Catalogue of special production lines (including large-scale wet granulation)
1、Y-sl integrated large continuous mixing granulation, drying and cooling fluidized bed production line
2、D-SLLarge continuous extrusion wet granulation and drying fluidized bed production line
3、Special production line for rumen products fluidized bed
4、DF dry suspending agent pressure spray tower production line
5、DF dry suspension continuous spray fluidized bed one-step pellets production line
6、Water soluble fertilizer continuous spray fluidized bed granulation special production line
7、Large scale continuous spray fluidized bed production line for biological whole product chain
8、F-YPLSpray drying small granule preparation line for anti sticking wall
9、Pellet production line

1、Y-sl integrated large continuous mixing granulation, drying and cooling fluidized bed production line


The production line belongs to wet cutting granulation, which is to continuously mix the dry powder materials in the system with the incoming wet materials (such as the blanking of the centrifuge in the front channel), use the dispersing cutting granulator to disperse or granulation, and continuously disperse them into the fluidized bed (such as internal heated fluidized bed) for drying and cooling, so as to obtain products without flying dust, Compared with the traditional continuous fluidized bed, batch fluidized bed, airflow drying, flash drying and other methods, it shows the great advantages of good energy-saving effect and no flying dust products; Compared with the traditional wet granulation and drying process, it reflects the advantages of several times increase in production energy, energy saving and automatic production line; After the proprietary technology is adopted, there is no agglomeration between the internal heat exchangers, which completely solves the disadvantage of the existing 98 acid drying fluidized bed, and achieves the height of a new process package in combination with the utilization function of tail gas.
At present, it can be widely used in powder and crystal products such as threonine drying, glutamic acid, starch and 98 lysine. It is especially suitable for the use of previous granular powder mixed products - reducing dust. It is also suitable for all products that can be wet granulation in history. Its market application prospect is broad.
(1) 工艺流程   见工艺流程图
设备可采用烘干冷却一体式。进料可采用螺旋混合输送。布袋等粉尘去向可为双轴混料器,可预留人工溶粉(可选择)。  
重点:布袋粉尘、旋风粉尘、粉碎机的料等干粉返回混料器与湿料进行混合并制粒;保证成品的均匀性。
(2)通用工艺流程说明
以下所说数据均为举例,结合工艺流程图描述。
a、通过主加母料口,通过双螺旋捏合机,连续加入湿晶体(开始时,床内已有固定料位的底料,即干底料),同时有螺旋输送机返回的旋风分离器干粉也进入双螺旋捏合机,干粉与湿料进行混合、采用打散切割制粒机进行制粒工作,进入流化床后进行烘干工作。同时混合可以降低原料水份,避免料太湿,烘干床内形成湿料。
b、进料仓,采用高温进风,烘干表面水。比如进风120-165℃可调。
c、进料旁边仓,进风接近进料仓,烘干表面水。比如进风110-160℃可调。
d、然后烘干仓,进风温度偏低,开始烘干内部水及稳定水份。比如进风100-150℃可调。
e、最后续冷却仓,执行冷却颗粒工作。
f、系统内粉尘的处理:固体处理系统如筛分机处、粉碎机处的粉尘通过相应管路吸入流化床旋风分离器前、流化床内;布袋除尘器分离下来的微粉尘分两路,进入双轴混料器或者送入溶粉罐溶解后重新结晶;旋风分离器的细粉,返回流化床进口与湿料进行混合、制粒,最终作为成品排出。
g、从以上看出,系统可以实现湿晶体的连续干燥、冷却的工作,并且与以前工艺相比,成品更均匀、成品内细粉大大降低、能耗更是进一步节省。
(3)具体生产线参数,需要根据具体物料、产量进行针对性的设计以进风150℃,原料水份为10%,成品水份0.5%举例,4吨生产线,约装机功率180KW、蒸汽用量750kg/h,冰水、压缩空气根据配套的辅机确定。

2、D-SL Large continuous extrusion wet granulation and drying fluidized bed production line

