CONTROL FOR THE PROCESS OF DRYING WET MATERIAL

Abstract

The present invention relates to a process for continuous of drying or removing the water phase from wet material, such as organic material and for regulating or controlling the drying mechanisms using heating and drying components in a mechanic set up for drying material. The steam generated in the pre-dryer in the process is sufficient to sustain the energy need of the system as the different components of a meal factory are set up as a closed system.

Claims

1. An apparatus for heating or removing a water phase from material, the apparatus comprising: a cooker 1 heating the material, a first dryer 2 for evaporating a portion of the water phase from the material, wherein the cooker 1 and the dryer each comprise: a chamber having a lower portion with a cylindrical or semi-cylindrical shape and an upper portion for receiving steam from the lower portion, heat exchange elements for conducting heat to the chamber, the heat exchange elements comprising at least one jacket arranged around the chamber, and a plurality of cylindrical or semi-cylindrical disc-shaped hollow compartments, arranged parallel with space between them in the lower compartment of the chamber, comprising hollow protrusions connecting the disc-shaped hollow compartments to the jacket through connection openings, an axis arranged centrally within the container, and scrapers attached to, and rotating on the centrally arranged axis between the cylindrical or semi-cylindrical disc-shaped hollow compartments, the apparatus further comprising: a duct 11 to the jacket of the first dryer 2 for feeding steam under pressure into the heat exchange elements of the first dryer, a duct 13 from the upper portion of the first dryer 2 to the jacket of the cooker 1 for feeding steam generated in the first dryer into the heat exchange elements of the cooker, sensing means 14 for monitoring the pressure in the first dryer 2, and control means 15 for receiving signals from sensing means 14 and to regulate the amount of steam under pressure which is feed into the system, wherein the control means 15 sends a feedback signal based on the monitoring of the pressure in the chamber of the first dryer for automatically adjusting the amount of steam under pressure introduced into the jacket of the first dryer 2 to maintain the pressure in the first dryer at a predefined range, and wherein the heat exchange elements of the cooker form a closed system with the chamber of the first dryer, such that the steam generated in the first dryer can only leave the closed system as condense.

2. The apparatus according to claim 1, said apparatus further comprising a secondary dryer 3 for removing more of the water phase from the material, and a transport means 10 for providing a flow of material from the first dryer 2 to the secondary dryer 3 wherein the duct 13 from the upper portion of the first dryer 2 also leads to the jacket of the secondary dryer 3 for feeding steam generated in the first dryer into the heat exchange elements of the secondary dryer 3, and wherein the heat exchange elements of the secondary dryer and the cooker form a closed system with the chamber of the first dryer, such that the steam generated in the first dryer can only leave the closed system as condense.

3. The apparatus according to claim 1, said apparatus further comprising a pre-cooker 4 to heat up the material before it is transferred into the cooker 1 using condense from the jacket of the cooker 1 and to the jacket of the secondary dryer 3 to heat up the material in the pre-cooker.

4. The apparatus according to claim 1, wherein a sensors 16, 20 monitor the amount of material in the first dryer 2 and in the cooker 1 by measuring the weight of material or the level of the material in the first dryer 2 and in the cooker 1.

5. The apparatus according to claim 1, further comprising a separation device 5 for separating the oil phase from the material.

6. The apparatus according to claim 5, further comprising a pump 17 for pumping the material to the separation device 5.

7. The apparatus according to claim 6, wherein the chamber of the first dryer 2 has an inlet 34 for receiving material from the separation device.

8. The apparatus according to claim 1, further comprising valves 18 in the top and bottom portion of the jacket of the cooker 2 and/or the jacket of the secondary dryer 3 for releasing light and heavy gasses respectively from the jackets.

9. The apparatus according to claim 3, further comprising a duct 19 for providing condense from the secondary dryer 3 and cooker 1 to the pre-cooker 4.

