THE FUTURE!
未来
INGREDIENTS
原料
Current Global Population of 6.0 Billion+
目前全球已超过60亿人
"87 Million People Added Annually"
每年增加8700万人
"Conventional technology alone will notallow
food, feed, and fiber production to be
increased sufficiently to meet the needs of the
10 billion global population of the 21st
century"
仅靠传统科技不能提高食品,饲料与纤维生
产来满足21世纪100亿人的需要.
Biotechnology is the only Significant
Means to Increase Food, Feed, and Fiber
Production
生物技术是提高食品,饲料及纤维产
品的唯一重要的手段
|Currently 5 billion tons of food is produced
annually.目前每年生产50亿吨食品
|30% (1.5 billion tons) is lost to pests
30%(15亿吨)失于虫害
|Loss of cultivable land (0.44 ha/capita in
1961; only 0.26 ha in 1997). 耕地的损失(
1961年6.6亩/人,1997年3.9亩/人)
Number of Transgenic Crop Field Trial Sites in
the USA 1987-1997
1987-1997年美国转基因作物的田间试验数
44%
4%1%11%
3%
11%
4%
2%
8%
12%
Corn玉米
Sugar beat 甜菜
Tomato番茄
Cotton棉花
Canola菜籽
Melon/squash
瓜类
Potato土豆
Others
其它
Soybean
大豆
THE FUTURE! 未来
INGREDIENTS 原料
Genetically Modified Organisms (GMO's)
基因改良物
Must be Identity Preserved 必须分开保存
May Have 4 to 6GMO'sPlus Commodity Grains
in a Single Feed Mill 在一家饲料厂中可能除普通
谷物外还有4-6种转基因粮
Bin Space, Grinding, Inventory, and QA 仓容,
粉碎,储存,质量保证
THE FUTURE! 未来
RECEIVING AND STORAGE
收储
* High-Speed Unloading 高速卸料
* Ingredient Segregation 原料分级
* Inbound Analysis and QC 厂内质检
High Speed Infrared Instrument 高速远红外仪
THE FUTURE! 未来
GRINDING OPERATIONS
粉碎工段
* Hammer Design and Metallurgy
锤片设计与冶炼加工
* Air Assist System Design 风助设计
* Noise Control 噪音控制
* Automation and Routing 自动化与程序化
* Quick-Change Screens 快速换筛
* Quick-Change Hammer Gangs 快速换锤片
THE FUTURE! 前景
GRINDING OPERATIONS
粉碎工段
* Vertical Shaft Hammermills
立轴式锤片粉碎机
-European Designs now available
欧洲设计,已出品
-Air-Assist not recommended
不建议用风助
THE FUTURE!前景
GRINDING OPERATIONS
粉碎工段
* AUTOMATION 自动化
-The One System That Clearly Should Be
Automated!! 很应自动化的系统
-Start-up/Shut-Down, Routing and
Ingredient Changes启动/停机,编程及换料
-Lights Out Operations 快跑的工段
THE FUTURE!未来
Proportioning Systems
配料系统
* On-line Reformulation 在线更改配方
* Weighing Accuracy 称量精度
Loss-in-WeightSystems 减重系统
* Short Cycle Batching 短周期配料
1.0-1.5 Min. Cycles 1.0-1.5分钟周期重量的误差分布,超过200%的放在200类(最大的
记录误差为440%)
THE FUTURE! 未来
Mixing and Mixing Equipment
混合与混合设备
* Trend is Toward Large
(12-16 Ton) Mixers.
趋势是用大混合机(12-16吨)
Concern with Uniformity!关注均匀度
* Smaller, Short-Cycle Mixers
小型短周期混合机
-1.0 to 1.5 Min.Mixing Cycles
1.0-1.5分钟混合周期
-High Flexibility 高灵活度IMPROVED RIBBON DESIGN 改良螺带
IMPROVED PADDLE DESIGN 改良桨片
H&S
TR Mixer
混合机
Pelleting 制粒
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
Pelleting Will NotGo
Away!!!
将来也要制粒
THE FUTURE!未来
PELLETING-CONDITIONING
制粒与调质
Conditioning Time Control
调质时间控制
-Variable Shaft Speed 变轴速
-Pick Angle Control 控制角度
-Steam Block Panels 蒸汽挡板
-Conditioner Angle 调质器角度
THE FUTURE!未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
On-Line Moisture Control
在线水分控制
"MOISTURE MANAGEMENT"
水分管理
The Effect of Precise Moisture
Control on Pelleting Operations
水分精确控制对制粒工段的影响
Incoming
进料
Target
目标
Actual
实际
Conditioned
调质后
(%)(%)(%)(%)
11.412.012.215.1
11.013.013.015.9
10.914.014.016.8
10.714.514.717.0
11.115.015.118.5
Moisture and Conditioning Results
水分与调质结果批模式
水分传感器
流量泵
水表
电磁水阀手动水阀
重量模拟
信号
72
74
76
78
80
82
84
86
88
90
12131414.515
PDI(%)
Effect of Added Moisture on Pellet Quality
加水对制粒质量的影响
PDI%
Starting Mash Moisture (%) 开始时水分
颗粒持久
性指数
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
EXPANDERS
膨胀器
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
COMPACTOR
压缩机
Compactor
Roll
Assembly
压缩机之压
轴组件
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
UNIVERSAL PELLET COOKER
通用制粒蒸煮机
The "UPC"
from
Wenger Manufacturing
料仓
进料器
2-3分钟驻留时间
制粒头
切刀
14-18%
水分的
颗粒料
加液体
加蒸汽电机
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
PRESSURE PELLETING
加压制粒PRESSURIZED CONDITIONING
PCI, Inc. Wichita, Ks.