This production line belongs to wet extrusion granulation, which is developed on the basis of the traditional wet granulation machine, combined with the requirements of large output, density, continuous production and automatic production.
The production line consists of: continuous mixing - continuous material separation - continuous granulation - continuous finishing grain - continuous drying - Screening - packaging.
(1) Background technology.
Common wet extrusion granulation has the following defects:
The output of single machine is only about 100kg / h, which is too low to meet the demand of large output;
The density of the product is difficult to adjust;
It can not solve the heating problem of products during extrusion.
(2) Advantages of this production line
Continuous mixing and continuous material distribution: This is the premise of realizing continuous granulation. The company has mature experience.
After development, the granulator overcomes the shortcomings of ordinary granulator. It is mainly composed of feeding bucket, cooling system, pressing knife, granulating knife, screen frame, discharge tray, transmission system, electrical system, etc; The mechanical transmission parts are arranged inside, and the professional transmission system makes the machine run smoothly and lower noise during operation; Equipped with water cooling system, it effectively reduces the temperature caused by rotating friction during granulation; When the granulating knife works, the speed of the pressing knife can be adjusted separately or stopped, which is more widely applicable; The machine is equipped with water cooling and air cooling devices, and the air tight sealing device can double protect the equipment; It can also control the whole particle speed to make more suitable particles (optional);  The split screen is adopted. One set of screen is two pieces. The new screen loading structure is more convenient and fast to disassemble and replace the screen. The deformation of the screen is small in production and the service life is significantly longer than that of the traditional screen; It greatly reduces the production cost, reduces the labor intensity and improves the production efficiency.
Continuous granulation: it is an important joint to ensure particle fluidity, less dust, bulk density requirements and particle uniformity.
Continuous drying: it is an important joint to ensure particle non adhesion, yield and particle hardness. Different forms of vibrating fluidized bed, belt dryer and vibrating fluidized bed + belt dryer can be selected according to process needs.
(3) Application scope of this production line
At present, it can be widely used in threonine granules, chicken essence and granule products, especially in the upgrading of the previous ordinary wet granulation production line, and its market application prospect is broad.


Previously, it was commonly used in the production of granules and instant granules. It belongs to a multi equipment combination technology, and the output of a single production line is relatively low.

3、Special production line for rumen products fluidized bed

Through long-term scientific research, the technicians of the company have obtained the technical ability to carry out the rumen industrialized production of amino acids, and have developed a 10000 ton production line in cooperation with relevant companies, which is the performance of the innovation ability of RIFA
(1)背景技术。
过瘤胃保护技术是将营养物质(如氨基酸、蛋白质、维生素等)保护起来,减少在反刍动物瘤胃内的发酵、降解,进入真胃及小肠后再被释放消化利用的技术,可以提高反刍动物营养物质的消化吸收利用率,具有重大经济和营养学意义,但过瘤胃保护存在高含量核丸制备和大批量包衣难题。
保护方法主要取决于两点:
一是核丸要圆滑,如有菱有角、在核丸的高点包衣很难合格,颗粒太大在瘤胃中也容易破坏;
二是包衣要均匀,强度要合适,如不均匀,在强度薄弱处,包衣很难起到过瘤胃效果,目前超过每批300公斤的大批量生产包衣工艺还没有成功的报道。
经目前公开的资料查询,比如一种过瘤胃保护氨基酸及其制备方法(申请公开号CN 100515415 C),公开的工艺内容通常包括:加辅料混合—加水湿法制粒—整圆抛丸—烘干—筛分—小批量底喷流化床包衣—(筛分)—得到成品;目前此类实验室方法,总结缺点如下:
(1)无法大生产,生产费用高;
(2)高含量的核丸基本生产不出来,产品品质不好(有效含量低)、收率低;
(3)现有包衣方法无法大生产,并且质量难以保证。

(2)喷雾流化床核丸包衣生产工艺
该工艺由包括核丸生产工艺、过瘤胃包衣工艺、不合格品处理工艺组成,其可以采用喷雾流化床造丸工艺进行过瘤胃产品核丸的生产,采用可调流化床包衣工艺进行过瘤胃包衣的生产,适合工业化大生产。具备产品品质好、收率高;生产费用低;运行稳定、安全的优点。
采用喷雾流化床造丸机1、抛光单元2、筛分机3、定量计量装置4、流化床包衣机5、筛分机6等工序制得过瘤胃产品。
通过以上方法,所得过瘤胃保护产品形状为近似球形,核丸颗粒直径在0.3-1.8mm,成品颗粒直径在0.6-3.6mm,并且筛分孔径大小之比值不大于50%。本发明所得到的过瘤胃颗粒核丸可以为不添加辅料的纯品质核丸,外壳为耐瘤胃的包衣成份,脂肪类型的过瘤胃成品中有效营养成份含量正常在40-60%之间,纤维素或树脂类型的过瘤胃成品中有效营养成份含量正常在50-90%之间,因为没有辅料,有效成份含量比传统工艺方法高出约20-50%。
过瘤胃保护产品应用示意,目前已开发成功的产品有:过瘤胃蛋氨酸、过瘤胃赖氨酸、过瘤胃氯化胆碱、过瘤胃维生素、过瘤胃苏氨酸、过瘤胃色氨酸

