AGRONOMY / HORTICULTURE 338 SEED CONDITIONING LAB

Transcription

1 AGENDA: AGRONOMY / HORTICULTURE 338 SEED CONDITIONING LAB (Corn) ISU August 24 th, 207 Tour of Seed Conditioning Lab Laboratory Exercise (equipment operation & sample analysis) Discussion (classroom) OBJECTIVES: Utilize small scale equipment to review the process flow and typical sample analysis procedures commonly used by seed corn conditioning facilities. Laboratory equipment will be used to predict sizing tower results and estimate bag weights. Sized fraction and discard percentages will be determined and appropriate quality control tests will be conducted on various fractions, including test weight, seed count, BCFM percentage, and visual defect levels. EQUIPMENT: Stopwatches, plastic containers, and calculators. Safety glasses, earplugs for hearing protection, and disposable dust masks are also available if desired. An electronic copy of the laboratory data sheet (in Excel) will be provided to assist with related calculations. LAB PROCEDURE: If necessary, divide into small groups for sampling various machines as per the task descriptions listed below. Groups will rotate between stations (-5) to obtain required data. Station 0: Seed Corn Shelling & Equipment Review [North of building, then in tower - full group] a) Brief demonstration of an AEC roller concave sheller and a Carter-Day laboratory aspirator for shelling and pre-cleaning of ear corn. Primary functions are ear sorting, alignment, shelling, and cob separation, followed by shelled corn aspiration. Both devices are laboratory machines intended for small batches. Commercial seed facilities typically use axial flow shellers and larger pre-cleaning devices capable of much higher capacities. b) Crippen H-434 Air-Screen Cleaner used for removal of lightweight and oversize foreign material, undersize and broken corn, and low density corn kernels. c) Satake ScanMaster II IE-200 Color Sorter for removal of dark kernels as well as some broken kernels with bright exposed starch. d) Carter-Day and Oliver sizing equipment: Review existing sizer stack and operation of a new Oliver 22 sizer with variable speed drive and an automated roller cleaning device. This machine is currently stored upstairs but will ultimately be moved to upgrade the first cylinder location in our sizing stack. It is equipped with a transparent door & cylinder cleaning system. e) Oliver GVX-020 Voyager gravity separator for removal of low density and some small or broken seed. This machine is equipped with PLC based controls to permit rapid recall of settings when running multiple seed sizes in sequence during larger seed corn lots. Station : Cleaner Screen and Sizing Cylinder Verification [Laboratory equipment room] Seed corn is frequently sized to improve density separation and planting uniformity. Laboratory tests are typically conducted to estimate yield and quality for each seed lot prior to full scale operations. Accurate simulation of a production sizing facility requires careful control of both sample size and run time to match the desired sizing efficiency. Improper batch intervals incorrectly predict the amount of "thrus" expected from a given sizing cylinder. We will use a laboratory cleaner and rotary batch sizer to predict cleaner discard, sized fraction percentages, and seed count estimates for the larger equipment in the sizing tower. The cleaner operation has been performed in advance to save time during the lab. Batch sizing operations are frequently used to predict results for larger continuous flow sizing stacks. Preparing four size fractions requires a minimum of three sequential operations. Each group will use a different sizer run time interval to demonstrate the effect on the predicted results. a) Select an after cleaner seed corn sample for analysis using the batch sizer. Page of 4

