RU2581238C2 - Method for production of food fibres from beet pulp and process line therefor - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: group of inventions relates to production of food fibres of beet pulp; food pipes are widely used in food and nonfood industry. Method for production of beet food fibres of beet pulp and the process line include: squeezing, preparation for drying, drying, fractionation, steaming and washing, bleaching and final washing with dehydration. Energy-saving method of secondary processing of sugar beet with final production of beet root food fibres ensures wasteless reproduction of sugar beet.

EFFECT: method for production of food fibres of beet pulp and the process line for its implementation allows to reduce costs for heat carriers, improves quality of drying, produces quality beet root food fibres, as well as improves technical and economic efficiency of production of food fibres.

2 cl, 2 dwg

Description

The proposed solution relates to the production of dietary fiber from beet pulp, which are widely used in food and non-food industries.

Dietary fiber is now recognized as an essential component of nutrition. Only balanced in the number and composition of dietary fiber food is complete. Dietary fiber is also used as a thickener, filler, and has been widely used in medicine. Outside the food industry in the production of biodegradable packaging, composite materials and other components.

A known method of producing pectin and dietary fiber from pumpkin pulp [RU 2422044 C1, A23L 1/0524 (2006.01), 06/27/2011], which provides for hydrolysis-extraction of the mixture. An anolyte is used as estrogen.

The hydrolysis of plant materials is inevitably accompanied by the decomposition of monosaccharides, in which undesirable by-products, furfural and hydroxymethylfurol, are formed, which in turn decompose to form levulinic and formic acids. The disadvantages of the method are the significant cost of heat, high hygroscopicity, the complexity of cleaning containers.

A known method of producing dietary fiber [RU 2330429 C1, A23L / 308 (2006.01), 08/10/2008], which provides for the mixing of plant materials with liquid carbon dioxide at a pressure above atmospheric pressure, its dearomatization by heating the mixture in a microwave field, depressurizing to atmospheric washing and drying.

The use of microwave devices entails high energy costs, which significantly increases the cost of the final product. During the operation of microwave ovens, the main and biggest drawback is electromagnetic radiation with a frequency of 2.45 (GHz), which causes the decay and change in the molecular structure of food products in the process of radiation, which leads to a malfunction of the human body.

A known method of producing microcellulose [RU 2501810 C1, C08B 15/00 (2006.01), C08B 15/02 (2006.01), D01F 2/00 (2006.01), 12/20/2013]. The method includes grinding and sieving the feedstock, steaming, squeezing, and also preparing an acid solution (oxalic, hydrochloric, nitric, sulfuric or other inorganic acids) for hydrolysis.

The method requires a large consumption of water, for the treatment of which significant costs are required. The use of hydrolysis also negatively affects the quality of the product.

Closest to the invention is a technological device for drying feed and a dryer [RU 2179810 C2, A23R 1/00, A01F 25/00, 02.27.2002]. The device contains a feed feeder, dryer, conveyor, fuel system, cyclone and screw press.

The technological device for drying the feed and the dryer are an integral part of the proposed method with the addition of a leveling device with preliminary extraction for loading wet materials into the dryer [Conference Materials]. These devices are included in the first, second and third technological stages of the proposed method for the production of dietary fiber from beet pulp and a technological line for its implementation, consisting of eight technological stages shown in FIG. one.

The technological solution relates to an energy-saving method for the secondary processing of sugar beet pulp and can be used for the production of dietary fiber, as well as in waste-free reproduction of sugar beet.

The technical essence of the proposed solution is as follows. The main direction to reduce the cost of production is to reduce energy costs. It is proposed to use boiler houses operating on gaseous fuels as a coolant at the technological stage of drying the exhaust gases, this can significantly reduce energy costs for drying. Leveling devices with preliminary extraction for loading wet materials into the dryer [Conference materials] and the technological device for drying feed and dryer [RU 2179810 C2, A23R 1/00, A01F 25/00, 02/27/2002] are used both for drying sugar beet pulp and and when drying beet fiber. This makes them universal, and also minimizes the number of technological steps. It is also known that in waste-free production, raw materials and energy are rationally used, the economic effect in this case is formed due to the direct return of raw materials (sugar beet pulp) to production, and the cost of its production is reduced. Waste-free production significantly reduces environmental pollution.

