Corn starch is a polysaccharide extracted from corn. With the growth of the global population and the improvement of people's living standards, the demand for food is increasing, and the food industry will continue to develop steadily, which will lead to the growth of the demand for corn starch in the field of food processing. For example, in baked goods, corn starch can make bread, cakes, etc. more fluffy and tasty, and its application as a thickener and stabilizer will be more widely used. In the field of biodegradable materials, corn starch can be used in the manufacture of disposable tableware, packaging materials, etc. With the increasing awareness of environmental protection and the promotion of relevant policies, there is an increasing demand for biodegradable materials, and corn starch has great market potential in this field. In addition, in the field of bioenergy, corn starch can be used as a raw material for the production of bioethanol and other bioenergy, and its demand is expected to further expand with the growth of clean energy demand.
With the continuous development of the corn starch production industry, starch enterprises are more inclined to adopt high-efficiency airflow drying technology in order to improve the production efficiency and reduce the production cost, so as to realize the rapid drying and continuous production of corn starch, which in turn promotes the growth of the market of corn starch airflow dryer. Jiangsu Jinwang continuously researches and develops new technologies and processes, develops new heating methods, improves the design of airflow drying structure, and applies highly efficient dust removal and waste heat recovery technologies, etc., in order to improve the performance of the equipment and reduce the energy consumption; and at the same time, it improves the quality and stability of the equipment, so as to ensure the long-term and stable operation of the corn starch airflow dryer.
Corn starch air dryer process flow
(1)Feed preparation
First of all, the wet corn starch pretreatment, usually after screening, debris removal and other processes, to remove the large impurities, fibers, etc., so that the starch particles as uniform as possible, to prevent clogging of the pipeline or affect the drying effect. Screening can use vibrating screen and other equipment, in addition to impurities can be used to remove magnetic impurities such as magnetic separator.
The pre-treated wet corn starch is fed continuously and stably into the drying pipe of the air dryer through the screw feeder or other suitable feeding device according to a certain feeding speed.
(2) Heating and drying
The cold air from outside is filtered through the air filter to remove the dust and other impurities and get clean air.
The clean air is heated through the heat exchanger, and the heating method includes steam heating, electric heating, coal-fired hot air furnace heating, fuel oil hot air furnace heating, etc., which can be selected according to the actual production conditions and demands, and the heated air becomes high-temperature hot air.
High temperature hot air and wet corn starch sent from the feeding device are fully mixed in the drying tube, and the hot air rapidly transfers the heat to the corn starch granules, so that the water on the surface of the corn starch and inside is quickly evaporated into water vapor.
The hot air will transfer the heat to the corn starch particles rapidly, so that the moisture on the surface and inside of the corn starch will be evaporated into water vapor and mixed into the airflow, thus realizing the drying of corn starch.
(3)Gas-solid separation
The dried corn starch particles enter the cyclone separator together with the airflow. In the cyclone separator, due to the centrifugal force, the corn starch particles with larger mass are thrown to the wall of the machine and fall down along the wall of the machine, and then discharged through the air shut-off device to become the dried finished product.
The exhaust gas containing water vapor is discharged into the atmosphere through the fan, and a small part of the fly powder can be recycled by the secondary cyclone dust collector or cloth bag dust collector to reduce the material loss and environmental pollution.
(4) Discharge and subsequent treatment
After the dried corn starch is discharged from the air shutter at the bottom of the cyclone separator, it can directly enter the packaging process for packaging and storage, or it can be further processed or handled according to the needs, such as crushing, screening, mixing and so on, in order to satisfy the different product quality requirements and the use of needs.
(5) Equipment cleaning and maintenance
At the end of production, the air dryer needs to be cleaned up to remove the residual materials and impurities inside the equipment to prevent them from accumulating and deteriorating inside the equipment, affecting the quality of the products produced next time and the normal operation of the equipment.
Regular inspection and maintenance of the equipment, including checking the operating conditions of the heat exchanger, fan, screw doser and other equipment, replacing worn parts to ensure stable performance and service life of the equipment.
Corn starch air flow dryer performance characteristics
(1)High drying efficiency
Fast heat and mass transfer: hot air and corn starch particles in the drying tube in full contact, due to the high speed of airflow, material particles suspended in the airflow, air-solid heat transfer between the surface area of the large heat transfer coefficient is high, can be achieved in a short period of time to transfer heat and moisture evaporation, drying time is usually only a few seconds, and greatly improve the drying efficiency.
Instantaneous drying: adopting the principle of negative pressure drying, the material is rapidly dried in the airflow, realizing instantaneous drying effect, especially suitable for drying heat-sensitive materials, which can effectively avoid the deterioration of corn starch due to prolonged heat, paste, etc., and ensure the quality of the product.
(2)High drying intensity
Large processing capacity: the processing capacity of the air dryer is strong, and its moisture evaporation capacity ranges from 50kg/h to 15000kg/h, which can meet the needs of different scale production enterprises and can effectively improve the production efficiency and reduce the production cost.
Small equipment volume: compared with some traditional drying equipment, air dryer in the case of the same processing capacity, small footprint, compact structure, can save a lot of space, reducing the cost of plant construction.