加压调质
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
"ON-LINE"
ROLL ADJUSTMENT
"在线"压辊调节
Remote Roll Adjust 远程压辊调节
THE FUTURE! 未来
PELLETING AND OTHER
HYDROTHERMAL PROCESSES
制粒及其它湿热加工
Formulating for Pellet
Quality !!给颗粒质量做配方
Is It Possible 可能吗
THE FUTURE!未来
COOLERS AND COOLER DESIGN
冷却机及其设计
Counter Flow Coolers
Are Here To Stay!
逆流式冷却机使用良好
THE FUTURE! 未来
COOLERS AND COOLER DESIGN
冷却机及其设计
Future Designs Will
Include Drying Capability
未来的设计将包括干燥能力
THE FUTURE! 未来
Post Pellet Additive Application
制粒后添加
*Low Inclusion Liquids
低含量液体
-Enzymes 酶
-Drugs 药物
-Vitamins 微生物
-Biologicals 生物品
THE FUTURE! 未来
Load Out System Design
出料系统设计
* Finished Feed Blending
成品料混合
Can Create an Infinite number of
Feeds to Match Stage of Growth
为配合生长阶段能造出无数种饲料
SUMMARY 结语
*Consider the Economics
虑及经济性
* Consider the Alternatives
考虑其它可选方案
*Make Logical, Rational Decisions
做出合理决策
*Watch Related Developments
关注相应进展
DRY MATERIAL HANDLING
EQUIPMENT SELECTION
干物料输送设备的选择
by
Fred J. Fairchild, P. E.
Professor
Department of Grain Science and Industry
Kansas State University
Manhattan, Kansas
DRY MATERIAL
HANDLING
干物料的输送
Definition定义:
"The movement of a material from one
location to another while insuring its
arrival in proper condition." 将物料从一
处运到另一处,并在适当条件下保证其
到达.
MATERIAL HANDLING
物料输送
High Speed
高速
Self Cleaning
自清
Minimum Interchanges
交换少
Eliminate Void Areas
消除无用空间
Material Handling
物料输送
Handling Methods:输送方法
Manual 手工
Gravity 重力
Mechanical 机械
Pneumatics 气动
Material Characteristics Affecting
Equipment Selection
物料特性影响设备的选择
Size 大小
-Fine, Granular, Lumpy
细,颗粒,块状
Flowability 流动性
-Very Free Flowing, Free Flowing, Sluggish
很易自流,易自流,缓流
Friction 摩擦
-Abrasiveness, Stickiness
磨蚀性,粘性
Material Characteristics Affecting
Equipment Selection
物料特性影响设备的选择
Hydroscopic吸湿性
Corrosive 腐蚀性
Fumes or Dust 烟尘
Degradability 降解性
Particle Separation 颗粒分散
Contamination 污染
Fluidity 液体
Packing or Pressure 成团或压力
Temperature 温度
Age 年龄
Factors Affecting Equipment
Selection
影响设备选择的因素
The characteristics and behavior of the
material(s) to be handled is the most
important consideration in handling
equipment selection.
物料的特性及其在输运时的表现是选择
输送设备时应考虑的重要因素.
Types Handling Equipment
输送设备的类型
Gravity Spouting, Valves and Distributors 重力
喷管,闸门和分配器
Screw Conveyors 螺旋输送机
Drag Conveyors 刮板输送机
En-Masse Conveyors 整体输送机
Belt Conveyors 皮带输送机
Pneumatic Conveyors 气动输送机
Oscillating / Vibratory Conveyors 震动输送机
Bucket Elevators 斗式提升机
Gravity Conveying
重力输送
Gravity Conveying重力输送
Valves 闸门
Flip/Flop Type 翻板式
"A"Style
A型
"K" or "Y" Style
K 或Y型
Gravity Conveying重力输送
Valves闸门
Flip/Flop Type翻板式
"A"Style
A型
"K" or "Y"Style
K 或Y型
Gravity Conveying重力输送
Valves闸门
Bucket Type 斗状
"A"Style
A型
"K" or "Y"Style
K 或Y型
Gravity Conveying重力输送
Valves闸门
Bucket Type斗状
"A"Style
A型
"K" or "Y"Style
K 或Y型
Gravity Conveying重力输送
带仓管转头式分配器系统
Gravity Conveying重力输送
Requires no energy to move materials. 输送物料不
需能源
Minimal mechanical components to maintain.