10. The apparatus according to claim 3, further comprising a transport means 9 for feeding the cooker 1 with material.

11. The apparatus according to claim 2, wherein the transport means 9 and transport means 10 is a pump or a screw conveyor.

12. The apparatus according to claim 1, wherein the first dryer 2 has a first jacket 30 and a second jacket 29 parallel arranged around the chamber, and wherein the first jacket 30 receives steam under pressure from a steam boiler 12, the apparatus further comprising: a duct 32 leading from the upper portion of the first dryer 2 into the second jacket 29 of the first dryer 2, and one or more high pressure fans 33 in the duct 32 between the upper portion of the first dryer 2 and the second jacket 29 of the first dryer 2 for increasing the pressure and the temperature of the steam before injecting it into the second jacket 29 of the first dryer 2.

13. A method for control of devices for heating or removing a water phase from material using the apparatus of claim 1, the method comprising: feeding material comprising water phase into a cooker 1, heating the material in a cooker 1, transferring the material from the cooker 1 to a first dryer 2 for evaporating a portion of the water phase from the material, feeding steam under pressure from a steam boiler to a heat exchange elements of the first dryer, evaporating at least a portion of the water phase from the material in the first dryer thereby generating steam rising to the upper portion of the chamber, feeding the steam from the upper portion of the chamber to the jacket arranged around the cooker, monitoring the pressure or temperature in the chamber of the first dryer, wherein a control means 15 sends a feedback signal based on the monitoring of the pressure in the chamber of the first dryer for automatically adjusting the amount of steam under pressure introduced into the jacket of the first dryer 2 to maintain the pressure in the first dryer at a predefined range, and wherein the heat exchange elements of the cooker form a closed system with the chamber of the first dryer, such that the steam generated in the first dryer can only leave the closed system as condense.

14. The method according to claim 13, wherein the method further comprises the step of: monitoring the amount of the material in the first dryer and the cooker, transferring the material from the first dryer 2, wherein the control means regulates the amount of material comprising water phase transferred into the cooker 1 based on the amount of the material in the first dryer and the cooker.

15. The method according to claim 14, wherein the amount of material in the first dryer 2 and/or cooker is monitored by weight or height in the container.

16. The method according to claim 13, wherein the method further comprises the step of: transferring the material from the first dryer 2 to a secondary dryer 3 for removing more of the water phase from the material, and feeding the steam from the upper portion of the chamber to the jacket arranged around the secondary dryer 3,

17. The method according to claim 13, wherein the method further comprises keeping the pressure in the first dryer is kept constant or continuous.

18. The method according to claim 13, wherein an oil phase is separated from the material in a separating device 5 after heating the material in the cooker 1 and prior to transferring it into the first dryer 2.

19. The system according to claim 16, wherein water condensate from the secondary dryer 3 and cooker 1 is transported to a pre-cooker 4 to pre-heat the material.

20. A system for heating or removing a water phase from material, the system comprising: feeding material comprising water phase into a cooker 1, heating the material in a cooker 1, transferring the material from the cooker 1 to a first dryer 2 for evaporating a portion of the water phase from the material, transferring the material from the first dryer 2 wherein the cooker 1 and the dryer each comprise: a chamber having a lower portion with a cylindrical or semi-cylindrical shape and an upper portion for receiving steam from the lower portion, heat exchange elements for conducting heat to the chamber, the heat exchange elements comprising at least one jacket arranged around the chamber, and a plurality of cylindrical or semi-cylindrical disc-shaped hollow compartments, arranged parallel with space between them in the lower compartment of the chamber, comprising hollow protrusions connecting the disc-shaped hollow compartments to the jacket through connection openings, an axis arranged centrally within the container, and scrapers attached to, and rotating on the centrally arranged axis between the cylindrical or semi-cylindrical disc-shaped hollow compartments, a duct 11 to the jacket of the first dryer 2 for feeding steam under pressure into the heat exchange elements of the first dryer, a duct 13 from the upper portion of the first dryer 2 to the jacket of the cooker 1 for feeding steam generated in the first dryer into the heat exchange elements of the cooker, sensing means 14 for monitoring the pressure in the first dryer 2, and control means 15 for receiving signals from sensing means 14 and to regulate the amount of steam under pressure which is feed into the system, feeding steam under pressure from a steam boiler to a heat exchange elements of the first dryer, evaporating at least a portion of the water phase from the material in the first dryer thereby generating steam rising to the upper portion of the chamber, feeding the steam from the upper portion of the chamber to the jacket arranged around the cooker, and automatically adjusting the amount of steam under pressure into the jacket of the first dryer to maintain the pressure in the first dryer at a predefined range, wherein the control means 15 sends a feedback signal based on the monitoring of the pressure in the chamber of the first dryer for automatically adjusting the amount of steam under pressure introduced into the jacket of the first dryer 2 to maintain the pressure in the first dryer at a predefined range, and wherein the heat exchange elements of the cooker form a closed system with the chamber of the first dryer, such that the steam generated in the first dryer can only leave the closed system as condense.