2 b) Divide the clean seed into two roughly equal fractions using the riffle divider. c) Run each of the fractions through the batch sizer using a 9/64 round hole cylinder and the designated run time interval for your group. Combine the two over (large) and through (small) seed fractions for subsequent operations. d) Run the combined large seed fractions through the batch sizer using a 3.5/64 slotted hole cylinder. Record the weights for the over (large round) and through (large flat) seed fractions. e) Repeat step d using the combined small seed fractions and a 3/64 slotted hole cylinder. Record the weights for the over (small round) and through (small flat) seed fractions. f) Utilize an optical imaging counter (OptiCount) to estimate the seed count (seed/lb) ratio for each of the four sizes. For each sample, place approximately /2 cup of seed in a tared container on the attached scale and press the scale button. When prompted, spread the sample evenly across the light table and press next. The table will vibrate to help distribute the sample prior to each counting operation. The sample weight, seed quantity, and seed count are displaying upon completion and should be recorded on the data sheet. Note: Larger and/or additional samples would typically be used to provide a better seed count estimate. g) Place the resulting sized seed samples in Zip-Loc bags with the provided labels for temporary storage. Return the various discard fractions to the original sample container. h) Sample data for additional sizer run time intervals should be obtained from other groups prior to completion of the lab. Sizing cylinder capacities are typically rated for 95% efficient removal of undersize (thru) product, but some companies use slightly different target values for sizing efficiency. A similar method is typically used to determine an appropriate runtime for a given batch separation process. Once determined, a "standard" time is typically used for a given product, cylinder selection, and initial sample size. Station 2: Color Sorter (Satake ScanMaster II-IE) [tower, upper floor] Many seed corn facilities have added color sorters for selective removal of discolored seed. For this demonstration, the color sorter will be running un-sized product immediately following the air-screen cleaner. Each group will run a different dark trip level to demonstrate the effect on removal of discolored seeds. Data will be shared between groups to save time. a) The color sorter has been preset for removal of dark discolored seed and light broken kernels. The machine can be started & stopped using the digital touchscreen controls. b) Adjust the dark trip setting to match the designated level for your group. Record the trip level used on your data sheet. Each group will run a different trip level and share data when finished. c) Collect timed samples of the accept (20 seconds) and reject (60+ seconds) fractions. d) Determine the accept and reject timed sample weights using the nearby digital scale. e) Manually sort visually defective from good seeds for one pint of the accept and reject samples. Weigh the four subsamples and record the results in the visual defects field on your data sheet. f) Place the manually graded sub-samples in Zip-Loc bags with the provided labels for temporary storage. The remainder of the collected samples can be stored in a nearby plastic barrel. Station 3: Sizer Stack (Carter-Day VT units) [tower, upper floor] The sized fraction percentage and sizing efficiency is typically monitored during operation of a commercial seed sizing stack. Flow rates vary depending on input feed rate and the relative size distribution within the seed lot and can be estimated using timed sample weights. Sizing efficiency is normally determined using hand screens to verify size distribution of each outlet fraction. a) Timed samples have been in captured in advance due to the difficulty of diverting product flow using our existing spout configuration. Each group will analyze one size fraction and share data to save time. Record the sample weight and time interval for the specified seed size. Data for the undersized discard will also be provided. b) Collect a one pint (jar) subsample from all four sized corn samples. Page 2 of 4

3 c) Sieve each sample over a set of round hole hand screens (26R, 9R, and 5R) to determine the width size distribution. The whole seed (between 26R and 5R) should then be sieved using the appropriate slotted screen (3.5S for LR and LF, 3S for SR and SF). d) Record the weights for each screen fraction on the data sheet. The spreadsheet will be used to evaluate the sizing efficiency for each machine in the sizing stack. Station 4: Gravity Separator (Oliver GVX-020 Voyager) [tower, lower floor] A gravity separator is typically used to remove low density seed from each seed corn size. For this demonstration, we will simply run one of the sizes and collect timed samples to estimate outlet fraction percentages and relative test weights. [one fraction per each group] a) The gravity separator will need a few minutes to stabilize after operation begins. b) Use a stopwatch and plastic containers to obtain a timed sample from each of the four outlets: a. Extra Heavy: Vibratory conveyor for cutoff gates on upper side (30 sec) b. Heavy: Upper end of deck near leg (30 sec) c. Medium: Center outlet (60 seconds) d. Light: Lower end of deck (60+ seconds) c) Weigh each sample using the nearby digital platform scale. Record the sample time and weight for subsequent flow rate and discard percentage calculations. d) Collect approximately quart from each of the four samples and determine the test weight and seed count for each gravity discharge fraction. e) Return the product samples to the respective container and/or handling system. Station 5: Automatic Batch Seed Treater (Gustafson BMC) [Laboratory equipment room] We will check the current application rate for a small version of a commercial automatic batch seed treater with a rate and time chemical metering system. The procedure listed will be used to verify the seed and chemical delivery rates using the existing equipment settings. The tests will be conducted using tap water for safety reasons but disposable gloves should be used when operating the treater since this machine is also used for research treating applications. a) Seed corn has been provided for the treater demonstration. The seed count values from Station #3 should be used for calculation purposes. Record the values in the data sheet. b) Seed corn has been placed in the feed hopper for use during the demonstration. c) Fill the left hand graduated cylinder by opening the cylinder inlet valve and the premix tank outlet valve. Close the premix tank outlet valve when a known full level has been reached. d) Verify the position of the pump outlet selector valve and switch the valve position if required. Product should normally be re-circulated to the premix tank during initial calibration. Chemical is then diverted to the atomizing disc for subsequent treatment operations. e) Enable the treater and run a few batches. Stop the treater prior to running out of chemical in the graduated cylinder. Record the batch quantity, total seed weight, and total chemical usage. f) The spreadsheet will be used to estimate the chemical delivery rate in fluid ounces per hundredweight and milligrams of active ingredient per seed. g) A commercial facility would typically adjust the pump speed and/or operating time to obtain the desired application rate. This recursive step has been skipped to save time but would obviously be important if we were actually treating seed for commercial or research applications. If time permits, a laboratory batch treater (Hege model ) will be demonstrated briefly. Page 3 of 4