需维护的机械部件很少
Requires large vertical heights. 需要较高垂直高度
Slope must exceed angle of static friction. 倾斜要大
过静流角
High wear at contact points. 接触磨损严重
Can break up materials being conveyed. 有可能将
输送的物料打碎
Advantages优点:
Disadvantages缺点:
Screw Conveyor 螺旋输送器
Screw
Conveyor
螺旋输送器
特殊输送螺旋
Screw
Conveyor
螺旋输送器
特殊输送螺旋
Screw Conveyor 螺旋输送器
15% Loading 装料15%
Very abrasive, Fine particles/irregular shapes
Mineral powders 用于非常高磨蚀性
30% Loading 装料30%
Mildly/moderately abrasive 中等磨蚀性
Most soft feed ingredients 多数软饲料原料
45% Loading 装料45%
Mildly/abrasive, Free flowing中等磨蚀性,易流动
Whole grains, pelleted feed 全谷物,颗粒料
100% Loading 装料100%
Screw feeders 螺旋进料器
Volumetric metering 体积计量器
Screw
Feeder
螺旋进料器
MAJOR
INGREDIENTS
主原料
MINOR
INGREDIENTS
次原料
LIQUIDS
液体
MICRO
INGREDIENTS
微量原料
GROUND
GRAINS
已粉碎谷物
SCALE
称#1
SCALE
称#2
SCALE
称#3LIQUID
SCALE 液体称
MIXER 混合机
SURGE BIN 缓冲仓
Multiple Feeders & Conveyors
多进料器及输送机
Screw Conveyor
螺旋输送机
Low initial cost. 初装成本低
Can be used in horizontal, inclined or vertical
position. 可为卧式,斜式或立式
Continuous rate of discharge. 连续卸料
Can combine conveying and mixing. 可同时输送
和混合
Convey widely varying materials.可输送变化范围
很大的原料
Multiple inlets and outlets. 多进口和出口
Reasonably low maintenance. 维护成本相对较低
Advantages 优点:
Screw Conveyor
螺旋输送机
Not self-cleaning. 不能自清
Low efficiency. 效率低
Can break or damage materials being
conveyed. 可能破损所送物料
Can only be installed in a straight line. 只
能直线安装
Subject to material buildup at
intermediate outlets. 中间出口可能积料
Disadvantages 缺点:
Drag Conveyor
刮板输送机
Round Bottom
Style
圆底式
Drag
Conveyor
刮板输送机
Flat
Bottom
Style
平底式
Drag Conveyor
Side Wall Return Style
'侧壁回弯'式刮板输送机
Drag
Conveyor
刮板输送机Side
Wall Return
Style
'侧壁回弯'式刮
板输送机
Drag Conveyor
刮板输送机
圆底侧弯
平底
Drag Conveyor
刮板输送机
Moderate initial cost. 中等初装成本
Can convey both horizontal and vertical in
some models. 某些型号可同时平输和立输
Can turn corners in some models. 某些型号
可转角
Reasonably self-cleaning.适度自清
Minimum material breakage or damage. 很
少物料破损
Advantages 优点:
Drag Conveyor
刮板输送机
Usually low efficiency.
Dense ingredients difficult to convey.
Paddle wear.
Material carryover.
Disadvantages:
En-Masse
Conveyors
平底整体式输送机
En-Masse Conveyors
整体式输送机
More efficient. 更高效
Conveys large volumes of material. 输送大量物料
Self-Cleaning. 自清
Conveys free-flowing granular materials well.很好地输
送易流动的颗粒
Some material carryover. 有些残余料
Loses capacity quickly on incline. 内嵌式对输送能力损
失很快
Won't convey fine or fluffy materials 不能输送细粉或
蓬松的物料
Advantages 优点:
Disadvantages 缺点:
Belt Conveyors
皮带输送机
封闭辊式皮带输送机
Belt
Conveyors
皮带输送机
Belt Conveyors皮带输送机
High efficiency, low power requirements. 高效
,低能耗
Large capacity over long distances. 长距离,高
能
Practically self-cleaning.实际自清
Gentle material handling. 轻缓送料
Low maintenance. 低维护
Sometimes difficult to enclose. 有时难封闭
Not made for easy intermediate discharge
points. 难设中间卸料口
Advantages 优点:
Disadvantages:
Pneumatic Conveyors
气动输送
Positive Systems 正压
正低气压输送机
Pneumatic Conveyors
气动输送
Positive Systems正压
Pneumatic Conveyors
气动输送
Positive Systems正压
Pneumatic Conveyors
气动输送
Positive Systems正压
Can be discharged to multiple locations.
可在不同位点卸料
Most efficient use of air for conveying. 运
用输送气流效率高
Can operate at high pressure and dense
loading. 可在高压下运转,提装料强度
No special filtration required for intake
air. 入气无需特别过滤
Advantages优点:
Pneumatic Conveyors
气动输送
Positive Systems正压
Difficult to use multiple pickup points. 难用做多点
取料
Heat build-up in air due to compressing air at
pump. 因气泵压缩,气温上升
Drying affect on materials.使物料干燥
High velocity can cause material breakup. 高速可
导致物料破损
High wear potential for system components. 可能磨
损系统配件
High energy use. 能耗多
Disadvantages 缺点:
Pneumatic Conveyors 气动输送
Negative Systems 负压系统
Pneumatic Conveyors 气动输送
Negative Systems 负压系统
Can pickup materials from multiple sources. 可
在多点取料
Operates at negative pressure and controls dust
emissions. 负压操作,控制尘漏
Can handle heat sensitive materials. 可输送怕
热的物料
Advantages 优点:
Conveyors 气动输送
Negative Systems 负压系统
Single discharge point. 单卸料点
Low efficiency, high energy requirements. 低效,高能
耗
Low material to air ratio. 料,气比低
Drying effect on materials handled. 对所送物料有干燥
作用
Must protect blower/fan from materials. 须防止物料到
吹气扇上
Higher energy use. 高能耗
High maintenance. 高维护
Disadvantages 缺点:
Oscillating/Vibratory
Conveyors 震动输送机
Oscillating/Vibratory
Conveyors 震动输送机
Convey hot, abrasive or corrosive materials. 输送高温
,磨蚀腐蚀性的物料
Self-cleaning. 自清
With screen bottoms can be a screener.