An important task in obtaining beet dietary fiber by recycling sugar beet pulp is to fulfill the following requirements:

- ease of maintenance of components and assemblies;

- minimization of the number of technological steps by the universality of certain technological steps;

- obtaining a high quality product;

- obtaining technical and economic efficiency;

- minimal use of chemicals.

The technical result is achieved by the fact that at the technological stage - drying, the exhaust gases of the boiler house operating on gaseous fuel are used, which reduces energy costs. An important role is also played by the direct return of raw materials to production - granular and non-granulated dry sugar beet pulp.

In FIG. 1 - a vector diagram is shown, which consists of eight technological stages; in FIG. 2 is a diagram of a production line.

A method for the production of dietary fiber from beet pulp and a production line for its implementation consists of eight technological stages shown in FIG. 1 - is spinning, preparation for drying, drying, fractionation, steaming and washing, bleaching, re-washing and dehydration, packaging. These technological stages comprise the technological line depicted in FIG. 2, which is: a diffusion valve 1 of a sugar factory, a feeder 2 for feeding raw sugar beet pulp to a vertical press 3, under which a belt conveyor 4 is installed for feeding pressed sugar beet pulp to a leveling device 5 with preliminary extraction for loading wet materials into the dryer [Conference materials], on which the press roll 6 and the leveling shaft 7 are installed. The dryer 8 is installed directly under the leveling device 5 with preliminary extraction for loading wet m into the dryer aterials [Conference proceedings]. The fuel system of the dryer 8 consists of a fan 9 and a boiler room pipe 10. As a pneumatic conveying system, a cyclone 11 with a slide valve 12 is installed to determine the receipt of dry sugar beet pulp for packing 13 or the hopper 14 for further processing. Behind the hopper 14, a hammer crusher 15 and a vibrating screen 16 with fractional hoppers 17,18,19 are installed. The slide valve 20 is designed to feed one of the fractions with a metering screw 21 into the reactor 22 with a crane 23. After the reactor 22, a vibrating screen 24, a steaming screw 25, a washing tank 26 with a crane 27 and a pump 28, a collector crane 29 are installed a reactor 30 on which a crane 31 is installed and a pump 32 for supplying contents to a container 33 on which cranes 34 and 35 are installed. A decanter 36 with a crane 37 and a metering screw 38 for feeding dietary fiber to the leveling device 5 with preliminary pressed to load in the dryer zhnyh materials [Proceedings of the conference], which directly from the dryer 8. After drying the dietary fiber is packed into the filling shop 13 and then stored.

The water heater 39 is designed to heat drinking water to a predetermined temperature, on the pipeline of which an emergency valve 40 and workers 41, 42 are installed.

The bypass line is a steam generator 43, an emergency valve 44, working valves 45, 46 and valve 47.

To provide compressed air, a compressor unit 48 and a valve 49 for supplying air are installed.

A tank 50 is provided for wastewater. A tank 51 for caustic potassium (KOH) and a tank 52 for hydrogen peroxide (H ₂ O ₂ ) are made with a common collector tap 53. Collector taps 54, 55 are installed to supply softened water from a water heater 56 and a six percent solution of acetic acid (6% solution of CH ₃ COOH) from tank 57.

The workflow of each stage (Fig. 1) of the production line (Fig. 2) is as follows.

Spin.

At this technological stage squeeze sugar beet pulp to a moisture content of 30-40%. Raw beet pulp from the diffusion valve of the sugar factory 1 (Fig. 2) is fed to feeder 2 and sent to the screw press 3. The pressed beet pulp is fed to the conveyor belt 4, through which it is sent to the next technological stage - preparation for drying.