设备组成:采用本公司的FLZ或YLZ流化床造粒包衣机和配套辅机组成。
过瘤胃生产线技术参数参考举例
 

参数表随具体设计会有细微变动。

4、DF dry suspending agent pressure spray tower production line

Based on the production line of F-YPL anti sticking wall spray drying small granule preparation line, our technician has developed a special production line for pesticide suspension concentrate (DF preparation), which is another typical representative of the company's innovative capability.

(1) Dry suspending agent

Water dispersible granule, also known as dry suspension, is a new pesticide dosage form and preparation processing technology successfully developed in the 1980s. It is a solid preparation that can be dispersed in water. At the Sixth International Conference on Pesticide Chemistry in 1986, it was considered to be an ideal pesticide dosage form with both the advantages of granules and the high dispersion performance of suspension agent. It will be one of the important development trends of pesticide dosage form processing, and can be used for reference in medicine, chemical industry, food and other industries.

(2) Dosage form characteristics

Dry suspending agent does not use solvent. The processed particles are easy to flow freely, have certain strength and easy to disintegrate. After dispersion, the suspension rate is high without dust. It is safe to use. It is becoming a hot spot in the development of new dosage forms. It has the same effect as the suspending agent, but its storage stability is better than that of the suspending agent.

(3) Scope of use

At present, dry suspensions have been widely used in pesticides, medicine and veterinary medicine.
4连续式防粘壁喷雾干燥小颗粒制剂生产线
通用工艺流程说明:由进料装置、进热风装置、冷风、主塔、收料装置、二级流化床、尾气系统组成。
进料装置一般由料液池1、过滤器2、料液泵3、稳定器4、进料阀5、雾化器7依次组成,作用是将料液处理后由雾化器7雾化进入干燥塔内。
进热风装置一般由热鼓风机11、高温热源12、进风温度测量13、进风管和热风分配器6组成,作用是提供干燥用的热工艺空气进入干燥塔8内,形成塔内热风31。
在干燥塔内,热工艺空气与雾化的液滴接触,起瞬间干燥作用。
二级流化床的作用是将半成品采用低温烘干到合适水份,并防止成品粒子高温变质,而影响崩解性能。
冷风一般由风送风机27、加热器28、风送管组成,作用是成品粒子降到低温度。
尾气系统E一般由引风机21、排风管道、尾气处理装置10组成,作用是避免不良尾气的气味和微量粉尘造成环境污染,实施例中可采用水除尘的方案。
本生产线具有以下突出的效果:成品颗粒直径为80-150目左右中空粒子,大大减轻或避免了物料不干粘壁、粉尘静电粘壁、热粘性粘壁,最终生产效率、单台设备产量、连续生产时间、安全生产性、产品品质得以提高,整体能耗降低,以上工艺可以作增减设计。

另具备的功能:根据设定的进风温度自动控制,根据设定的风压自动控制风机,根据出风温度自动调节喷雾压力,根据设定的喷雾压力自动控制料液泵转速,等,从而实现自动控制。

5、DF dry suspension continuous spray fluidized bed one-step pellets production line

By developing a lot of energy and tackling key problems, the company has developed a continuous spray fluidized bed pellet process by successfully working together with key experts. It has successfully obtained the "rapid wetting ball" process for fast wetting, improving particle strength and improving suspension ratio (especially low melting point materials). Moreover, the comprehensive energy consumption is much more than that of the spray tower.

The production line is based on the y-wq one-step micro pill special production line, especially for the requirements of low melting point dry suspending agent and "rapid wetting ball", and the DF dry suspending agent pill making process package is formed, which forms different technical matching with the DF dry suspending agent pressure spray tower production line to solve the manufacturing process of DF dry suspending agent products.