如有筛底可做筛用
Limited capacity.产能有限
Capacity varies with materials. 不同物料不同产能
Conveys in straight line only. 只能直线输送
Advantages 优点:
Disadvantages 缺点:
Bucket
Elevators
斗式提升机
Bucket Elevators斗式提升机
Self-Cleaning
Elevator Boot
自清式斗式提升机
Bucket Elevators斗式提升机
Lowest power for vertical conveying. 垂直输送
能耗低
Positive movement of materials.物料正移动
Carries most types of materials. 可送多数原料
Can be slowed down for gentle handling. 可调
慢以便轻缓运料
Advantages 优点:
Bucket Elevators斗式提升机
Conveys only vertically. 只能垂直输送
Can emit dust unless attached to dust system.
不装除尘系统便会排尘
Potential for dust explosions. 有粉尘爆炸的可
能
Requires regular maintenance. 需要经常维护
Disadvantages 缺点:
SUMMARY 结语
Know the characteristics of the material
conveyed. 了解要送物料的特性
Select the proper equipment for the
application. 按用途选择设备
Material handling equipment handles material
by volume, not weight. 输送设备是按体积运料
并非重量
Select conveying equipment to minimize
damage to conveyed material(s). 选择合适的设
备防止损伤物料
SUMMARY 结语
Do not overfill/overload the conveying
equipment. 不要给输送机超量
Choose conveying equipment that requires the
least amount of energy to do the job. 选择用能
量少的输送设备
As density changes, so do energy requirements
to power the equipment. 容重变化,设备用能
力变化
Consider the needed useful life of the
equipment. 考虑设备的使用寿命
GRINDING
PARTICLE SIZING
粉碎粒度确定
By
Fred J. Fairchild, P. E.
Professor
Department of Grain Science &
Industry
Kansas State University
Manhattan, Kansas, USA
WHY DO WE GRIND
为什么要粉碎
IMPROVED ANIMAL
PERFORMANCE 动物性能
INCREASED MIX UNIFORMITY
混合
IMPROVED PELLETING制粒
MEASURING PARTICLE
SIZE 测粒度
PARTICLE SIZE TEST
(ASAE STANDARD -S319)
测粒度
This method involves using a sieve stack
to determine the geometric mean particle
size (dgw) and the geometric standard
deviation (sgw).
Results can be obtained either
graphically or through calculations.
Ro-tap Sifter
with
Sieve Stack
摇筛机与套筛
A Quick Method for Estimating
PARTICLE SIZE
快速法评定粒度
No. 14 Sieve
A Quick Method for Estimating
PARTICLE SIZE 快速粒度估测法
100050-60%
90060-70%
80065-75%
70070-80%
60080-90%
50090-95%
Particle Size
粒度(Microns)
Minus 14 Mesh
14目下(%)
METHODS OF GRINDING
粉碎方法
Impact 撞击
Compression 挤压
Shear 剪切
Attrition 研磨
HAMMERMILLS 锤片式
受锤片末端速度影响
ADVANTAGES 优点
Ability to grind a wide variety of
materials原料范围广
Ease of maintenance, less maintenance
cost 易维护
Versatility 多功能
Less complicated to operate 易操作
Less initial cost 初价低
DISADVANTAGES 缺点
Energy consumption
耗能
Produces a greater Sgw
标准差大
Noise and dust pollution
吵,粉尘
Heat generation and moisture loss
产热,失水
AIR ASSIST SYSTEM
风助系统
AIR ASSIST SYSTEM
风助系统
AIR ASSIST SYSTEM
风助系统
ROLLER
MILLS
压辊式粉
碎机
ADVANTAGES 好处
Electrical efficiency
电效高
Particle size uniformity
粒度一致
Less maintenance
少维护
Less dust pollution
少粉尘
DISADVANTAGES 缺点
Higher initial cost 初价高
When maintenance is needed it is
expensive 维护成本高
Can not effectively grind fibrous
materials 不适宜纤维粉碎
Reduced throughput at small particle
sizes 粒度小时产量低
粉碎玉米时的效率对比
ENERGY COST
COMPARISON 辊式与锤片式能耗对比
Roller Mills vsHammermills
.05
.35
.47
.65
1.31
1.56
Energy
Cost
($/ton)
861,813Roller Mill
2,040Hammermill
28709Roller Mill
718Hammermill
辊式
16432Roller Mill
399Hammermill
锤式
Savings
(%)
Particle
Size
(microns)
Grinder
Type
GRINDING
SYSTEMS
粉碎系统
PRE-GRINDING SYSTEM
前粉碎
Advantages 好处
Longer grinding time a t full motor load 电
机满负荷时,粉碎时间长
Gives a buffer for down time or maintenance
on the grinder 留出了维护和停机时间
Disadvantage 缺点
Requires more storage bins for both ground
and raw ingredients 需要更多的料仓来存放
已粉碎及原料
POST GRIND SYSTEM
后粉碎
Advantages 优点
Accommodates material changes易应付原料
变化
Does not require as many storage bins 不要
太多料仓
Disadvantages 缺点
Less energy efficient 能量利用率低
Directly affects the capacity of the facility 直
接影响设施产能
需粉碎原料去混合机原料
称
喂料
锤片粉
碎机
混合
FINE GRINDING
EQUIPMENT
微粉碎设备
BURR MILL 强压磨粉机
Fine Grinder 微粉机
FitzMill
Air Swept Pulverizer
风扫研磨机
Direct Cooled Grinding System
直冷粉碎系统
INNOVATIONS
IN
GRINDING
粉碎创新
THE FUTURE! 前景
GRINDING OPERATIONS
粉碎操作
* Hammer Design and Metallurgy
锤片设计与冶炼加工
* Air Assist System Design 风助设计
* Noise Control 噪音控制
* Automation and Routing 自动化与程序化
* Quick-Change Screens 快速换筛
* Quick-Change Hammer Gangs 快速换锤片
THE FUTURE! 前景
GRINDING OPERATIONS
粉碎工段
* Vertical Shaft Hammermills
立轴式锤片粉碎机
-European Designs now available
欧洲设计,已出品
-Air-Assist not recommended
不建议用风助
VERTICAL
SHAFT
HAMMERMILL
立轴锤片粉碎机
THE FUTURE! 前景
GRINDING OPERATIONS
粉碎工段
* AUTOMATION 自动化
-The One System That Clearly Should Be
Automated!! 很应自动化的系统
-Start-up/Shut-Down, Routing and
Ingredient Changes启动/停机,编程及换料
-Lights Out Operations 快跑的工段
LIQUIDS:
New Ingredients, New
Applications
液体:新原料,新用法
by
Fred J. Fairchild, P. E.