4 DISCUSSION QUESTIONS: ) Seed companies typically perform laboratory sizing operations prior to production cleaning and sizing operations. The results may include size distribution, cylinder size selection, sized fraction percentages, and seed count values for each size. Laboratory warm and cold germination tests are also frequently performed for each size. Explain why this information might be important for both management of the sizing tower operation and seed marketing purposes. 2) The color sorter was used to remove discolored seed immediately after the cleaner. What types of contaminants were removed? Explain the relative merits of locating the color sorter immediately after the cleaner vs after the gravity for a seed corn conditioning facility. 3) Sizing: Compare the prediction results from Station # ( incoming samples) with the actual samples from the sizing tower. Were the predicted sized fraction percentages and seed count values reasonably close to the final results? Which batch sizing time interval best reflected the tower values? 4) A gravity separator uses a reciprocating fluidized bed for density separation and is typically used as a finishing machine after the majority of the contaminants have been removed. The data collected during the lab procedure includes test weight and seed count information for four fractions. Compare and explain the results for the four discharge fractions. How might a company decide where to place the divider gates for the discard and middling fractions? 5) Calibration methods were demonstrated using a small automatic batch seed treater. The calibration results were calculated in two different units, including fluid ounces per hundredweight and milligrams per seed. Why? How might a seed corn company utilize a dual premix tank system to manage treatment rate requirements for different seed sizes? LAB REPORT: ) Summarize the responses for the above discussion questions, including a brief explanation of the reasons or methods used to arrive at each conclusion. 2) Attach a printed copy of the data spreadsheet, including the data collected during the lab and the calculated results. Page 4 of 4

5 Aspirator Catwalk Seed Receiving Area Station 0A Station 0B Station 0E Stairs Lab Sheller Crippen H-434 Air- Screen Cleaner Catwalk Oliver Voyager GVX-020 Gravity Crane Bay Westrup Belt Separator Mitchell Leg Forsberg 0M2-S Rotary Spiral Forsberg 40V Gravity Measurement Heid Gravity Catwalk and Stairs Station 4 LMC Gravity Leg 4 El-Con Leg Sortex Color Sorter Pilot Plant Lower Level Seed Conditioning Lab (Lower Level) Dust Filter Bagging Electrical Panel Air-Oven Dryer Cabinet Cabinet Cabinet Tool Box Screen Shaker Brushing Westrup Air-Screen Cleaner Equipment Table Carter-Day Batch Sizer Workbench Soybean Samples Forsberg Destoner Station Equipment Table OptiCount Imaging Counter Cabinet Hand Screens for Sizer Efficiency Analysis Station 3 Divider IMD Seed Counter Station 5 Small Equipment Lab Hege Lab Treater Shop Equipment N Harada Belt Separator Ball Counter BMC Batch Treater Dust Filter Forsberg TKV-25 Gravity Seed Conditioning Lab Upper Level Stairs Leg Dust Filter Carter-Day VT Sizers Station 0D Carter-Day VT Sizers Crane Bay Mitchell Leg Satake DE Color Sorter Cabinet Profile Spiral Leg 4 Station 0C Station 2 Satake Color Sorter Table Pilot Plant Upper Level Carter-Day #3 Uniiflow Gustafson GLCPS Treater Oliver 22 Sizer Stairs Storage Shelving Mezzanine Level Carter-Day Fractionating Aspirator Station Sequence: 0) Cleaner, Batch Sizer, Counter (L) ) Air-Screen Cleaner (L) 2) Satake color sorter (U) 3) Seed Sizing Stack (U) 4) Oliver gravity (L) 5) BMC Treater (L) N