Preparation for drying.

Preparation for drying, which directly determines the quality of drying, is performed on a leveling device 5 with preliminary extraction for loading wet materials into the dryer [Conference Materials], which works as follows. From the conveyor belt 4, pressed sugar beet pulp is fed to the leveling device 5 with preliminary extraction for loading wet materials into the dryer [Conference Materials]. If the moisture content of the mass is higher than 40%, then it is passed through the press shaft 6 to reduce moisture by 5-6%, after which it is fed to the leveling shaft 7, where the necessary layer is formed in width and height, and then sent to the next technological stage - drying .

Drying.

The cascade arrangement of perforated conveyors with partitions in the dryer 8 provides a sequential flow of the heat carrier pumped by the fan 9 from the base of the boiler room pipe 10. As the heat carrier agent, the exhaust gases of the boiler house operating on gaseous fuel are used. The gases are removed through a pipeline from the nearest boiler room with a gas temperature of 170-200 ° C. The passage of hot gases from bottom to top ensures the drying of sugar beet pulp to a moisture content of 10-12%. Cyclone 11 is used as pneumatic conveying. By the position of the slide gate 12, dry sugar beet pulp is sent to the filling shop 13 for storage or to the hopper 14 for further processing.

Fractionation.

Fractionation refers to the preparation of dry sugar beet pulp for further processing. From the hopper 14, dry sugar beet pulp is fed to a hammer mill 15, the crushed dry sugar beet pulp is sent to a vibrating screen 16, into which four fractions are divided:

- fraction less than 1 mm in size enters the hopper 17 for waste;

- a fraction larger than 3 mm is sent to the hopper 14 for re-grinding;

- a fraction of size 2-3 mm is sent to the hopper 18;

- a fraction of 1-2 mm in size is sent to the hopper 19.

5. Steaming and washing.

Steaming is as follows - sugar beet pulp swells, resulting in its partial softening and removal of contaminants (soil, sand, etc.), and also remove residual organic matter.

The fractions 1.0-2.0 and 2.0-3.0 are steamed with drinking water separately, since when using the combined fraction 1.0 and 3.0 mm, the fine fraction softens before the large fraction, which is not permissible. Therefore, the slide valve 20 sets the supply of one of the fractions to the screw dispenser 21. Using the screw dispenser 21, one of the fractions of sugar beet pulp is fed into the reactor 22 with pre-drawn drinking water for steaming. Drinking water heated to a temperature of 40-45 ° C in a water heater 38 is supplied to the reactor 22 by opening the valve 41. The filling of the reactor 22 with drinking water and sugar beet pulp is monitored by the tensile weights on which it is installed. When the reactor 22 is filled to the required level with drinking water, the drinking water supply is turned off by the valve 41 and the mixing device (35-40 rpm) is started in the reactor 22. During the introduction of the sugar beet pulp, the contents of the reactor 22 are constantly mixed (35-40 rpm ) The temperature regime is provided by heating the steam jacket of the reactor 22 with steam, for this purpose a crane 45 is installed on the bypass line of the steam generator 43, through which steam is supplied to the steam jacket of the reactor 22. During the steam is also stirred with a stirrer (35-40 rpm) and maintain the temperature 40 -45 ° C for:

- 30 minutes for a fraction of 1.0-2.0 mm;

- 40 minutes for a 2.0-3.0 mm fraction.