Professor
Department of Grain Science and Industry
Kansas State University
Manhattan, Kansas
Chronology of Liquid
Addition液体添加史
Molasses糖蜜 1850
Animal Fat 动物脂 1954
Liquid Methionine1977
液体蛋氨酸
Chronology of Liquid Addition
液体添加史-1990's
Amino Acids 氨基酸
Vitamins 维生素
Pigments 着色素
Mold Inhibitors 防霉剂
Flavorings 调味剂
Enzymes 酶
Liquids Used in Feeds
Fats & Oils
用于饲料的液体油脂
Liquid 液体Addition Point(s) 添加点Maximum 最大量Remarks 备注
Animal 动物Mixer, 混合机6%Heated storage/dispensing
Conditioner, die, coater 12%加热储存/添加
调制器, 压模, 喷涂机
Fatty Acids 脂肪酸Mixer, die, coater6%Heated storage/dispensing
混合机, 压模, 喷涂机加热储存/添加
Palm Oil 棕榈油Mixer, die, coater6%Heated storage/dispensing
混合机, 压模, 喷涂机加热储存/添加
Lethicin Mixer, die, coater2%Heated storage/dispensing
混合机, 压模, 喷涂机Difficult to pump 难以泵送
Liquids Used in Feeds
Molasses
用于饲料中的液体糖蜜
LiquidAddition Point(s)MaximumRemarks
液体添加点最大量备注
BeetMixer 混合机4%Some heating required
甜菜 Conditioner, Loadout/Bag10%需要一些加热
调制器, 装车/包袋
CaneMixer 混合机4%Some heating required
甘蔗 Conditioner, Loadout/Bag14%需要一些加热
调制器, 装车/包袋
Liquids Used in Feeds
Amino Acids
用于饲料中的液体氨基酸
LiquidAddition Point(s)MaximumRemarks
液体添加点最大量备注
Lysine 28%Mixer2%Heating reqd., Corrosive
赖氨酸混合机需加热,腐蚀性
Lysine 50%Mixer1%Corrosive
赖氨酸混合机需加热,腐蚀性
Methionene Mixer1%Corrosive
蛋氨酸混合机需加热,腐蚀性
Liquids Used in Feeds
Other Liquids
用于饲料中的液体其它液体
Liquid 液体Addition Point(s) 添加点MaximumRemarks 备注
Pro-Vitamin 维生素类最大量
Choline 胆碱Mixer 混合机1%Corrosive 腐蚀性
Enzymes 酶
Phytase 植酸酶Coater 喷涂机0.02%Heat sensitive 热敏感
B-Gluconase 葡聚糖Coater 喷涂机0.10%Heat sensitive 热敏感
Acids 酸
Proprionic 丙酸Mixer 混合机1%Corrosive 腐蚀性
Formic 甲酸Mixer 混合机1%Corrosive 腐蚀性
Positive Displacement Meter
正位移计
Accuracy Affected by:
精度受以下因素影响
Temperature 温度
Pressure 压力
Voids 空间
Viscosity粘度
Measures by Volume
体积定量
Mass Flow Meter
质量/容积流量计
Measures by
Mass of Liquid
质量定量
Compensates
for:补偿以下方面
Temperature温度
Pressure 压力
Voids 空间
Viscosity 粘度
Strainer 滤器
Meter 表
Spray Nozzle
喷嘴
1.Direct Liquid Addition System
直接液体添加系统
Pump 泵
Liquid
Tank
液体罐Strainer 滤器
2. Batch Liquid Addition System
分批液体添加系统
Pump泵
Liquid
Tank
液体罐
Liquid
Weigh
Hopper
称量斗
To Mixer/Coater
至混合机/喷涂机
3. Batch Liquid Addition -Fixed Rate Application
分批液体添加-固定量添加
Strainer
滤器
Pump泵
Liquid
Tank
液体罐
Liquid
Weigh
Hopper
称量斗
Metering
Pump计量泵
Spray Nozzle
喷嘴
4. Direct Liquid Addition System-
Controlled/Variable Flow Rate
直接液体添加系统-可控/变速流量
Strainer
滤器
Spray Nozzle
喷嘴
Liquid
Tank
液体罐
Variable Speed
Positive Pump
变速主动泵
Dry Flow Rate Sensor
干流量传感器
Mass
Flow
Meter
质量表
5. Batch Liquid Addition -
Controlled Rate Application
分批液体添加-可控流量添加
Strainer
滤器
Pump泵Liquid
Tank
液体罐
Liquid
Weigh
Hopper
称量斗
Spray Nozzle
喷嘴
Dry Flow Rate Sensor
干流量传感器
Mass
Flow
Meter
质量表Variable Speed
Positive Pump
变速主动泵
LIQUID APPLICATION
SYSTEMS
液体添加系统
Point 位置Type 种类System 系统Dry Ingredient 干原料Remarks 备注
Mixer 混合机Batch 分批1, 2, 3Weighed Batch 称重配料
Mixer 混合机Continuous 连续4, 5Weighed Rate 称重率Cont. Monitoring 连续监控
Conditioner 调质器Continuous 连续4, 5Weighed Rate 称重率Cont. Monitoring 连续监控
