25-30 T/H Extruded Feed Raw Material Production In Russia

As the application of extruded feed becomes more and more widespread, the processing of extruded feed raw materials has also attracted more attention from feed processors and investors.

This Russia extruded feed raw material production project was built in Russia and is specialized in processing extruded feed raw materials. The products of this raw grain puffing project will be sold to various aquatic feed factories, floating fish feed factories, pet feed factories, pig feed factories and other livestock and poultry feed factories.

The client's company in this Russia extruded feed raw material production project was originally a company specializing in supplying feed ingredients. But these raw materials are just some conventional corn, soybean meal, sunflower seeds and other grain raw materials, which are not puffed.

Due to in-depth research on the market of extruded feed and extruded feed raw materials, it was discovered that many aquatic products and pet feed factories have been built in Russia in recent years, and the Russian government is vigorously supporting the aquaculture industry.

Therefore, the Russian customer finally decided to invest a total investment of US$940,000 to establish this project. The product plan is extruded single feed raw material powder, with a total production capacity of 70,000 t/a.

• Number of employees: The total number of employees in this project is 20, and they all dine in the factory.
• Working system: 8-hour working system per shift, 1 shift per day, 300 working days per year.

The total land area of the project is 6522m2, and the total construction area is 6915.64m2. The main construction content is 1 office building and 2 standardized factory buildings. The details of the main construction contents of the project are shown in the table below:

The main products of this Russia 25-30t/h extruded feed raw material production project are shown in the table below.

The main raw and auxiliary materials of the 25-30t/h extruded feed raw material production in Russia project are shown in the table below.

The main equipment of this project is shown in the table below.

The total water consumption of the 25-30t/h extruded feed raw material production in Russia project is 1800m3/a, and the water source is city tap water, which can meet the normal water supply needs of the project's life and fire protection.

Adopting a rainwater and sewage diversion system, the wastewater in the factory can be pre-treated by septic tanks to meet the water quality requirements of the sewage treatment plant, and then discharged into the park's municipal sewage pipe network and enter the sewage treatment plant for advanced treatment.

The electricity used in this 25-30t/h extruded feed raw material production in Russia project is uniformly supplied by the local power grid and is mainly used for lighting, equipment operation, daily life, etc. A backup generator is set up.

The steam required for the expansion process of the puffing raw grain production process is provided by the local power plant. The steam pipeline has been connected in the area. The steam can be passed into the production workshop during the project production process.

The amount of steam required during the project production process is approximately 1,500 tons/year. Power plant steam can meet production requirements.

• The gate of the project factory area is located on the north side of the factory area.
• From north to south, the factory area is composed of office buildings, 1# standardized factory building, and 2# standardized factory building.
• The raw material silo is located on the east and south side of the 2# standardized factory.
• The overall layout of this 25-30t/h extruded feed raw material production in Russia project relies on the characteristics of the existing buildings, is simple and compact, and has high land utilization.
• The general solid waste temporary storage room and the hazardous waste temporary storage room are arranged in the northwest of workshop #1.
• The layout of buildings and structures meets the smooth process flow, facilitates the smooth flow of logistics and people, and at the same time ensures hygiene and fire safety requirements.

According to the general layout principle, the overall layout of the 25-30t/h extruded feed raw material production in Russia project is simple and compact, and the land utilization rate is high. The layout of buildings and structures meets the smooth process flow, facilitates the smooth flow of logistics and people, and at the same time ensures hygiene and fire safety requirements.

The graphic design of this project is based on the requirements of the process and equipment operation, and the production equipment is arranged according to the needs of the process, operation sequence and safety production, which satisfies the reasonable and smooth process flow and enables the centralized layout of the production equipment. In summary, the layout of the factory area of this project is reasonable.

01

Screening

The cleaning equipment mainly focuses on screening. According to the differences in particle size, width, and thickness of the material particles, part of the material passes through the screen surface and becomes the under-sieve material, while the other part remains on the screen surface and becomes the over-sieve material.

This separates raw materials from impurities and achieves the purpose of removing impurities. The screening equipment removes large and long debris such as grass, wheat straw, hemp rope, paper, soil clods, leaves, sticks and other debris in the raw materials. The screening process is completely sealed, and qualified raw materials after screening are lifted into the silo for temporary storage.

02

Crushing process

The screened materials enter the crusher from the silo through the feeder and are crushed by the impact of the hammer (the raw material is crushed using a hammer crusher, which uses the impact of the high-speed rotating hammer to crush the material).

Materials smaller than the screen hole are quickly discharged from the crusher under the negative pressure of the dust collector to achieve the purpose of crushing. The particle size of the crushed material is about 1-3mm.