The supply of dry sugar beet pulp is carried out in two stages of 150 kg. This is necessary to better collect litter from the surface of the water during the steaming process. The collection of litter is carried out using a portable device for collecting litter, while stopping the mixing device. After collecting the litter, a stirrer (35-40 rpm) is started and the second part of the dry sugar beet pulp of the same fraction is introduced, followed by the collection of litter. Through the crane 23, the steamed sugar beet pulp is gravity fed to a vibrating screen 24, in which it is passed through a grid with 0.75 mm holes for dehydration of the product. The separated water from the screw press 3, the leveling device 5 with preliminary extraction for loading wet materials into the dryer [Conference materials] and the vibrating screen 24 are discharged by gravity into the waste water tank 29. The dehydrated sugar beet pulp comes off the net and enters a gravity flow, through which it is sent to a steaming screw 25, on which two engines are installed. One motor rotates the feeder, and the second - the shaft of the steaming screw. Steam is supplied only to the steaming screw 25. The crane 45 for supplying steam during steaming is opened completely. Steam removes product odors. Steamed pulp of sugar beet is sent to a tank 26 for washing with pre-drawn drinking water, for this, open the tap 42, the required amount is monitored by the ten weights on which the tank 26 is installed.

First flushing.

After the reactor 22 is completely released from the product, as well as the vibrating screen 24 and the steaming screw 25 are released, the contents of the vessel 26 are pumped to the reactor 22 for washing, while the mixing device operates at a constant speed (35-40 rpm), as well as when filling the tank 26. Pumping is as follows. Open the valve 27 and start the pump 28, while the collector valve 29 is installed towards the reactor 22. After complete pumping to the reactor 22, the product is washed for 15 minutes.

After the process of steaming, steaming and one washing, pulp of sugar beet pulp and waste - waste water are obtained.

After 15 minutes, the pulp is fed to the vibrating screen 28 for dehydration. The second and, if necessary, the third washing is done similarly to the first washing, except for steaming on the steaming screw 25. The dehydrated pulp from the vibrating screen 24 is directed by gravity to the steaming screw 25, through which it passes in transit. Steam in the steaming screw 25 during repeated washing is supplied if there is an odor. Dehydrated pulp is fed into a container 26, in which there is no water. After emptying the reactor 22 from the product, osmotic water is pumped from the water heater 56 into the tank 26, for this purpose, the collector taps 54 and 55 are installed in the appropriate position. The amount of osmotic water depends on the amount of raw material steamed, filling is monitored by tensile weights. After filling the tank 26 with osmotic water, the collector valve 55 is closed, after which the mixing device (35-40 rpm) is started.

Bleaching.

Bleaching is performed to remove dyes and hemicelluloses from the pulp. Do a deep sterilization and disinfect the pulp.

After filling with osmotic water in the tank 26, the pulp is pumped into the reactor 30 for bleaching. For this, the collector valve 29 is installed in the appropriate position, the valve 27 is opened, the pump 28 and the mixing device of the reactor 30 are started (35-40 rpm). At the same time, steam is supplied to the steam jacket of the reactor 30. To do this, slowly open the bypass valve 46, thereby warming the jacket of the reactor 30 and avoiding water hammer, and then open the valve 47 to supply steam to the reactor 30. The contents of the reactor 30 are heated to t 45 ° C and close valve 47, after that 6% potassium hydroxide (KOH) solution is introduced from the tank 51 to adjust the pH to 10.5-11.0, for this the collector valve 53 is set to the appropriate position, a 6% KOH solution flows by gravity into the reactor 30 After making 6% sol. OR KOH, the pH of the pulp is measured; if necessary, an additional adjustment is made. After adjusting the pH, hydrogen peroxide (H ₂ O ₂ ) is slowly introduced from the tank 52; for this, the collector crane 53 is installed in the corresponding position. The amount of H ₂ O ₂ also depends on the amount of the original sugar beet pulp used for steaming.

H ₂ O ₂ contribute in three stages:

1 part - 2/3 of the total at t 45 ° C;

2 part - 1/6 of the total amount at t 55 ° С;

3 part - 1/6 of the total at t 65 ° C.