Pellet Die 压模Continuous 连续1*, 3Volumetric Rate 体积率*Metering Pump 计量泵
Pellet Die 压模Continuous 连续4, 5Weighed Rate 称重率Cont. Monitoring 连续监控
Coater 喷涂机Continuous 连续4, 5Weighed Rate 称重率Cont. Monitoring 连续监控
Vacuum Coater真空喷涂机分批Batch 分批3Weighed Batch 称重配料
Dry Product Weighing
Accuracy
干品称量精度
Weighing Equipment 称量设备Accuracry* 精度System 系统
Volumetric Metering 体积计5%Continuous 继续
Impact Plate 冲击板5%Continuous 继续
Drag/Screw Conveyor on Scale System3%Continuous 继续
称量系统的螺旋输送器
Loss-In-Weight 重量损失1%Continuous 继续
Scale Hopper 称量斗0.1 - 0.2%Batch 分批
*Accuracy based on plus or minus % variation applied to scale system including weight of equipment.
精度基于称量系统,包括设备重量的变异+, -的%Liquid Application at the Mixer
混合机上的液体添加装置
重量
喂料斗
中的重
量损失
制粒机
调质器
失重
喂料系统
低重量填料点
Liquid Application at the Pellet Die
制粒机上的液体添加设备
Post Process Coating
加工后喷涂
Accurate dry mass rate flow
精确干料流动
Uniform distribution of dry material
干料整齐分散
Accurate measurement of liquid application rate
液体添加精准
Proper droplet size of applied liquid
液滴大小合适
Post Process Coating
加工后喷涂
Proper temperature of dry material and
liquid(s)
干料,液体温度合适
Uniform distribution of liquid(s) (atomization)
液体分布整齐(自动)
Adequate mixing
混合充分
Adequate retention time
停留时间充分
Post Processing
Post Process Liquid Application
after Pelleting
制粒后的液体添加
Loadout
Post Process Liquid Application
at Loadout/Bagging
卸料/打包口处的液体添加系统
Enzyme Addition Flow
酶制剂添加
Metering Pumps
计量泵
Flow Meters
流量计
Controller
控制器
Liquid Tank
液体罐
Enzyme/Water Metering (BASF)
酶/水计量/(BASF)
ProMinet
Liquid
Addition
Cabinet
液体添加柜
ProMinet
Liquid
Addition
Scale
液体添加称
ProMinet4 Enzyme Addition System
ProMinet4 酶剂添加系统
ProMinet4 Water Addition System
ProMinet4 添加加水系统
ProMinet4 Liquid Mixing System
ProMinet4 液体混合系统
Micro Fluid System Coater
(Sprout Matador)
微量液体系统喷涂
Weigh Table
Spray Chamber
Individual
NozzlesVolumetric
Feeder
Micro Fluid System Coater
(Sprout Matador)
微量液体系统喷涂
Liquid Addition Accuracy > 98%
液体添加精度
CV's < 10%
Xylanase 500g./ton
木聚糖酶
Apply Up To 8 Liquids Simultaneously
同时可添加多达8种/液体
Micro Fluid System Diagram
微量液体添加流程图
Mistcoater (APEC)
雾状喷涂
Spinning Disk -Dry Product
旋转碟-干料
Spinning Disks -Liquid
旋转碟 -液体
Mixing Chamber
混合室
Mistcoater(APEC)
雾状喷涂
No pressurizing or spraying of liquid
无液体压力或喷雾
Disk speeds vary by application
碟盘速度可变
Will handle anyflowableliquid
适于任何流体
Auto-Koter (Hayes & Stolz)
Surge Hopper
缓冲料斗
Metering Conveyor
on Load Cells
装料室的计量输送器
Spray Chamber
喷雾室
Mixing Conveyor
混合输送器
Auto-Koter(Hayes &Stolz)
Fat addition accuracy = 2-5%
油脂添加精度
At 5% addition rate = 4.9 -5.1 % fat
added
添加5%时=加了4.9 -5.1 %
Enzyme addition with water and air
added for atomization
酶与水,气共同添加可自动化
MicroCoater(Beta Raven)
Conveyor Belt
"S" Shaped
Spray Chamber
Mass Flow Meter
MicroCoater
(Beta Raven)
Liquid Application
Point #1
Product Stream
Liquid Application
Point #2
Momentum Meter
MicroCoater(Beta Raven)
"S" Shaped chamber prevents product damage.
S 型状料室防止产品损伤
Thin curtain of product = consistent coating.