03

Heating and puffing

The puffing method of the 25-30t/h extruded feed raw material production in Russia project is wet puffing. Puffing is a gelatinization process under the combined effects of moisture, heat, mechanical shear, friction, kneading and pressure difference.

The project's expansion heat source is the steam provided by the power plant. When the powder is mixed with steam, the powder particles begin to absorb water and expand. When passing through the expansion chamber, the rapidly rising temperature and the rubbing of the spiral blades cause the net bag-shaped starch particles to accelerate water absorption and crystal structure.

It begins to disintegrate, the hydrogen bonds are broken, and the expanded starch granules begin to rupture and become a viscous melt. Due to the instantaneous pressure drop at the outlet of the extruder, the instantaneous loss of steam (moisture) causes a large number of expanded starch granules to disintegrate starch gelatinization.

High temperature, high pressure and mechanical shearing make extrusion puffing more complete starch gelatinization than other processing methods. Generally, the degree of gelatinization can reach 90% to 100%.

Compared with the conventional cooking process, it can rupture plant cell walls. The starch chains are shorter, thus improving digestibility more efficiently. The expanded material becomes crystalline particles.

04

Cooling of puffed materials

During the puffing process, due to the introduction of high-temperature and high-humidity steam and the extrusion of the material, a large amount of heat is generated, which makes the temperature and humidity of the puffed particles higher.

Under this condition, temporary storage will occur. To prevent adhesion and mildew, the moisture must be reduced to less than 14% and the temperature must be reduced to less than 8°C higher than room temperature.

The cooling of the 25-30t/h extruded feed raw material production in Russia project uses air cooling, and the air sent by the fan is used to cool the expanded material.

05

Crushing

The cooled materials enter the crusher through the impeller feeder. After crushing, the further crushed pellets are transported by the screw conveyor and lifted to the temporary storage bin by the bucket elevator. The purpose of crushing is to increase the particle size of the material.

The specific surface area improves its utilization in subsequent feed production, increases the contact area of digestive enzymes with raw materials, and reduces the energy consumption of chewing during animal feeding.

06

Packaging

Finally, according to market demand, the crushed powder is packaged in plastic bags in the packaging room into finished products for external sale.

The technology used in the 25-30t/h extruded feed raw material production in Russia project is common in the industry, and the product quality can meet the requirements and is advanced.

At the same time, during the production process of the project, the feeding and discharging processes are automatically sealed by the machine, and the project only involves simple crushing and puffing processing of raw materials, and does not involve the addition of feed additives.

The air pollution generated by this 25-30t/h extruded feed raw material production in Russia project mainly comes from the dust generated during the feeding, crushing, mixing, crushing, screening and material loading and unloading processes during the production process, and the odor during the cooling process of puffed feeding, etc.

01

Dust

The industry category of this project belongs to the feed processing industry. This project is equipped with bag dust removal devices in the main pollutant-generating processes (screening process, crushing process, and packaging process).

Due to the layout of the factory, it is difficult to collect all the process dust and then discharge it. Therefore, the customer company divides the process dust into grain screening dust, crushing dust and puffing dust according to its distribution concentration.

• This project is equipped with two sets of grain screening equipment. After the grain screening dust is collected in a sealed manner, it is processed by two sets of pulse dust removal devices (single air volume: 4000m³/h) and then discharged by a 15m high exhaust pipe (DA001). The organized emission of grain screening dust is 0.903t/a, the emission rate is 0.376kg/h, and the emission concentration is 47.031mg/m³.
• This 25-30t/h extruded feed raw material production in Russia project is equipped with a total of four sets of crushers. After the crushed dust is collected in a sealed manner, it is processed by four sets of pulse dust removal devices (single air volume: 5000m³/h) and then discharged from a 15m high exhaust pipe (DA002). The organized emission of crushing dust is 1.806t/a, the emission rate is 0.753kg/h, and the emission concentration is 37.625mg/m³.
• This project is equipped with two sets of puffing equipment. After the puffed dust is collected in a sealed manner, it is processed by two sets of pulse dust removal devices (single air volume: 3000m³/h) and then discharged from a 15m high exhaust pipe (DA001). The organized emission of puffed dust is 0.301t/a, the emission rate is 0.125kg/h, and the emission concentration is 20.903mg/m³.

02

Foul smell

According to the definition of malodorous gases in the "Emission Standards for Odor Pollutants", all gases that stimulate the olfactory organs, make people unhappy and damage the living environment are malodorous gases.

The odorous gases in this 25-30t/h extruded feed raw material production in Russia project mainly come from the puffing and air-cooling processes. The main components of the odor generated are NH3, H2S and other odorous gases. Since the amount of generated odorous gases is very small, the discharged odorous gases can meet the "Emission Standards for Odor Pollutants".