21. The system according to claim 20, wherein the control means regulates the amount of material comprising water phase transferred into the cooker 1 based on the monitoring of amount of the material in the first dryer and the cooker.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0057] The present invention will be further described with reference to the drawings using reference numbers in the drawings to identify the individual components of the invention.

[0058] FIG. 1 shows a shows a schematic drawing of system and device of the present invention outlining the route of the material through and the input and distribution of heating media through the system.

[0059] FIG. 2 outlines the control components and signals of the embodiment shown in FIG. 1.

[0060] FIG. 3 shows the construction of a cooker, a first dryer or a secondary dryer of the present invention.

[0061] FIG. 4 shows an embodiment according to claims 1 and 18 of the present invention with a combined cooker and dryer device.

[0062] FIG. 5 shows a schematic drawing of system for recovery of fish meal and oil from fish raw material according to claims 1, 13 and 20 of the present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0063] In the following, exemplary embodiments of the invention will be described, referring to the figures. These examples are provided to provide further understanding of the invention, without limiting its scope.

[0064] In the following description, a series of steps are described. The skilled person will appreciate that unless required by the context, the order of steps is not critical for the resulting configuration and its effect. Further, it will be apparent to the skilled person that irrespective of the order of steps, the presence or absence of time delay between steps, can be present between some or all of the described steps.

[0065] FIG. 1 shows a schematic drawing of system for recovery of fish meal and oil from fish raw material, where the route of the material through the system is shown as well as the input and distribution of heating media (steam and condense) through the system. The apparatus shown in this embodiment comprises a cooker 1 heating the material, a first dryer 2 for evaporating a portion of the water phase from the material, and a secondary dryer 3 for removing more of the water phase from the material. Optionally, a pre-cooker 4 can be used to pre-heat the material before it is feed into the cooker. The cooker and the two dryers are chambers having heat exchange elements for conducting heat to the chamber, the heat exchange elements comprising at least one jacket, 6, 7, 8 arranged around the chambers connected to hollow discs (not shown in this drawing) in the chamber. The material is feed to the cooker 1 by means of a pump or a screw conveyor 9. A second pump or a screw conveyor 10 is in piping for feeding material from the first dryer 2 to the secondary dryer 3. The heat exchange system of the device uses steam generated in a steam boiler 12 and feeds steam under pressure from the steam boiler 12 into the jacket of the first dryer 2 via a duct 11. A duct 13 leading from the upper portion of the chamber of the first dryer 2 to the jacket of the cooker 1 and to the jacket of the secondary dryer 3 is used for leading steam generated in the first dryer into the heat exchange elements of the cooker and the secondary dryer 3. The heat exchange elements of the secondary dryer 3 and the cooker 1 form a closed system with the upper chamber of the first dryer 2, such that no steam is allowed to exit system, but only condense. The apparatus may also comprise a separation device 5 for separating the oil phase from the material as shown in this drawing. A pump 17 is used for pumping the material into a separation device 5 for separating the oil phase from the material. After separation of oil from the material, the remaining phase is feed back into the dryer device through an opening and into the first dryer section. Valves 18 arranged at the top and bottom portion of the secondary dryer 3 and cooker 1 (not shown for cooker) are used for releasing light and heavy gasses respectively from the jackets 6 and 8 on the secondary dryer 3 and cooker 1. The apparatus of the invention may also have a duct 19 for providing condense from the jackets 6 and 8 on the secondary dryer 3 and cooker 1 to the pre-cooker 4. The embodiment shown in FIG. 1 also shows a sensor 20 for monitoring the amount of material in the first dryer 2 by measuring the height or level of material in the first dryer 2.