薄料层= 连续喷涂
Normally no additional mixing required after
chamber. 料室外不需再混合
99.1% Accuracy 99.1%精度
Average Cv is 7.8 for phytase applied at rate of
0.1 pounds per ton. (diluted 8:1)
每2000磅加0.1磅加植的酶的变异系数Cv为
7.8(8:1稀释)
Vacuum Core Coater (Dinnissen)
真空中心喷涂
Vacuum Core Coater System
真空中心喷涂系统
Vacuum Coating -Incoming Product
真空喷涂 -进料
料中含0-10%脂肪
Vacuum Coating -Incoming Product
真空喷涂-进料
Fissures & Pores
裂缝与气孔
Vacuum Coating -Incoming Product
真空喷涂-进料
空气
Vacuum Coating -Air Removal
真空喷涂-去气
真空
Vacuum Coating -Liquid Application
真空喷涂-加液体
维生素
真空
涂料
油/脂
Vacuum Coating -Liquid Penetration
真空喷涂-液体渗透
加压后
空气
回复正常
Vacuum Coating -Surface Application
真空喷涂-表面添加
Vacuum Coating -Finished Product
真空喷涂-成品
成品
Summary 结论
More ingredients in liquid form.
液态原料越来越少
Proper liquid storage/handling
systems. 需要合适的储藏/处理系统
Properly designed dispensing.
合理设计分散装置
Dry/liquid flow rate accuracy
固/液流量精度
Liquid droplet size 液滴大小
Summary 结论
Proper distribution patterns
合适的分送方式
Proper incorporation/mixing
适当混合
Adequate retention time
充分的存留时间
Proper equipment selection
选取适当设备
Proper system design 适当的系统设计
System interfaces/controls
系统控制/面板
Preventative Maintenance
for
Feed Processing Plants
饲料加工车间的预防性维修
By
Fred J. Fairchild, P.E.
Professor
Department of Grain Science
Kansas State University
Manhattan, Kansas USA
Maintenance
维护
Keeping facilities and equipment in
good operating condition to avoid
unexpected failures and unplanned
production losses. 使设施/设备保持良好
的操作状态,以避免未预计的失误及未
计划的生产损失.
Types of Maintenance
维护的类型
Routine
例常
Emergency
紧急
Outside
外聘
Preventative
预防
Types of Maintenance
维护的类型
Routine Maintenance:例常维修
" Servicing equipment on a regular basis."
定期经常给设备做维护
Draining Air Lines 抽空空气管道
HammermillScreen Replacement更换筛片
Checking Oil Levels 查油位
Tightening Belt Drives 紧皮带
Types of Maintenance
维护的类型
Emergency Maintenance:紧急维修
" Immediate reaction to unscheduled
breakdowns." 对未预料的停机的及时反应
Broken Shafts 断轴
Torn Belts 断皮带
Burned Out Motors 烧电机
Jammed Equipment 堵塞设备
Types of Maintenance
维护的类型
Outside Maintenance:外聘维修
"Requires calling in outside help."需要请外人帮
忙
Repair Expertise Not in Plant 维修专家不在厂内
Need Special Repair Equipment 需要特殊维修设备
Need Outside Services 需要外部服务
Types of Maintenance
维护的类型
Preventative Maintenance:预防性维修
"Keeping Equipment in Working Order."
让设备保持可工作状态
Repair / Replace Equipment Before Failure在
失误前即修理/更换设备
Scheduled Inspections 有安排的巡视
Scheduled Repairs / Replacement 有安排的修
理/更换
Preventative Maintenance
预防性维修
"For every unit of cost spent on
preventative maintenance, at
least 5 times that cost will be
saved in subsequent expenses."在
预防性维修上的一块钱,可在后
果的花费上省出至少5块钱.
Developing A Preventative
Maintenance Program
制订预防性维修方案
"Requires collecting good information and
organizing it into a useful format."
"需要收集好的信息并编成有用的格式"
Equipment Identification 设备号
Equipment Information 设备信息
Equipment Maintenance Requirements设备维
修要求
Proper Parts Inventory 合理备件/库存
Maintenance Records 维修记录
Developing A Preventative
Maintenance Program
制订预防性维修方案
Equipment Identification:设备编号
All Equipment Needs Maintenance at Some
Point.所有的设备到时都需要维修
Tracking Maintenance Type and Cost
Necessary.跟踪维修方式及其必要成本
Separate Identifying Number for Each Piece
of Equipment. 每件设备均需分别编号
Developing A Preventative
Maintenance Program
制订预防性维修方案
Equipment Information:设备信息
Part Numbers 零件号
Assembly Drawings 组件图
Operating Manuals 操作手册
Purchase Records and Supplier Information
购买记录及供应商资料
Supplier Codes 供应商号
Developing A Preventative Maintenance
Program
制订预防性维修方案
Maintenance Requirements: 维修要求
Required Inspections 必要查看
Lubrication Requirements 润滑要求
Recommended Servicing 建议维护
Recommended Servicing Intervals建议维护
间隔
Developing A Preventative
Maintenance Program
制订预防性维修方案
Proper Parts Inventory:零件的合理库存
Recommended Spare Parts 建议备件
Availability of Parts零件可获得性
Critical Parts 关键零件
Cost of Inventory 库存成本
Location of Parts 零件位置
Developing A Preventative
Maintenance Program
制订预防性维修方案
Maintenance Records 维修记录
Work Performed 已做工作
Who Did the Work 谁做
Parts Used 所用零件
Cost of Parts 零件
