4) a. kirchner (iff)-influence of a liquid application in the...
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Forschungsinstitut FuttermitteltechnikResearch Institute of Feed Technology
Influence of a liquid application in the main mixer on mixture homogeneity of feeding stuffs
Dipl.-Ing. Alexandra Kirchner
IFF Research Institute of Feed Technology, Braunschweig-Thune, Germany
BRAUNSCHWEIG
Location of IFF
2
Braunschweig
Federal State of Lower Saxony
250,000 inhabitants
INTRODUCTION
International Research Association of Feed Technology
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International Research Association of Feed Technology (IFF) in head points
founded in 1961 on the initiative of the German Association of Feed Industry
supports German and international members in the feed processing industry by
– results of joint research projects and
– service activities
maintains a Research Institute of its own
International Research Association of Feed Technology (IFF) in head points
100 members (national and international companies as well as associations and organisations)
SME oriented industrial cooperative research in the fields of
– feed quality and safety as well as – feed quality and safety as well as
– process optimization
member of the Working Pool of Industrial Research Associations (Arbeitsgemeinschaft industriellerForschungsvereinigungen “Otto von Guericke” e.V.) at Cologne, Germany, since 1964
Impressions
Impressions
RESEARCH INSTITUTE OF FEED TECHNOLOGY
International Research Association of Feed Technology
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Research Institute of Feed Technology in numbers
Head of the Institute: Dr.-Ing. Alexander Feil
4 scientists
3 technicians
2 laboratory technicians
1 assistant
Research Institute of Feed Technology in facts
Pilot plant/test facilities (capacities from 10 kg/h up to 1 t/h)
Milling: hammer and roller mill
Mixing (capacities from 10 up to 1,000 l):
single-shaft slanted vane mixer, ribbon mixer, double-shaft paddle mixer, vacuum twin-shaft paddle mixer, … paddle mixer, vacuum twin-shaft paddle mixer, …
Pelleting and agglomerating:
2 ring-die presses, laboratory flat-die press,
expander/extruder, belt cooler, vertical cooler
Conveying:
mechanical and pneumatical conveying devices
Research Institute of Feed Technology in facts
Physical analyses
density, bulk density, tap density, flowability
pellet & agglomerate abrasion/durability
dusting behaviour (rotation drum, single drop devices)
particle-size distribution (sieving analysis, laser-diffraction)
Chemical analysesChemical analyses
Weender analysis
wet-chemical analysis according to the VDLUFA method manual
fat indicators
photometry
element analysis (AAS), additive analysis (HPLC)
starch gelatinisation
protein dispersibility index
Examples of terminated research projects
Investigation and evaluation of alternative technological processes for the production of medicated feeding stuffs
Comparing investigations for improving the product safety of mash compound feed by low energetic irradiation and hydrothermal treatment
Investigations on the applicability of the vacuum-coatingprocess for the production of compound feed rich in energyand for the application of liquid formulated additives afterpelleting
Production of structurised and mixing-stable mineral feedswith high product safety and quality by using selected compaction processes
STARTING POINT AND SELECTED RESULTS
Research project on optimized liquid application
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Liquid addition to feeding stuff powders as an aspect of feed quality and safety
Liquids are added to feeding stuffs to
• decrease dusting behaviour,
• increase taste and nutritional value,• increase taste and nutritional value,
• avoid segregation.
Liquid application in the main mixer – Problems
caking and agglomerates
• feed quality
• cross-contamination
negative influence on mixture homogeneity
• feed quality and safety
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Liquid addition for avoidance of segregation
formation of liquid bridges – agglomeration
definition of the project must be to find an optimum between desired and undesired effects when adding liquids to feeding stuffsregarding• technological parameters• material characteristics
Technological parameters
fogging
two component nozzle
addition as droplets
one component nozzle
fluidizing of dispersible materials
addition as continuum
pipe
bulk / feeding stuff
mixer
mixing and wetting of bulk
dry mixingadditional mixing
replacement of liquids
Liquids
1.000
10.000
100.000
. v
isco
sity
[m
Pa
s]
Rübenmelasse (47%)
Rübenmelasse (42%), NZ
Rübenmelasse F-805 (42%)
Rübenmelasse F-934 (42%)
sugar beet molasses (47%)
sugar beet molasses (42%)
sugar beet molasses (42%)
sugar beet molasses (42%)
0
1
10
100
20 °C 32 °C 38 °C
dy
n.
