Make it work. The most modern feed manufacturing plant in the world. A complete turnkey solution. Design Production Maintenance

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1 Make it work. The most modern feed manufacturing plant in the world A complete turnkey solution Design Production Maintenance

2 The most modern feed manufacturing plant in the world The Koskenkorva feed manufacturing plant is the most modern feed factory in the world. The design of the plant is based on hygiene and energy efficiency as well as usability. The production capacity is tons of finished product per year, and the capacity of the grain storage is 7000 tons. The plant can be adjusted for producing pig, cattle or chicken feed. Production started at the plant in autumn 2013, approximately one year after starting the earthworks. JPT delivered the feed manufacturing plant as a complete turnkey solution, including the following elements: Process design Layout design Manufacture of the steel structures and complete installation, including the stressed skin structure Equipment engineering, manufacture and delivery, including the required installations Electrical wiring and automation system design and installation Testing and commissioning. 2

3 Grains Powdery raw materials Liquids Unloading stations The manufacturing plant is equipped with three weatherproof unloading stations which can be accessed by trucks. The capacity of the stations is 60 to 80 tons per hour. Unloading station 1 for powdery raw materials includes: - Unloading pit: 60 m³ - Unloading conveyor and elevator - Moving scales (3,000 kg) for transfer into silos. The scales are certified for sales purposes. Unloading station 2 for grains includes: - Unloading pit: 80 m³ - Unloading conveyor and elevator - The preliminary cleaning line with a wind sieve for light refuse, a sieve for rocks and clods, magnet - Built-in unloading scales. The scales are certified for sales purposes - Conveyor system for the storage silos. Unloading station 3 for liquids includes: - Unloading pump 60 m³/h for oils - Possibility to reload the vehicle from the storage tanks - Unloading into four liquid tanks, and loading from four tanks - Enzyme unloading from containers into four tanks. 3

4 Grain storage Silos for powdery raw materials Oil tanks Raw material storages a) Grain storage - 6 pcs of 1,700 m³ grain silos and 2 pcs of 700 m³ soy silos - The silos are flat-bottomed and all are equipped with conveyors - Conveyor system from the plant to the silo block b) Storage silos for powdery raw materials - 46 pcs of 100 m³ and 50 m³ silos for powdery raw materials. - The silos are angular and have smooth walls - The bottoms of the silos are equipped with oscillating side gates - The silos are filled by the moving scales through automatic valves - 16 pcs of 1.5 m³ premix silos - Premix silos are filled from the big bag with a hoist - Material: stainless steel c) Liquid storage - Oil tanks: 4 pcs, 60 m³ - Material: stainless steel - Enzyme tanks: 4 pcs, 10 m³ - Material: stainless steel 4

5 The moving scales are operated with servo motors The MultiCracker is energy-efficient Counter flow separator Grinding by hammer mill is only used when necessary Side gates are extremely accurate Grinding line There are two grinding methods available in the grinding line: grinding can either be run in series through two different mills, or separately in both mills. Grinding is a continuous process, which means that grain is ground from the storage silos into the plant batching hoppers. 1. MultiCracker line - Line capacity: 40 tons/h - MultiCracker MC370 twin, energy consumption: 4 x 18.5 kw The MultiCracker achieves energy-efficient grinding at 1.5 kw per tonne, while the hammer mill requires 7 to 8 kw per tonne. 2. Vertical hammer mill grinding - Capacity: 40 tons/h - Energy consumption: 2 x 110 kw Grinding by hammer mill is only used when necessary. Dosage The plant is equipped with two moving scales for 3,000 kg for measuring the main raw material into batches, one 50 kg moving scales for measuring the premix, and a liquid dosage system for measuring the oils and enzymes. The premixes and liquids can be measured into the main mixing lines (2 pcs) or the pelleting lines (2 pcs). Powdery raw materials are weighed by with the moving scales. All batches are measured with extremely accurate oscillating side gates. - The total power consumption of the oscillating side gates is approximately 4,4 kw - The moving scales are operated with servo motors. The brake energy from the motors is reclaimed into the electrical network. 5

6 Pelletizing Double deck counter current cooler Mixing and hygienisation Moving finished product into silos Mixing and pelletizing The plant can be equipped with 1 to 4 pelletizing lines, depending on the desired capacity. The capacity of one pellet production line is 20 tons/h. Each pellet mill has a specific mix ratio. The hygienisation of the product takes place during mixing. Pellet production line 1. Hopper that receives the batch-type dosed mix 2. The main mixer (a 3-tonne vertical model) for improved hygiene. The main mixer is used for mixing the liquids and steam into the product 3. Lower tank of the mixer (JLTC). In the JLTC, the long-term heat treatment of the product takes place. There is a full bottom screw feeding system from the JLTC to the pellet mill 4. Before the pellet mill, the homogenisation mixer (JPTM20) can be used to add steam or water 5. Pellet mill according to choice (model and make) 6. Double deck counter current cooler 7. Flat screen 8. Pellet coating mixer (3-tonne vertical assembly), with the possibility of negative pressure 9. Moving scales for moving finished product into silos for transfer. Bulk loading - Oscillating side gates on the silos for finished product. - In the bulk loading, the moving scales (4 tons) are equipped with loading bellows and dust removal equipment, and the loading capacity is tons/h. 6

7 Reliable Energy-efficient Hygienic Automation The plant is equipped with a Siemens S7 automation system. The operation of the plant is fully automated. - Frequency converter drives - The plant process requires only two operators per shift. The total energy consumption of the feed manufacturing plant is approximately 600 1,000 kw/h, when running 40 tons per hour on two pellet production lines. In addition, the exess heat from the coolers is recycled back to be used in the plant, both for the preheating air as well as heating of the property. The level of hygiene is significantly higher than in feed factories built using traditional techniques. For instance, the moving scales ensure that there is virtually no process residue when compared to traditional feed plants, in which the amount of residue accumulating in chain conveyors and dosing screws can be significant. Furthermore, the system reduces future maintenance costs, as there are fewer pieces of equipment to maintain and these are not equipped with wearing pipelines, all of which contributes to the reliability of the plant. Less equipment and no unnecessary idling in the process, combined with optimal grinding, ensure that the energy consumption is considerably lower than in traditional feed factories. In fact, the level of automation is so high that only two operators per shift are needed to run the plant. 7

8 Benefits in comparison to plants built with traditional technology Energy-efficient - significantly lower power consumption Hygienic - less process residue Reliable - fewer individual pieces of equipment increases operational reliability Lower production costs - high level of automation combined with energy efficiency Suitable for the production of a wide variety of products - the process can be adapted to many kinds of product High up-time and low maintenance costs - fewer pieces of equipment means less maintenance - less maintenance means more running time High level of automation - reduced need for operators Contact JPT-Industria Oy Kestopuuntie 5 FI Ilmajoki