The existing noise sources of the project are mainly noise generated by grain screening equipment, crushers, extruders, balers, etc. The noise is 75~85dB (A).

The 25-30t/h extruded feed raw material production in Russia project noise adopts relevant shock reduction measures, building sound insulation, distance attenuation, and strengthens the maintenance and upkeep of equipment to avoid the generation of abnormal equipment noise.

• When purchasing equipment, enterprises should purchase low-noise equipment that meets various mechanical noise standards promulgated by the state to ensure that the operation can meet the noise hygiene standards of industrial enterprise workshops and ensure that the factory boundary noise control value is reached.
• Equipment with high noise pollution, such as crushers, grain screening equipment, fans, etc., must be equipped with vibration reduction devices.
• For the mechanical impact noise generated, use soundproof doors and windows with good performance to isolate the noise to reduce the spread of noise. Set up a soundproof control room to separate operators from the noise source.
• Measures should be taken to control noise transmission pathways. For example, the building envelopes of workshops with strong noise sources should be closed. At the same time, greening outside the workshops and factory boundaries should be adopted, and buildings and trees can be used to block the spread of sound.
• Noise pollution prevention and control work shall implement the environmental protection system for construction project completion. Noise reduction equipment such as anti-vibration pads, sound insulation, sound absorption, and mufflers should be regularly inspected and repaired, and those that do not meet the requirements should be replaced in a timely manner to prevent the increase in mechanical noise.
• Strengthen the maintenance of equipment to keep the equipment in optimal working condition.

During the operation of this 25-30t/h extruded feed raw material production in Russia project, the solid waste generated is discarded packaging bags, cleaning waste residue, dust collector ash, domestic garbage and hazardous waste (waste mineral oil).

There are many types of solid waste in this project, and the overall principle of disposal measures is "classified collection, classified storage, separate utilization or disposal".

01

Domestic garbage

After the project domestic waste is collected in categories, it will be handed over to the environmental sanitation department for unified removal and transportation.

02

General solid waste

Waste packaging bags are sold to material recycling units; dust collector ash is collected and returned to the production line to continue production; cleaned waste residue and domestic garbage are handed over to the sanitation department for unified removal and transportation.

01

Domestic garbage

It is prohibited to mix general industrial solid waste in domestic waste storage areas.

02

General industrial solid waste

The construction unit shall establish a general industrial solid waste temporary storage area in accordance with the relevant requirements of the "General Industrial Solid Waste Storage and Landfill Pollution Control Standards".

General industrial solid waste must not be piled up anywhere, and domestic waste is prohibited from being mixed in. This 25-30t/h extruded feed raw material production in Russia project plans to build a general industrial solid waste temporary storage area, located northwest of workshop #1, with an area of 50m2. General industrial solid waste temporary storage areas should meet the following requirements:

• The ground should be hardened and meet the bearing capacity requirements. If necessary, corresponding measures should be taken to prevent the foundation from sinking.
• Necessary wind, rain and sun protection measures are required, and diversion channels should be set up around the storage yard.
• Set up environmental protection graphic signs in accordance with the requirements of "Environmental Protection Graphic Signs - Solid Waste Storage (Disposal) Sites".

03

Hazardous waste

After the 25-30t/h extruded feed raw material production in Russia project's hazardous waste is sealed and temporarily stored in the temporary storage room, it is regularly sent to units with hazardous waste treatment qualifications for disposal. The temporary solid waste storage site should take measures to prevent leakage and meet the "Pollution Control Standards for Hazardous Waste Storage".

This project will build a hazardous waste temporary storage room with an area of 2m2 in the northwest of the 1# workshop to classify and temporarily store the hazardous waste generated by the project. According to the "Hazardous Waste Storage Pollution Control Standards", the construction of hazardous waste temporary storage rooms should be carried out in accordance with the following requirements:

• The floor and skirtings must be constructed of solid, impermeable materials, and the building materials must be compatible with hazardous waste.
• There must be a leakage liquid collection device.
• There must be safety lighting facilities and observation windows in the facility.
• The hazardous waste room must have a corrosion-resistant hardened floor with no cracks on the surface.
• A skirt to cut off leakage should be designed, and the volume enclosed by the ground and skirt should not be less than one-fifth of the maximum storage capacity of the largest container to be cut off or the total storage capacity.

The collection, temporary storage and management of hazardous waste temporary storage rooms and the transportation of hazardous waste must be strictly implemented in accordance with the relevant provisions of the "Hazardous Waste Storage Pollution Control Standard" and the "Hazardous Waste Pollution Prevention and Control Technical Policy".

To sum up, the solid waste of the 25-30t/h extruded feed raw material production in Russia project can be disposed of reasonably, effectively and safely, with little impact on the environment.