FORBERG INTERNATIONAL AS - … · FORBERG INTERNATIONAL AS Presents Forberg Twin Shaft Drying...

June 20, 2008

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FORBERG INTERNATIONAL AS

Presents

Forberg Twin Shaft Drying System


Contents of PresentationContents of Presentation

• Where used

• System & Process description

• Three Case Histories

• Drying of wheat

• “One Pot Processor”/ pharmaceutical process unit

• Drying of waste on cruise ships

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• Where used



• Drying of wheat




Where usedWhere used

• All branches of industry, mainly powders

• Drying of wheat, food waste and waste water on board of cruise ships, detergent powders,

pharmaceutical powders

• Various Food Industry:

• Potato starch

• Drying/ granulation of enzymes on flour

• Protein-rich by-products fish industry

• Various chemical powders, like:

• Welding flush powder

• Glass filter cake

• Catalyser powders

• Quartz sand

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• Where used



• Drying of wheat




Heart of all Forberg® machines: Heart of all Forberg® machines:

”Twin Shaft Mixing System””Twin Shaft Mixing System”

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Main Principles Forberg Mixing…Main Principles Forberg Mixing…

Heart of all ForbergHeart of all Forberg®® machines: machines:

””Twin Shaft Mixing SystemTwin Shaft Mixing System””


Demand for effective drying: "Mixing of energy and product in thDemand for effective drying: "Mixing of energy and product in the best e best

possible way". possible way".

In which way: intensive movement of particles i dryer. In which way: intensive movement of particles i dryer.

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Air Flow in the Forberg DryerAir Flow in the Forberg Dryer

Air inlet

Product outlet

Air outlet

Product inlet


Advantages of the Forberg DryerAdvantages of the Forberg Dryer

High thermal efficiency, app. 80 per cent.

Can operate close to the product’s maximum temperature,

increasing the drying efficiency.

Constant and controlled air supply.

Combined process possible: mixing of various ingredients,

spraying of liquids

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Advantages of the Forberg DryerAdvantages of the Forberg Dryer

Stop and Go feature

In case of emergency shut downs, power failures or any other error, the feed

remains in the batch system and it can be re-treated while manually

controlling the process to the end.

Saving on additives

Any kind of heat sensitive additives such as vitamins, enzymes,

pharmaceuticals, medicines, colours and flavour can be added after the

treatment at normal temperatures thus saving on these expensive

components.


Limitations Limitations

The area in top of the mixer is a bottle neck. Largest capacity:

• app. 1700 kW heating power

• 38000 m3/h Air Flow

Typically used for processes with "lower and mid range

capacity" bulk drying

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• Where used



• Drying of wheat




Example of a Drying ProcessExample of a Drying Process

Drying of WheatDrying of Wheat

Batch 3 26.01.2002

0

20

40

60

80

100

120

Tid 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32

min

Verdi

Produkttemp

Utluft

Rel %

InnluftRel %

Innluft

Produkttemp

Utluft

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FTFT--350 Mixer 350 Mixer -- Granulator Granulator –– DryerDryer

“One Pot Processor”/ pharmaceutical process unit “One Pot Processor”/ pharmaceutical process unit


FTFT--350 Mixer 350 Mixer -- Granulator Granulator –– DryerDryer

“One Pot Processor”/ pharmaceutical process unit “One Pot Processor”/ pharmaceutical process unit

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FT – 350

Machine number 2401

System number S45-01

Year of production 2001

Process time 30 - 45min

Maximum filling mixer/dryer 490 litre Nominal filling mixer/dryer 350 litre Lower filling mixer/dryer 180 litre

Rotor shaft speed 32-100 rpm

Components: Mixer

Filter

Frame mixer

Q-rohr DN600

Air-system

Nominal Operation pressure( Po) Atmosphere

Reduced explosion pressure

Volume of process chamber 2 349 litre


First, stage - Filling

The rotors are started. Product is filled

into the mixer chamber. Filling of the

mixer chamber is done by a pneumatic

conveying system via a Quadro-Comil.

Two different powders, lactose and

potato starch, in an approximate 60/40

division, are to be added.

While filling is performed two butterfly

valves close the pipelines from the

heater system into the mixer. This

hinders ingestion of unwanted powder

into the heating and condensation

system.

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Second, stage - Mixing

Product valve is closed. The two

different powders, lactose and

potato starch, are mixed. Mixing

time may be as little as 10

seconds.


Third, stage – Spraying (Coating)

Coating of the powder is achieved by

spraying a liquid solution of binder/carrier

and active substance, onto the dry powder.

Spray pattern and droplet size is controlled

by type of nozzle (opening and angle),

applied pressure, time for spraying and

distance between nozzle and hit point.

A spray tank is filled with the

liquid. The spray tank is

pressurized by compressed air.

Correct spraying is enabled by

compressed air actuated, spray

nozzles. Spraying is actively

controlled.

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Fourth, stage – Granulation

Granulation of the powder is achieved by the

liquid solution of binder and dry powder

which are “wet” mixed together. Multiple

stage spraying and wet mixing may be

necessary to build up granules.


Fifth, stage - Drying

The inlet air pipe butterfly valves are opened.

Warm, clean and dry air is blown into the

mixer chamber via the integrated side

funnels. Paddles bring the air through the

material and up in the fluidized zone.

The granules are slowly dried to the required

moisture content. Moist air and free

suspended particles flow up to the primary

filter. The primary filter, which is mounted

over the chamber, stops most of the free

suspended particles from flowing into the

return pipeline. The individual primary filter

pockets are cleaned by compressed air. The

separated particles fall back into the

chamber. Operating the vibrators in pre-

programmed pulses prevents unwanted build

up of powder on the walls.

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The air continues through the door

to the secondary filter cassette. The

secondary filter stops 99.997% (0,3

µm particles) of the remaining

particles. Moist clean air continues

through a pipeline to the fan. The

fan blows moist air from the

secondary filter down into a coil

cooler. Condense from the

dehumidified air is drained out

beneath the droplet chamber.

Cold and humid air flows up into the

heater where it is heated and

returned to the process chamber.


Last stage - Discharge

Airflow is stopped. The air inlet

pipe butterfly valves are

closed. The system is run

through a final additional

cleaning cycle of the filter and

walls to allow all powder to

settle.

Product is discharged through

the discharge doors into the

discharge hopper. The rotors

are stopped.

From the discharge hopper

granules are transported by a

pneumatic conveying system

through the Quadro-Comil and

into containers.

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General description of cleaning

The system includes an integrated

CIP nozzle system complete with

control valves and a customised

PLC system. The system enables

CIP (Cleaning In Place) of the

main process chamber and main

filter.

Due to the product qualities the

primary filter unit may need

additional manual cleaning.

The quick access and

exchange system of the

primary filter unit enhances this

manual cleaning. Tap water,

process water and detergents

supply and removal with

treatment are not included.


”Filter Unit with extractable Filter”

Example of ”Cleanability”Example of ”Cleanability”

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Maritime Maritime –– Waste ManagementWaste Management


Drying of food waste and waste water on boardDrying of food waste and waste water on board

=> Burning in incinerator

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ForbergForberg®® Drying Systems Drying Systems

Illustration of an installation (”Sørfold”)


Thank you Thank you

for your attention!for your attention!

FORBERG INTERNATIONAL AS - … · FORBERG INTERNATIONAL AS Presents Forberg Twin Shaft Drying...

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Transcript of FORBERG INTERNATIONAL AS - … · FORBERG INTERNATIONAL AS Presents Forberg Twin Shaft Drying...