After the last part of H ₂ O _{2 is} introduced, a 6% KOH solution is added until a pH of 9.0–9.5 is reached. Then it is heated to t 81 ° C, after which the valve 46 of the steam jacket of the reactor 30 is closed. After that, exposure is done at t 81-85 ° C for 15 minutes. After 15 minutes, the product is selected to determine the color and state of aggregation. The heating and aging process in the reactor 30 is carried out with the mixing device turned on (35-40 rpm). After holding the pulp for 15 minutes, it is pumped from the reactor 30 to the tank 34. To do this, open the valve 31, start the pump 32, while the speed of the mixer is increased (45-50 rpm). While pumping the pulp from the reactor 30 to the tank 33, water is pumped out from under the grid space, for this purpose the valve 34 is opened, and compressed air is also supplied to the tank 33 for better discharge, for this purpose the valve 49 of the compressor unit 48 is opened. The mixer turns in the tank 33 (45-55 rpm). After pumping the pulp from the reactor 30 to the vessel 33, the reactor 30 and the pipeline are flushed with osmotic water. The supply of osmotic water is as follows. From the water heater 56, the osmotic water is sent to the tank 26, the positions of the collector taps 54, 55 and 29 are set accordingly. In the tank 26, the valve 27 is opened, the pump 28 is started, the valve 31 is opened in the reactor 30, the pump 32 is started and the osmotic water is pumped into the tank 33, this is done for 1 minute. Then the osmotic water supply is stopped, the collector valve 54 is closed, and the remaining osmotic water in the reactor 30 and pipelines is also pumped into the vessel 33. During the water collection in the reactor 30, the stirrer speed is 75-80 rpm. After separating the water from the pulp in the tank 33 and draining it into the tank 50, rinse after bleaching. Pulp washing is performed to remove dyes that have passed from the pulp to water. The osmotic water from the water heater 56, heated to t 70-75 ° C, is fed into the tank 33, the filling is also monitored by tensile weights. To this end, collector taps 54 and 55 are suitably installed. The pulp is washed with hot osmotic water for 15 minutes, after which the water is drained into the container 50, for this purpose the valve 34 is opened, air is also supplied to the container 33 for better discharge, for this open the valve 49 of the compressor unit 48. The stirrer speed (45-55 rpm). When draining water, water is sampled for quality indicators, as well as for the presence of the product in the effluent. The second and optionally third washing is carried out similarly to the first washing.

After washing and dehydration.

Additional washing is carried out to finally remove odor, taste and neutralize hydrogen peroxide. Before additional washing, the decanter 36, feeder screw 38, leveling device 5 with preliminary extraction for loading wet materials are disinfected [Conference materials], the belts of the dryer 8 are wiped. Disinfection is performed with a 2% solution of acetic acid (CH ₃ COOH), which is fed from the tank 57, for this, a crane collector 54 and a crane 37 are installed along the disinfection line. After disinfection, rinse with osmotic water a decanter 36, a metering screw 38 and a leveling device 5 with a preliminary spin to load wet materials into the dryer [Conference Materials], for this purpose, the collector crane 54 and the crane 37 are in the corresponding position. Rinsing osmotic water and a 2% solution (CH ₃ COOH) are poured into a container 50.

After washing the pulp, one additional washing is done. To do this, pump the osmotic water from the water heater 56 (t 25-30 ° C) into the tank 33, depending on the amount of steamed sugar beet pulp, tracked by ten weights. For this, the collector taps 54 and 55 are installed in the appropriate position. After pumping the osmotic water into the container 33, the contents are kept for 10 minutes and then fed to the decanter 36. The dewatering is carried out on a centrifuge or other equipment for water separation, in this technological the lines use decanter 36. To do this, open the crane 35, stirrer speed when downloading (45-50 rpm), do not supply compressed air. The rotor speed of the decanter centrifuge 36 is set in the range of 1600-1800 rpm. The separated water after the decanter 36 is dumped into the tank 50. At the end of the download of the tank 33, a flush from the net is carried out using a “Karcher”.