(1) Particle strength

The characteristic of pressure spray is that it can produce an average of 80-150 mesh number hollow spherical particles, characterized by hollow particles and dense eggshell. The larger the particle and the higher the hollow degree, the easier the shell is to be broken, resulting in the disadvantage of dust flying.

Taking three pesticides as examples, the particle morphology is as follows.




Continuous spray fluidized bed pellets can produce 10-70 mesh number spherical particles (adjustable particle size, which can be controlled within the 20 mesh number  limits of the upper and lower limit), characterized by solid particles with a large number of capillary pores, because there is no hollow eggshell, and the particle size is much larger than the pressure sprayed product and the particle size can be adjusted. Therefore, the particle strength is much greater than that of "broken egg shell" particles.
For the same three pesticides, the particle morphology is as follows.

(2) Wetting time

The size of the pressure sprayed product can not be enlarged because the average size is only 80-150 mesh, and the hollow egg shell shape causes a major drawback: the longer the water entry time is, the longer the wetting time is, even longer than the 3 minutes required by the national standard. In the extreme state, there is a small cluster particle "tug" phenomenon, which is worse than that of the WG preparation, although the single particle is qualified. However, the overall wetting time is unqualified, especially after particle breakage.润湿时间、状态:甲维盐约在4分钟之后,水面的“团”才能完全崩解;嘧菌酯约在3分钟之后,水面的“团”才能完全崩解;拿敌稳约在2-3小时之后,水面的“团”才能完全崩解,极端状态始终有残留。

The continuous spray fluidized bed pellets are characterized by the fact that each particle is a solid particle with a large number of capillary pores. When the density is similar to that of the pressure spray stack, there is no obvious hollow gap between the shell and the eggshell, so the small internal capillary gap is very large, and it is full of particles and dense, resulting in the "dissolving" degree of disintegration. It ensures the qualification of dry suspending agent and the purpose of saving the use of additives. Wetting time and state: the three sample products have achieved the purpose of "rapid wetting ball";甲维盐时间约2秒,嘧菌酯约3秒,拿敌稳约6秒,具体可见视频介绍。



  (3) Suspension rate
After testing the three samples, they all reached the level of 0.4g sample / 100ml water, standing for one hour, less than 0.05ml; Among them, the material with low melting point represents "拿敌稳". Even if the product of pressure spray is used in the market, the suspension rate is between 88-91% (unqualified), and the continuous spray fluidized bed pellet method can increase the suspension rate by about 1-5%.
 (4) Environmental protection
The characteristics of pressure spray are relatively high equipment. The characteristics of the spray fluidized bed are highly variable, usually 1/3 lower than the pressure spray tower, and have a natural "height" advantage in environmental protection.
Taking three kinds of DF pesticide dry suspension preparation as an example, the characteristics of the continuous spray fluidized bed pellet production technology were compared with the pressure spray sample. The characteristics of rapid drying, high particle strength and high suspension rate (especially low melting point materials) formed a "rapid wetting ball". This continuous spray fluidized bed pellet process is now relatively mature with many patent applications of the author. For the development of a comprehensive "process package" preparation process with high particle strength, less wetting time, high suspension rate, environmental protection and small dispersed particle size, it is necessary to combine the scientific research forces of all parties, strengthen technological innovation and joint cooperation, solve the comprehensive problems of performance, investment and environmental protection, and achieve further safe production and cleaner production.

 

6、Water soluble fertilizer continuous spray fluidized bed granulation special production line

In the production process of fermentation and other industries, for example, the fermentation tail liquor not only contains high concentration of organic substances, but also contains high inorganic salts such as sulfate and ammonia nitrogen, and low pH value, but also contains other inorganic substances. This high concentration organic wastewater is difficult to be degraded by microorganisms. At present, most enterprises use the method of roller jet granulation to produce fertilizer, Due to the high temperature of air inlet and material layer, organic substances will be transformed into organic gas and carbonized, and discharged into the atmosphere with steam, resulting in pungent odor and pollutants, especially in cloudy and rainy days or low air pressure, which often leads to smog in the plant area and nearby residential areas, and the emission concentration of smoke, dust and waste gas is far higher than that specified in the national emission standard, It has a great negative impact on the environment and human body. It is impossible to granulate some normal wastewater and waste liquid by using traditional fluidized bed.
In order to solve the above problems, our technicians have developed a special production line for water-soluble fertilizer on the basis of LLL large fluidized bed granulation production line.