vis
cosi
ty [
temperature
Betriebsmelasse (Rüben)
Betriebsmelasse (Rüben)
Apfelmelasse
Apfelmelasse
Vinasse
Sojaöl
Wasser
sugar beet molasses (42%)
sugar beet molasses (42%)
vinasses
apple molasses
apple molasses
soy oil
water
67 mm
Viscosity – Dispersibility of liquids in nozzles
32 °C 38 °C20 °C
15 mm
84 mm144 mm
51 mm
142 mm
One comp. nozzle 80 °sugar beet molasses F-909
Feil, Kirchner (2007), Final Report of the IGF-project “Melasse” No. 14210 N
Droplet size and droplet size distribution
equation author
x50/D≈6*Re-0,15 Panasenkov
x0,999/D=We-0,333(23,5+395*10-6*Re) Miesse
x32 /D=47/v (σ/ρG)0,25 (1+331*Oh) Tanasawa
Calculation of characteristic droplet diameters
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Re - Reynolds number
We - Weber number
Oh - Ohnesorg number
x50 - average droplet diameter
x32 - Sauter diameter
D - diameter of nozzle outlet
ρG - density of gas atmosphere
σ - surface tension
Particle-size distribution
0,50
0,75
1,00
dis
trib
uti
on
fun
ctio
nQ
3(x
)
0,00
0,25
10 100 1000 10000
dis
trib
uti
on
mesh width w [µm]
pig feed (F-752) pig feed (F-683) colour indicator cattle mineral feed (F-803)
pig mineral feed (F-802) cattle mineral feed (F-664) layer meal (F-857)
State-of-the-art
The binding of particles is caused by liquid bridges and therefore a reduction in the number of particles occurs
� negative influence on optimal mixture homogeneity but
� avoidance of segregation
Free flowability of particles is limited
� negative influence on mixture homogeneity
A dry mixing cycle is necessary because liquids may cause a “freezing” of the state of the mixture
The liquid must be evenly distributed in the mash to avoid the occurrence of rough agglomerates
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Experimental study
An experimental study was carried out to mark up
technological parameters and material properties for optimized discontinuous liquid application in the main mixer regarding feed quality in the cases of
– mixture homogeneity
– avoidance of segregation and – avoidance of segregation and
– dusting behaviour
and to minimise cross-contamination – caused by unbound fines on the one and caking on the other hand
The project is funded by the German Ministry of Economics via AiF (AiF-Code 16016 N, 2009-2011)
Experiment
mineral
concentrate
rough and fine dry mixing
twin shaft
paddle mixer
one component
nozzle
20 l
molasses
1-3%
rough and fine
compound feed
rough and fine
dry mixing
additional mixing
Cut out from experimental plan IGF-project “Flüssigkeitszugabe“ No. 16016 25
colourant as indicator
(micro component)
20 l
intensive mixer
pipe
45 l
vinasses
soy oil
Analysis
For the characterization of the mixture homogeneity a particulate organic colourant was used as additives’ indicator (ratio of 1:100,000 or 1:50,000)
The colourant can be detected photometrically with a low analytical error
The concentration of the indicator in single samples was The concentration of the indicator in single samples was analyzed and statistically evaluated by the coefficient of variation (CV)
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Mixture quality of cattle mineral feed
0,054
0,069
0,042
0,14
0,104
0,099
soy oil + subsequent mixing
colourant + oil addition
colourant + oil addition + subsequent mixing 1%
3%
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0,087
0,054
0,139
0,113
0,00 0,05 0,10 0,15
dry mixture
soy oil
coefficient of variation (CV)
area of good mixture homogeneity
Sample concentration of colourant
60
80
100
120
sam
ple
co
nce
ntr
ati
on
in
%
CV (colourant) = 0.054
CV (soy oil) = 0.087
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0
20
40
60
1 2 3 4 5 6 7 8 9 10
sam
ple
co
nce
ntr
ati
on
in
%
sample no.
colourant soy oil
Conclusions
The estimation that liquids must be evenly distributed in the mash to avoid the occurrence of rough agglomerates could be validated by the experimental study
It seems to be essential that the liquid is spread evenly on the particle surfaces of all particles to avoid undesired agglomerates and increase mixture homogeneity. Therefore a material specific amount of liquid is Therefore a material specific amount of liquid is necessary.
Under defined circumstances a dry mixing cycle is not necessarily needed to reach an adequate mixture homogeneity
At the moment a general conclusion on the influence of a liquid addition on the mixture homogeneity is not possible
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