6 Pending Lab Seed Corn Process Shelling & Aspiration Air-Screen Cleaner Color Sorter Sizing Gravity Table Seed Treater (Packaging) Sample Analysis & Cylinder Verification Rotary Batch Sizer Air-Screen Cleaner Imaging Counter Clean seed prior to sizing Create 4 seed sizes Evaluate size %, seed count Station 2: Satake Color Sorter Outlet Spouts Accept Sampling Valves Satake ScanMaster IE Review Operation at four dark trip levels Each group runs one setting Collect timed sample weights Evaluate sample quality Calculate: % Discard by Fraction and Defect Removal Efficiency

7 Input From Cleaner Station 3: Sizing Stack Over 9R Thru Over 5R Thru Thru 2S Over.5S Thru Over LF LR SF SR Discard Timed samples have been collected in advance to save time Evaluate each sample to verify sizing efficiency for each stage Estimate flow rate, sized fraction percentage, and efficiency Sampling Locations Station 4: Oliver Gravity Separator X H M L Review concepts and demonstrate operation Collect 3 timed sample weights Light, Medium, and Heavy ( per group) Record sample weight and related run time Lab sample analysis Model GVX-020 Voyager Gravity Station 5: BMC Batch Seed Treater Review basic components, product flow, and operation Verify chemical and seed metering rates using closed circuit calibration tubes and timed sample weights Given: Initial batch weight, pump speed and cycle time Calculate: Estimated seed capacity, chemical application rate, and anticipated hourly chemical usage Gustafson / BCS model BMC laboratory batch treater 2

8 Group Number: ALL Agronomy Seed Corn Conditioning Lab Data Sheet (Blank - for Data Entry) August 24, 207 Station #: Batch Sizer - Data Group #, Run Time (sec): 20 Group #2, Run Time (sec): 40 Group #3, Run Time (sec): 60 Group #4, Run Time (sec): 20 Sample Weight (g) Fraction (qty/lb) Sample Weight (g) Fraction (qty/lb) Sample Weight (g) Fraction (qty/lb) Sample Weight (g) Fraction (qty/lb) Large Round (LR) 0.0% 0.0% 0.0% 0.0% Large Flat (LF) 0.0% 0.0% 0.0% 0.0% Small Round (SR) 0.0% 0.0% 0.0% 0.0% Small Flat (SF) 0.0% 0.0% 0.0% 0.0% Total Batch Size/Avg S.C % % % % 0.0 Station #: Batch Sizer - Results Input (g) Thru Sizing Eff. Input (g) Thru Sizing Eff. Input (g) Thru Sizing Eff. Input (g) Thru Sizing Eff. Position (9R) 0.00 #DIV/0! #DIV/0! 0.00 #DIV/0! #DIV/0! 0.00 #DIV/0! #DIV/0! 0.00 #DIV/0! 00.0% Position 2 (3.5S) 0.00 #DIV/0! 0.00 #DIV/0! 0.00 #DIV/0! 0.00 #DIV/0! Position 3 (3S) 0.00 #DIV/0! 0.00 #DIV/0! 0.00 #DIV/0! 0.00 #DIV/0! Position Input Rate (lb/hr) Position 2 Input Rate (lb/hr) Position 3 Input Rate (lb/hr) Sized Fraction Variation Variation Equivalent Input Rate vs Location Sizing Efficiency (Pos. #) vs Time 00% 00% Fraction 90% 80% 70% 60% 50% 40% 30% 20% 0% SF SR LF LR (seeds/lb) 0 0 T=20 T=40 T=60 T=20 Equiv. Input Rate (lb/hour) T=20 T=40 T=60 T=20 Sizing Efficiency 90% 80% 70% 60% 50% 40% 30% 20% 0% 0% LR LF SR SF 0 (L/S) 2 (LR/LF) 3 (SR/SF) 0% Time Interval Time Interval Cylinder Position Time Interval Crippen Air Screen Cleaner (207 Workshop Data) Sample Weight Sample UOM Sample Time (sec) Flow Rate (lb/hr) Fraction Total Fraction Pint Cup Weight (g) (lb/bu) BCFM Seeds per pint (seeds/lb) Visual Defect Upper Air 3.60 lb % 0.% Scalpings (oversize) 3.65 lb % 0.% Siftings (undersize) 7.35 lb % 0.% Lower Air lb %.8% Clean Seed Output lb % 97.9% Total Cleaner Input % 00.0% Page of 2