Cost of Labor 人工零件
Frequency of Repairs 修理频率
Types of Repairs 修理类型
Developing A Preventative
Maintenance Program
制订预防性维修方案
Maintenance Records 维修记录
Set Preventative Maintenance Schedule 制订预防维修计划
Determine Inspection and Replacement Schedule 确定检查
及更换计划
Indicate Potential Trouble Spots 指出可能出错的位点
Indicate Continuing Trouble Spots指明正出错的位点
Indicate Parts Needs and Frequency指明需要的零件及频
率
Guide Repair/Replacement/Elimination Decisions 指导修
理/更换/清除决策
Process Flow Diagram 流程图
Chart 1
Equipment
List
设备表
Equipment
List
设备表
Rail Receiving Conveyor Grain Screener w/ Aspiraion
Truck Receiving Conveyor Two-Way Valve
Magnet Grain Cleaner
Receiving Elevator Crimped Grain Elevator
Two-Way Valve Transfer Conveyor
Transfer Conveyor Two-Way Valve
TurnheadDistributor Ingredient BinScrew Feeders
Corn Storage Bin Main Ingredient Scale
Milo Storage Bin Mineral Ingredient Scale
Alfalfa Storage Bin ScaleAir Gate
Receiving Scalper ScaleAir Gate
Receiving Distributor Batch Mixer
Storage Bin Feeders Surge Bin
Grain Transfer Conveyor Surge Conveyor
Grain Transfer Conveyor Mixing Elevator
Two-Way Valve Magnet
= Surge Bin and Level Control Mash Cleaner
HammermillFeeder OversRegrinder
Hammermill Mash Distributor
HammerrmillDischarge Conveyor Mash Transfer Conveyor
HammermillAir System Mash Distributor
Grinding Elevator Slide Gates
Grinding Distributor SurgeBin
Pneumatic Receiving Pipes Pellet Mill
Chart 2
Equipment
Information
设备信息
Equipment
Information
设备信息
Chart 3
Supplier
List
供应商表
Supplier
List
供应商表
A-1
Acme Electric Co.
610 Green Street
Smallton, Kansas
USA
785-555-5555
785-555-1234
785-456-7890
Bill Smith
A-2
Adams Supply Company
1613 Highway 1
Southtown, Kansas
316-444-5555
316-444-1000
316-987-6543
John AdamsChart 4
Maintenance
Schedule
维修计划
Maintenance
Schedule
维修计划
Pellet Mills
Pellet Cooler
Moxer
Augers
60, 61, 102
96',96-A,100
101
Milo Cooler
Boiler
Air Comp.
Fork lifts
Milo Cooler
Fan
Pellet Cooler
Fan
28A-27 B&C
Chem. Pump
Feedes,
Bins 11-22
Rollers 1-2,
Hammermill,
Hammermill
Fan
Leg33-41
Augers 41-
106
Scalper
Pellet Mills
Conditioner
Bins 29 -36
Boiler
Air Comp.
Fork lifts
3-ton Mixer
Scales
Pellet Cooler
Air Lifts
Tractors
Bobcat
Air Comp.
Fork lifts
Air Comp.
Air Comp.
Fork lifts
Manlift
Boiler
Boiler
Boiler
Bins 1-10
Pellet Mills
Pellet Mills
Pellet Mills
Rollers 1-2
Hammermill
Fat Filter
Mol. Filter
Hammermill
Hammermill
Legs 53-54
Hammermill
Leg
Cooler
Leg
DistributorsBagging
Scales
Pellet
Cooler
Hyd. Pump
Mol. Pump
Fat Pump
Tractors
Bobcat
Pellet
Cooler
Mix. Leg
Rec. Leg
Mix. Leg
Rec. Leg
Chart 5
Maintenance
Calendar
维修日历
Maintenance
Calendar
维修日历
Pellet Mills
Pellet Cooler
Moxer
Augers
60, 61, 102
96',96-A,100
101
Milo Cooler
Boiler
Air Comp.
Fork lifts
Milo Cooler
Fan
Pellet Cooler
Fan
28A-27 B&C
Chem. Pump
Feedes,
Bins 11-22
Rollers 1-2,
Hammermill,
Hammermill
Fan
Leg33-41
Augers 41-
106
Scalper
Pellet Mills
Conditioner
Bins 29 -36
Boiler
Air Comp.
Fork lifts
3-ton Mixer
Scales
Pellet Cooler
Air Lifts
Tractors
Bobcat
Air Comp.
Fork lifts
Air Comp.
Air Comp.
Fork lifts
Manlift
Boiler
Boiler
Boiler
Bins 1-10
Pellet Mills
Pellet Mills
Pellet Mills
Rollers 1-2
Hammermill
Fat Filter
Mol. Filter
Hammermill
Hammermill
Legs 53-54
Hammermill
Leg
Cooler
Leg
DistributorsBagging
Scales
Pellet
Cooler
Hyd. Pump
Mol. Pump
Fat Pump
Tractors
Bobcat
Pellet
Cooler
Mix. Leg
Rec. Leg
Mix. Leg
Rec. Leg
Chart 6
Maintenance
Record
维修记录
Maintenance
Record
维修记录
Developing A Preventative
Maintenance Program
制订预防性维修方案 Program Administration:方案管理
Manual Record Keeping 手写记录
Computerized Record Keeping 电脑保存记录
Manual or Computerized Scheduling手工或电
脑排计划
Work Order Generation 开工表制作
Lifecycle Predictions 寿命期预测
Equipment Improvement/Redesign 设备改进/
重新设计
Costs vsRevenue Generation 成本/收入的产生
Preventative Maintenance
预防性维修
A Properly Designed and Used Preventative
Maintenance Program Will More Than Pay
Itself in Prevention of Lost Production
Time.
设计和使用合理的预防性维修计划,在防
止生产时间的损失方面是有超额回报的.
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