After bleaching, washing and one additional washing, beet fibers are fed, which enter the next production stage.

Preparation for drying beet fiber is carried out on a leveling device 5 with preliminary extraction for loading wet materials into the dryer [Conference Materials] similar to preparing for drying raw beet pulp. From the decanter 36 with the feeder screw 38, the beet fiber is fed to the leveling device 5 with a preliminary spin for loading wet materials into the dryer [Conference Materials], for this purpose the valve 37 is opened. After that, the beet fiber is fed to the next technological stage - drying. The drying of beet fiber is carried out similarly to the drying of raw beet pulp.

Packing.

After drying, beet fiber is fed to the final technological stage - packaging 13, with subsequent storage.

The method of production of dietary fiber from beet pulp and the production line for its implementation can reduce the cost of heat carriers, improve the quality of drying and minimize the use of chemicals, which allows to obtain high-quality beet fiber, and also improves technical and economic efficiency.

Claims (2)

1. The method of production of dietary fiber from beet pulp involves pressing the pulp before drying to a moisture content of 30-40%, drying the beet pulp of sugar beet to a moisture content of 10-12% by exhaust gases from boiler houses operating on gaseous fuels, the temperature of which is 170-200 ° C, dried pulp they are crushed and fractionated into four fractions: 0-1 mm, 1-2 mm, 2-3 mm and more than 3 mm, a fraction of 1-2 and 2-3 is fed for further processing, the fractions are steamed separately, since the steaming time is 30 minutes for a fraction of 1.0-2.0 mm, and 40 minutes for a fraction of 2.0-3.0 mm, when steaming and one of the fractions it is fed in two stages of 150 kg, this is necessary for better collection of litter from the surface of the water in the process of steaming, after collecting the litter, the second part of the dry pulp is introduced, the steaming is carried out with the stirrer turned on, 35-40 rpm, then the product dehydrated, steamed to remove odor, do 1-2 washings, after which pulp of sugar beet pulp is obtained, which is sent to bleaching, for this purpose a 6% solution of caustic potassium is added to adjust the pH to 10.5-11, after which peroxide is slowly added hydrogen: 1 part b - 2/3 of the total amount at t 45 ° C, 2 part - 1/6 of the total amount at t 55 ° C, 3 part - 1/6 of the total amount at t 65 ° C, after applying hydrogen peroxide, add 6 % potassium hydroxide solution to adjust the pH to 9-9.5, the contents are heated to a temperature of 81-85 ° C and maintained for 15 minutes, after 15 minutes washings and one additional washing with osmotic water are performed, after which the product is obtained - beet fiber , which are sent to spin, then to drying and packaging. 2. A technological line for the production of dietary fiber from beet pulp containing a diffusion valve of a sugar factory, a feeder for supplying raw sugar beet pulp to a vertical press, a belt conveyor is installed under the vertical press for feeding pressed sugar beet pulp to a leveling device with preliminary extraction for loading into a wet material dryer, on which a press roll and leveling shaft are mounted, the dryer being installed directly below the leveling device with a preliminary by pressing it to load wet materials into the dryer, and the dryer’s fuel system consists of a fan and boiler room pipe, a cyclone with a slider valve is installed as pneumatic conveying system to determine the receipt of dry sugar beet pulp on the packaging or hopper for further processing, and a hammer crusher is installed behind the hopper and vibrating screen with fractional hoppers, the slide valve is designed to feed one of the fractions with a screw metering device to the reactor with a crane, after the reactor using a technological line a vibrating screen, a steaming screw, a washing tank with a crane and a pump, a collector crane, a reactor on which the crane is installed, and a pump for feeding the contents to the tank are installed, a decanter with a crane and a metering screw for feeding dietary fiber to the leveling is installed behind the tank a device with preliminary extraction for loading wet materials into the dryer, after which filling equipment is installed.

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