Effect of ring mode compression ratio on efficiency and quality of granulator
1 Overview of the
This article explores large pig pellets. Due to the current fierce competition in the feed market and the change in people's farming concepts, the market demand for large pig feed has gradually changed from pelletized feed to pellet feed in the past. In order to improve the competitiveness of feed mills, the control of feed costs is particularly important. Therefore, the production efficiency of the pellet machine becomes a key point in feed cost control.
2 Basic parameters
(1) Comparison on the basis of the same formula: the content of corn in the formula is about 65%, the protein raw material accounts for about 34% in the formula, and the minerals and other about 1%;
(2) The raw materials in the formula are the same batch (the same moisture, impurities, etc.);
(3) crushing fineness 2.0mm diameter sieve piece crushed, mixed water after about 12.5%;
(4) The pressure of the cylinder is 8 bar before granulation, the pressure is 5 bar after decompression, and the temperature is 80-85 °C;
(5) 150KW of granulator motor and 230A of actual working current;
(6) particle diameter 4.0mm;
(7) The opening of the cooling fan damper is unchanged, and the unloading position of the cooler is unchanged;
(8) Two-layer grading sieve (top 3 mesh, lower 8 mesh).
That is to say, tests performed between different compression ratio ring modes performed under substantially the same parameters.
3 test pellet machine model (shepherd MUZL610TW)
(1) The ring mold aperture is 4.0mm, the compression ratio is 1:6, the production time is 12.6h, the actual dosage is 200t, the powder rate is about 5%, the average production is about 15.9t, the finished product moisture is about 12.3%, and the particle hardness is not tested;
(2) The ring mold aperture is 4.0mm, the compression ratio is 1:5, the production time is 10.1h, the actual dosage is 200t, the powder rate is about 5.3%, the average production is about 19.8t, the finished product moisture is about 12.4%, and the particle hardness is not tested;
(3) The ring mold manufacturer is the same, the material is 4Cr13, and the opening ratio of the ring mold is about 38.6%.
4 test results comparison
(1) Electricity cost when using 1:6 ring die granulation: electricity consumption = 150KW × 12.6 = 1890 degrees, electricity consumption is 9.45 degrees, electricity consumption per ton is 0.56 yuan / kWh, that is, electricity cost per ton is about 5.3 yuan;
(2) Electricity cost when using 1:5 ring mold granulation: electricity consumption = 150KW × 10.1 = 1515 degrees, electricity consumption per ton is 7.58 degrees, electricity consumption per ton is 0.56 yuan / kWh, that is, electricity cost per ton is about 4.24 yuan;
(3) The cost per ton of pellet machine efficiency can be about 1.1 yuan;
(4) It can be seen from the moisture of the finished product that the loss can be reduced by about 0.1%, which improves the product yield, indirectly reduces the cost, and produces benefits (according to 3,000 yuan/t, the income can be increased by about 3 yuan/t);
(5) From the comparison results, the cost per ton can be reduced by 4.1 yuan; if the annual output reaches 50,000 tons, the annual cost can be reduced by 205,000 yuan.
5 Discussion
According to the test process, it can be found that the modulation temperature of the compression ratio can be greatly improved, and the starch in the corn can be more gelatinized, which can improve the palatability of the feed; for the large pig material, it does not affect Under the premise of product quality, the effect of the compression ratio of the ring mode on production efficiency is obvious, and the reduction of feed cost can also be calculated. At the same time, the improvement of granulation efficiency also drives the efficiency of each process link associated with it, which can reduce costs in many aspects. Of course, in this related test, due to the limited conditions, the multiple performances of the feed cannot be compared one by one. It is simply to start from the power consumption and give us a reference, which will occur in the actual large-scale production. Such problems are the bottlenecks of our cost control and deserve our research.
6 Conclusion
The results of the above experiments are much lower than the compression ratio of the large pigs in the past using the ring mold compression ratio of 1:10-12, which is closely related to the gradual rationality and level of the current breeding industry, which brings about the improvement of production efficiency. Great changes have also played a role in improving the market competitiveness of feed mills.
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