[0066] FIG. 2 outlines the control components of the embodiment shown in FIG. 1 for the route of the material through the device of this embodiment. An advantage of the present invention is that the meal factory and the control process presented here provides a system where the factory can run automatically as long as there is material to be feed into the factory. If the factory is temporarily out of raw material, no pre-dried material leaves the first dryer 2 and thereby no energy (as steam under pressure) is introduced into the hear exchange elements of the first dryer. First, the pump 10 is set to pump the material from the first dryer 2 to the secondary dryer 3. A pressure or temperature sensor 14 in the first dryer monitors the pressure or the temperature in the chamber. The pressure sensor 14 is connected to the control computer 15 of the system and a signal (I) from the sensor regulates the input (II) of steam under pressure from a steam boiler 12 into the jacket 7 of the first dryer 2. So if the pressure or temperature drops more steam is injected into the jacket 7 of the first dryer 2, but if the pressure or temperature increases over a set range, the input of steam under pressure/temperature is reduced. Based on pressure measurements in the chamber of the first dryer, ensures that the thermal surfaces in the cooker 1 and secondary dryer 3 are always at about 100 C. The cooker 1 and first dryer 2 are arranged on weight cells in the embodiment shown in FIG. 2 for monitoring the amount of material in each chamber. If the amount of material decreases in either the cooker 1 or first dryer 2 as measured by the weight cells, a signal (III) is sent to the control computer 15 of the system, which in return sends a signal (IV) to the pump 9 via and more material is pumped into the factory.

[0067] FIG. 3 shows the construction of a cooker or a first dryer according to claim 1, where the cooker/dryer has a single jacket 21 arranged around a lower semi-cylindrical chamber 22. The upper portion 23 of the chamber has a rectangular shape and sits on top of the lower semi-cylindrical chamber 22. Disc-shaped hollow compartments 24 are shown parallel arranged with space between them in the lower semi-cylindrical chamber 22, having a connection portion 25 on each side of the upper side of the disc and one at the bottom, where each connection portion 25 connects to the jacket 21 through openings in the lower semi-cylindrical chamber 22. An axis 26 arranged along the chamber rotates the scrapers 27.

[0068] FIG. 4 shows an embodiment of a dryer, where the dryer portion of the device has an MVR dryer arrangement. The apparatus shown in FIG. 4 has a dryer chamber in three sections having three jackets arranged around the chamber and a plurality of semi-cylindrical disc-shaped hollow compartments 24, where a set of disc-shaped hollow compartments 24 is connected to their respective jacket 28, 29, 30 to form a heat exchange unit or the heat exchange elements for that portion of the chamber. Therefore, the semi-cylindrical disc-shaped hollow compartments 24 are divided into three sets of disks, where each set provides a heat exchange unit to each section of the dryer. In this embodiment a jacket 28 is arranged around the first dryer section where the material comes in, where steam from the upper portion of the chamber feeds steam to the heat exchange elements/unit of the first dryer section through the duct 13. The second and third dryer sections have two heat exchange units with a first jacket 30 arranged around the chamber at the other end and a second jacket 29 arranged around the middle portion of the chamber as well as their corresponding semi-cylindrical disc-shaped hollow compartments. The jacket 30 arranged around the end of the dryer, where the material leaves the chamber, has an inlet 31 for receiving steam under pressure form a boiler. The second jacket 29 arranged around the middle portion of the dryer is connected to a steam duct 32 leading from the upper portion into the jacket 29 of the middle portion with a high pressure fan 33 arranged in the duct 32 for increasing the pressure and the temperature of the steam taken from the upper portion before injecting it into the respective disc-shaped hollow compartments 24.

