ow did Muyang increaseenergy efficiency of the extruder system?......With the developmentof extrusion technology, one of thedevelopment trends in aquafeedmilling is that the extruder is takingthe place of pellet mill and becomingthe most popular and most efficientmilling machine because of its flexibleproduction adaptability, high productquality and high sanitation assurance.
However, the obstacle impeding extrud-er popularisation is energy input, whichmust be decreased.As we all know, sufficient energy isrequired to put into the extrusion systemto sustain the whole extrusion process,from material conditioning to kneading,shearing, cooking, extruding, forming andfinally obtaining qualified aquafeed.Essentially, the input energy is normallydefined in two forms: the specific mechani-cal energy (SME) and thespecific thermal energy(STE).Analyzing the energyinputs that are requiredfor cooking raw recipecomponents, there arethree possible ways toimprove energy efficiencyof an extrusion system,that is, to increase production capacitywhile decrease the power consumption.They are:1) Improve the utilization efficiency of SME2) Improve the utilization efficiency of STE3) Try to input and utilize most STEfrom the relatively cheaper source -steam to substitute some SME input
Method to maximiseSME utilisation
First of all, the approach was studied tomatch the SEM input with that required formaterial ripening.If lower than that required, the inputSME could not ripen the material suf-ficiently even though it would result inhigher production capacity, and vice versa.Therefore, only proper SME input canguarantee high quality extruded aquafeedwhile maximising production capacity.By quantifying the abilities of each screwsegment (including conveying, shearing andmixing abilities) and testing the effectsof different screw combinations, Muyang’sextruder research team found out the opti-mal screw configuration that can achieveproper SEM input for a given aquafeedproduction task.Based on above mentioned studies anda perceptual as well as rational knowledgeof extrusion technology, Muyang’s extrusionteam worked out a new concept - “stabi-lised shearing”.Usually, the whole extrusion processthat material undergoes, from being fedinto the extruding chamber up to beingextruded out of the die plate, is a ‘hastyshearing’ process accompanied by highpressure, high power consumption andhigh wearing of working parts, and alsounconstant discharge of extrudates.The stabilised shearing technologybrought by Muyang Group can largely sta-bilise the shearing efficiency in the wholeextrusion process (see Figure 1). Theoptimal screw configurationcan not only impart to theextrusion process a properSME input but also ensure theproduct gelatinisation not lessthan that of the ‘hasty shearingtechnology’.It has been proven that,when producing aquafeed withstabilised shearing technology,
To substantially improve extruder performance in aquafeed production, in recent years Muyang Group made extensive research efforts into five aspects of extrusion and gained some key achievements: to increase energy efficiency of the extruder, to enhance pellet uniformity, to lengthen the service life of wear parts, to increase productionrate for sinking aquafeeds as well as that of micro-aquafeed, among which, the energy efficiency improving technology and its application as well as the development on pellet uniformity control will be introduced in this article.
by Ma Liang, Zhang Kuiyang, Mi Changyu, Zhang Wenliang, Muyang R&D Center, China
Energy efficiency improvingand pellet uniformity control in theextrusion of aquafeed
SPTZ Complex Conditioner vs SCTZ DDC Conditioner
SPTZ series ComplexConditionerSCTZ series DDCConditionerFilling degree55~60%30~35%Conditioning time (s)180~20040~45Gelatinization50~55%35~40%Remarks With the same effective volume and capacity
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F: Pellet uniformity
an extruder can increase the capacity by15 percent with an energy savage of 12percent per tonne of feed.
Method to maximiseSTE utilisation
Aquafeed mash needs to be pre-cookedin the conditioner with hot steam beforeentering into the extruder chamber forextrusion. How to maximise the utilisationof thermal energy from a given amountof steam, to improve the gelatinization of aquafeed mash in the conditioner, has beenthe focus of Muyang’s research efforts overmany years.The moisture and heat of steam is hardto penetrate into the core of feed mashparticles and ‘cook’ them just by the simplephysical mixing function of a conventionalconditioner, especially for the oil-rich aqua-feed mash.That means more steam and longerconditioning time has to be given in orderto achieve high mash gelatinisation.Targeting the goal of improving steamutilisation and enhancing feed gelatinisation,Muyang has invented the ‘reinforced condition-ing technology’, which can improve the massand heat transfer efficiency anduniformity of steam effectively.In addition, Muyang hasinnovated the SPTZ seriesComplex Conditioner by com-bining the reinforced conditioning technol-ogy with a Muyang SCTZ DDC Conditioner,which achieves excellent conditioning per-formance (see Table 1 and Figure 2).Besides, the production capacity of anextrusion system equipped with a SPTZ
Figure 2: SPTZ Complex Conditioner vs SCTZ DDCConditionerFigure 1: Stabilised shearing vs hasty shearing
-September-October 2011 | InnaIOnal
F: Pellet uniformity