(3) Good product quality
Low material temperature: despite the high temperature of the heating air, the surface temperature of the material can only reach the wet bulb temperature of the air and will not be too high because it is in the constant speed drying period during the drying process, thus preventing the problems of deterioration, discoloration and loss of nutrients of corn starch due to the high temperature, and ensuring the quality and performance of the product, which is especially suitable for drying corn starch that is sensitive to the temperature.
Avoiding pollution: the whole drying process is carried out in a relatively closed system, and the materials do not come into direct contact with the external environment, which reduces the possibility of mixing impurities, dust, etc., and reduces the risk of contamination, and ensures the purity and hygienic quality of corn starch.
(4)High degree of automation
Continuous operation: continuous and stable feeding and discharging can be realized without frequent interruption of production for manual operation, which reduces labor intensity, improves production efficiency and is suitable for large-scale industrialized production.
Precise control: through the advanced control system, it can precisely que control the parameters such as feeding speed, hot air temperature, airflow speed, etc., so as to ensure the stability of the drying process and the consistency of the product quality, and reduce the influence of human factors on the drying effect.
(5)Low running cost
Energy saving: hot air in the drying process and material full contact and heat exchange, heat utilization rate is high, at the same time, the dryer does not require additional mechanical mixing devices in the operation process, reducing power consumption and reducing energy costs.
Simple maintenance: the structure of the equipment is relatively simple, no complex transmission mechanism, fewer failure points, low daily maintenance costs, and the equipment has a long service life, which can effectively reduce the enterprise's equipment investment and operation and maintenance costs.
(6) High safety
Negative pressure operation: the drying system adopts negative pressure operation, the air pressure inside the tube is smaller than the outside world, which effectively prevents dust leakage and flying and avoids safety hazards such as dust explosion, providing a reliable safety guarantee for the production process.
Equipped with safety devices: In order to ensure the safety of operators and equipment, the air dryer is usually equipped with perfect safety devices, such as high temperature alarm device, abnormal pressure alarm device, explosion relief valve, etc., when the equipment is in an abnormal situation, it can send out alarms in time and take corresponding protective measures.
Corn starch airflow dryer technology improvement
(1) Upgrade of feeding and dispersing device
Uniform feeding device: Improve the structure and control mode of screw feeder, so that the wet corn starch can enter the drying tube more uniformly and stably, avoiding the problems of insufficient drying or local overheating caused by uneven feeding, and improving the consistency of product quality.
Material dispersing technology: special material dispersing device is set in the drying tube, such as airflow distribution board, stirrer, etc., so that the material is more dispersed in the airflow, increasing the contact area between the material and the hot air, improving the efficiency of heat and mass transfer, and speeding up the drying speed.
(2) Improvement of heating method
Combined heating: using a combination of heating methods, such as steam heating combined with electric heating. In the early stage of drying, the use of steam heating to quickly raise the temperature, after reaching a certain temperature, switch to electric heating for fine que temperature control, not only to improve the drying efficiency, but also to reduce energy consumption, while ensuring the stability of product quality.
Waste heat recovery and utilization: increase the waste heat recovery device, the waste heat in the exhaust gas will be recovered, used to preheat the cold air or wet materials into the dryer, improve the energy utilization rate, reduce production costs.
(3) Optimization of drying pipe structure
Pulse drying tube: the pulse airflow drying tube with alternately narrowing and expanding diameters is used to make the movement speed of material particles in the drying tube alternately accelerated and decelerated, so as to increase the relative speed between air and particles and the area of heat transfer, and to strengthen the rate of heat and mass transfer. At the same time, the air velocity decreases at the large diameter, increasing the drying time and improving the drying effect.
Variable diameter drying tube: design of thick and thin segments of variable diameter drying tube, such as two-stage or multi-stage variable diameter structure. This structure can make the hot air and wet starch full contact, extend the contact time, improve the drying efficiency, and can reduce the resistance of the drying wind, reduce energy consumption.
(4) Optimization of gas-solid separation system
High-efficiency cyclone separator: adopt new type of high-efficiency cyclone separator, optimize its internal structure and size parameters, improve the separation efficiency, reduce the entrainment loss of starch particles, and reduce product loss and environmental pollution.
Multi-stage separation technology: add two or more stages of separation devices, such as bag filter, electrostatic precipitator, etc., to further recover the fine powder in the exhaust gas and improve the material recovery rate, which is also conducive to meeting the more stringent environmental protection requirements.
(5) Perfect automation control system
Precise parameter control: Introduce advanced sensor technology and automation control system, real-time monitoring and precise control of key parameters in the drying process, such as feeding speed, hot air temperature, airflow speed, pressure in the drying tube, etc., to ensure that the drying process is stable and efficient, and to improve the stability and consistency of product quality.
Fault diagnosis and early warning: the establishment of fault diagnosis system, can automatically detect abnormalities in the process of equipment operation, and issue timely warning signals to remind the operator to deal with, reduce equipment failure downtime, improve production efficiency and equipment reliability.
(6) Equipment materials and insulation performance enhancement
Selection of high-quality materials: the key components of the dryer are made of corrosion-resistant, high-temperature-resistant and wear-resistant high-quality materials to improve the service life and stability of the equipment and reduce maintenance costs and downtime.
Strengthen the heat preservation measures: the outer surface of the drying pipe, hot air furnace, cyclone separator and other equipment with good heat preservation treatment to reduce heat dissipation, reduce energy consumption, but also conducive to improving the temperature of the working environment.
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