[0069] FIG. 5 shows a schematic drawing of system for recovery of fish meal and oil from fish raw material according to claims 1, 13 and 20, where the route of the material through the system is shown as well as the as well as the input and distribution of heating media (steam and condense) through the system. The apparatus shown in this embodiment comprises a cooker 1 heating the material and a first dryer 2 for evaporating a portion of the water phase from the material. The cooker and the first dryer are chambers having heat exchange elements for conducting heat to the chamber, the heat exchange elements comprising at least one jacket, 6, 7 arranged around the chambers connected to hollow discs (not shown in this drawing) in the chamber. A pump or a screw conveyor 10 is in piping for feeding material from the first dryer 2 to the secondary dryer 3. The heat exchange system of the device uses steam generated in a steam boiler 12 and feeds steam under pressure from the steam boiler 12 into the jacket of the first dryer 2 via a duct 11. A duct 13 leading from the upper portion of the chamber of the first dryer 2 to the jacket of the cooker 1 and to the jacket of the secondary dryer 3 is used for leading steam generated in the first dryer into the heat exchange elements of the cooker. The heat exchange elements of the cooker 1 forms a closed system with the upper chamber of the first dryer 2, such that no steam is allowed to exit system, but only condense. The apparatus may also comprise a separation device 5 for separating the oil phase from the material as shown in this drawing. A pump 17 is used for pumping the material into a separation device 5 for separating the oil phase from the material. After separation of oil from the material, the remaining phase is feed back into the dryer device through an opening and into the first dryer section. The embodiment shown in FIG. 1 also shows a level sensor 20 for monitoring the amount of material in the first dryer 2 by measuring the height or level of material in the first dryer 2.

[0070] The embodiments and definitions herein all relate to the apparatus, the method and the system of the invention.

[0071] As used herein, including in the claims, singular forms of terms are to be construed as also including the plural form and vice versa, unless the context indicates otherwise. Thus, it should be noted that as used herein, the singular forms a, an, and the include plural references unless the context clearly dictates otherwise.

[0072] Throughout the description and claims, the terms comprise, including, having, and contain and their variations should be understood as meaning including but not limited to, and are not intended to exclude other components.

[0073] The present invention also covers the exact terms, features, values and ranges etc. in case these terms, features, values and ranges etc. are used in conjunction with terms such as about, around, generally, substantially, essentially, at least etc. (i.e., about 3 shall also cover exactly 3 or substantially constant shall also cover exactly constant).

[0074] The term at least one should be understood as meaning one or more, and therefore includes both embodiments that include one or multiple components. Furthermore, dependent claims that refer to independent claims that describe features with at least one have the same meaning, both when the feature is referred to as the and the at least one.

[0075] It will be appreciated that variations to the foregoing embodiments of the invention can be made while still falling within the scope of the invention can be made while still falling within scope of the invention. Features disclosed in the specification, unless stated otherwise, can be replaced by alternative features serving the same, equivalent or similar purpose. Thus, unless stated otherwise, each feature disclosed represents one example of a generic series of equivalent or similar features.

[0076] Use of exemplary language, such as for instance, such as, for example and the like, is merely intended to better illustrate the invention and does not indicate a limitation on the scope of the invention unless so claimed. Any steps described in the specification may be performed in any order or simultaneously, unless the context clearly indicates otherwise.

[0077] All of the features and/or steps disclosed in the specification can be combined in any combination, except for combinations where at least some of the features and/or steps are mutually exclusive. In particular, preferred features of the invention are applicable to all aspects of the invention and may be used in any combination.