Optimizing Pelleting in the Crushing Plant. Phil Wellhausen Applications Manager California Pellet Mill Crawfordsville Indiana, USA

Transcription

1 Optimizing Pelleting in the Crushing Plant Phil Wellhausen Applications Manager California Pellet Mill Crawfordsville Indiana, USA

2 Why Pellet? Increase bulk density transportation $ Improve Characteristics: Dust and fines to pellets Flow ability Create a Marketable product for Cattle Feeds Market both High Protein Soybean meal & Pelleted Hulls Pelleting Adds Value to product

3 Bulk density of Soybean Hulls Hulls 140 to 190 kg/m 3 (10 to 12 lbs/ft3 ) Ground Hulls 350 to 460 kg/m 3 (21 to 27 lbs/ft 3 ) Pelleted ground hulls 560 to 610 kg/m 3 (34 to 38 lbs/ft 3 )

4 Pelleting Is. TAKING ingredient(s) with various characteristics. And by adding heat, moisture and pressure FORMING IT INTO PELLETS.

5 Optimizing Pelleting Pelleting is a process the Pellet Mill is towards the end of this process Every good pellet is a result of prior steps in this process being done correctly

6 Pelleting is a process Optimizing each step is vital for marketing the best product $$$

7 Optimize Pre - Pelleting Rule of Thumb Product size (grind) - Top size should be less than the pellet hole diameter to prevent grinding on the die surface Uniform Moisture Attain optimum moisture for capacity and pellet quality (about 14 to 16% for hulls) Physical preparation Have clean product - remove die killers (tramp metal, ball bearings, silica, etc.)

8 Generally Speaking Pellet ability is where both quality and capacity are optimal PROTEIN = Good for PELLETING (Quality and Capacity) FAT = Not good for quality, Great for capacity (As oil content changes pelleting changes) FIBER = Ok for pellet quality, not good for capacity

9 Ingredient Characteristics Ingredient % Protein % Fat % Fiber Pellet-ability Soybean Meal High Wheat Midds High Cottonseed Meal High Canola Meal High Meat Meal High Corn Med Corn Gluten meal Med DDG Med Blood Meal Med Alfalfa Meal Med Oats Med Soybean Hulls Med/Low Cotton Hulls Low Peanut Hulls Low Rice Hulls Low Sunflower Hulls Low Beet Pulp Low

10 Understanding the Dynamics Oil and water do not readily mix Fibers do not easily absorb moisture Low bulk density = lower capacity Moisture is the conduit for temperature change both for heating and cooling

11 Particle Size (Rule of Thumb) The smaller the particle size, the better the pellet quality Copyright 2011

12 Conditioning Copyright 2011

13 CONDITIONING FACTORS (What affects conditioning?) Particle size Retention time in conditioner Ability of ingredient(s) to absorb moisture Steam/liquid addition and quality Equipment size, rpm, design Copyright 2011

14 Particle Size Vs Steam/Water Penetration Steam Steam Steam Steam Steam Steam Steam Steam penetrates small particles to the core Steam Steam unable to penetrate large particles, leaving center dry

15 Conditioning Maximize Steam Quality Reducing Valve Reduce High pressure ( psi/6.5 bar) from boiler to conditioner (25-40 psi /2.2 bar) Steam Separator Remove High Velocity Entrained Water Steam Trap Remove condensate

16 When Condensate or water comes through. Wet Choke One glass of water can stop a 500 HP Pellet mill

17 CPM Pellet Mill

18 Reasons for good conditioning Add moisture (steam and or water) uniformly to the product. Better physical pellet quality (less fines, less waste) Consumption of electrical energy (PM) ($) Optimize pellet mill capacity ($) Increased life of dies & rolls ($) Copyright 2011

19 Maximize Retention Time Pick Angle Adjustment Adjust for retention time with attention to shaft speed and motor amps.

20 Water addition port Conditioner Inlet End Axial Steam Inlets Copyright 2011

21 Die Hole Design Straight Relief Step Relief If L length = 1 ¾ and D = 5/32 then L/D or compression ratio = 1.75/ = 11.2 L/D R = Relief (added just for strength)

22 Pelleting Soybean Hulls 70-77º Medium to easy running Low bulk density 70 to 77 degrees C 12 to 14 % moisture (includes 1.5 to 3% from steam and or water) Typical Die spec: ¼ x 2 ½ L/D of 10:1 ~14 HP per ton hour Copyright 2011

23 Pelleting Sunflower Hulls 70-77º Hard Running Low bulk density (6-7 lbs ft) 70 to 77 degrees C 12 to 14 % moisture (includes 1.5 to 3% from steam/water) Typical Die spec: ¼ x 2 ½ L/D of 10:1 ~20-25 HP per ton hour Copyright 2011

24 Soybean Meal and Hull Processing Pellet Mill Capacity s for Soybean Hulls MTPH CPM Model HP 1 to to to to

25 Soybean Meal and Hull Processing Pellet Mill Capacity s for Canola Meal MTPH CPM Model HP 12 to to to to

26 Dies and Rolls - What to look for? Inspect worn dies and rolls

27 Tramp Metal

28 Every die has a story to tell

29 What do you see? Is this good or Bad?

30 Copyright 2011

31 Copyright 2009

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33 Worn Clamp Worn Wear Ring Any shiny surface indicates movement Must correct

34 Coolers and Cooling What to expect out of the cooler? Pellets should be: 6º C above Ambient Temperature (or less) Within 0.5% moisture above meal moisture (before steam/water addition)

35 Drying and Cooling Pellets Requirements for Drying and Cooling Heat: Required to remove moisture (source is steam/friction) Heated air expands, lowering the relative humidity, & increases the drying capability of the air Air: Carries away heat and moisture (source is fan) Works only on the surface Time: Required for heat and moisture to migrate to the surface of the pellet (bed depth and size of cooler)

36 Moisture and Heat must diffuse to surface and get then carried away by the air

37 Coolers & Cooling Cooling efficiency starts in the conditioner Hot Air holds and carries more moisture Good quality pellets are easier to dry and cool than poor quality pellets Air takes the path of least resistance Coolers, ducts, and fans need to be checked and maintained to get the most efficiency from them

38 Summary Optimize each step of the process.. Particle size Steam Conditioning Die and Rolls/Maintenance Cooling

39 Thank you