参数随具体实际设计会有适当变动。

 

7、Large scale continuous spray fluidized bed production line for biological whole product chain   

The company has worked together with key experts through a great deal of energy, and developed a continuous spray fluidized bed pellet process. It has been successfully applied to high content amino acids, low content amino acids, whole fermentation broth, protein extraction and tail liquid. Data and corresponding preparation process database have been obtained in the application and development of the whole product chain.
本论:
(1)Amino acids and their salts
发酵液通过膜过滤、离心机等分离技术,得到高纯度的清液、并制备成高含量的发酵产品,比如各种氨基酸,可以作为饲料用、药用等产品。


(2)Low content of amino acids
在提取一定高含量的发酵清液之后,剩余的发酵液可以制备成“低含量氨基酸”,形成高、低含量结合的“全产品链”生产工艺。适用“连续喷雾流化床造丸粒”工艺。
  



(3)Total fermentation broth
将全发酵液采用“连续喷雾流化床造丸粒”工艺,从液态原料一步直接得到各种颗粒、丸粒,可以得到中等含量的发酵产品,比如氨基酸蛋白产品,简化了生产工艺,避免了废液排放,具有一定的工艺优势,但需要在发酵过程中降低有害成份使用量。 




(4)fermentation liquid protein
通常从膜过滤得到,每种发酵液的蛋白成份有区别,可以直接制备成“类球形”颗料,作为蛋白饲料使用,也可以添加一些氨基酸,得到精品蛋白、提高品质和附加值。适用“连续喷雾流化床造丸粒”工艺。
 



(5)Fermentation tail liquor
研究检测发现,发酵残液中通常含有各种有用氨基酸、残糖、无机盐等营养成份,可以制备成“水溶肥”,也可以作为“氨基酸渣”产品。适用“连续喷雾流化床造丸粒”工艺。


以常见几种大生产的氨基酸和酶制剂发酵液为实例,从高含量产品、低含量产品、全发酵液、提取蛋白、尾液几种形式组成的“全产品链”出发,将研发成功的“连续式喷雾流化床造丸粒并烘干冷却”工艺的特点作了一些浅显的阐述:产品品质可控、低能耗、稳定安全、清洁生产,结合形成了“工艺包”。

8F-YPLSpray drying small granule preparation line for anti sticking wall

The successful development of the production line provides the possibility for spray drying to prepare solid preparations for raw materials with strong hygroscopicity, electrostatic adhesion and thermal viscosity.

The tower diameter and height of the production line are not limited by the gas sweeping arm, with high production efficiency, low energy consumption, extended continuous production time, basically no wall sticking, good product quality, cleaning and improved safety production.
     主要特点: 
(1)减少物料不干的湿粘壁 
增加塔高、塔直径、气壁风装置。
(2)减少物料的静电粘壁
所生产物料颗粒平均达80-300目、平均120目,粒径足以避免粉料静电粘壁。
(3)减少物料的热融性粘壁
在保证系统干燥强度的前提下,让物料的温度始终可以保持在50-80度,避免热融性粘壁。
(4)系统密封,物料损失少,消除环境污染。
干燥机在微负压下操作。
(5)干燥机关键部件易更换,关键控制参数可调,以调整物料停留时间,适应多品种干燥的需要。



9Pellet production line

  The production line of the system is to mix powder materials with adhesives to make suitable soft materials, extrude the soft materials into cylindrical particles, put them into spherical shot blasting mechanism to form spherical particles with high sphericity, and finally dry the excess water with drying equipment to obtain the required spherical particles.

     系统组成:混合+初步制粒+抛圆+干燥+筛分=成品 
*混合:CH槽形混合机或其它混合机(混合类);
*制粒:GHL高速混合制粒机ZL旋转挤压式颗粒机或YK摇摆式颗粒机(制粒类);
*抛圆:QZL圆形整粒机(制粒类);
*干燥:GFG高效沸腾干燥机、FG沸腾干燥机、烘箱或其它;
*筛分:ZS振动筛或其它。

 

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