9 Station #2: Color Sorter Group - Trip Rate= Sample Weight Sample UOM Sample Time (sec) Flow Rate (lb/hr) Fraction Total Fraction Pint Cup Weight (g) (lb/bu) BCFM Seeds per pint Seeds per lb Visual Defect Accepts (Good Seed) lb % 0.0% Rejects (Discard) lb % 0.0% Total Color Sorter Input % 0.0%.00 Sorting Efficiency: Group 2 - Trip Rate= Yield: #DIV/0! Accepts (Good Seed) lb % 0.0% Rejects (Discard) lb % 0.0% Total Color Sorter Input % 0.0% Sorting Efficiency: Group 3 - Trip Rate= Yield: #DIV/0! Accepts (Good Seed) lb % 0.0% Rejects (Discard) lb % 0.0% Total Color Sorter Input % 0.0%.00 Sorting Efficiency: Group 4 - Trip Rate= Yield: #DIV/0! Accepts (Good Seed) lb % 0.0% Rejects (Discard) lb % 0.0% Total Color Sorter Input % 0.0% Sorting Efficiency: Note: Yield calculations are based on the incoming flow to the color sorter, assuming all non-visually defective material is good product. Yield: #DIV/0! Station #3: Sizer Stack (output rates, quality) Sample Weight Sample UOM Sample Time (sec) Flow Rate (lb/hr) Fraction Total Fraction Pint Cup Weight (g) (lb/bu) BCFM Seeds per Pint (seeds/lb) Visual Defect Large Round (Group ) lb % 0.0% 0.0 #DIV/0! Large Flat (Group 2) lb % 0.0% 0.0 #DIV/0! Small Round (Group 3) lb % 0.0% 0.0 #DIV/0! Small Flat (Group 4) lb % 0.0% 0.0 #DIV/0! Undersize (discard - provided) lb % 0.0% 0.0 #DIV/0! Total Seed Output % 0.0% 0 #DIV/0! Sample Fractions (g) Operation Efficiency / Yield Station #3: Sizer Stack Over 26R Over 9R Over 5R Thru 5R Over 3.5S Thru 3S Cylinder Cyl. Feed Percent Thrus Scalping Eff. Sifting Eff. (Efficiency, part ) (g) (g) (g) (g) (g) Over 3S (g) (g) Position Rate (lb/hr) Large Round (Group ) # (9R) - #DIV/0! #DIV/0! #DIV/0! Large Flat (Group 2) #2 (3.5S) - #DIV/0! #DIV/0! #DIV/0! Small Round (Group 3) #3 (5R) - #DIV/0! #DIV/0! #DIV/0! Small Flat (Group 4) #4 (3S) - #DIV/0! #DIV/0! #DIV/0! Undersize (discard - provided) Total Seed Output Station #4: Oliver Gravity Separator (large round) Sample Weight Sample UOM Sample Time (sec) Flow Rate (lb/hr) Fraction Total Fraction Pint Cup Weight (g) (lb/bu) Seeds per pint Seeds per lb Extra Heavy (Good, Group ) lb 0.0% 0.0% 0.0 #DIV/0! Heavy (Good, Group 2) lb 0.0% 0.0% 0.0 #DIV/0! Medium (Recycle, Group 3) g 0.0% 0.0% 0.0 #DIV/0! Light (Discard, Group 4) lb 0.0% 0.0% 0.0 #DIV/0! Total Gravity Input % 0.0% #DIV/0! Visual Defect Station #5: Seed Treater Chemical Mixture (Slurry) Properties: Specific Gravity:.0 (g/cm 3 ) Active Ingredient (% AI): 00.0% (seeds/lb) Output Sample Weight (lbs) Batch Qty (per test) Batch Cycle Time (sec) Slurry Volume (ml) Seed per Batch (lbs) Seed Qty (seeds/batch) Seed Flow Rate (lb/hr) Slurry per Batch (ml) Applic. Rate (fl oz/cwt) Applic. Rate (mg AI/seed) Slurry Usage (gph) Rate Verification (group ) #DIV/0! #VALUE! #VALUE! #VALUE! Rate Verification (group 2) #DIV/0! #VALUE! #VALUE! #VALUE! Rate Verification (group 3) #DIV/0! #VALUE! #VALUE! #VALUE! Rate Verification (group 4) #DIV/0! #VALUE! #VALUE! #VALUE! Average Values for all groups #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #VALUE! #DIV/0! #DIV/0! #DIV/0! #VALUE! #VALUE! Note: Compare estimated application rates for "weight based" (fl oz/cwt) and "quantity based" (mg AI/seed) label rating methods Page 2 of 2