4/4/2015

Cropresidueprocessingmachines

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Cropresidueprocessingmachines
Choppers
Thechopperismainlyusedforstalkforage,suchasricestraw,wheatstraw,maize
stoverandmaizeforensiling.Strawchopperscanbeclassifiedbysizeintosmall,
mediumandlarge.Thesmallsizechopperismainlyadaptedforchoppingdrystrawor
silageonsmallscalefarms.Thelargechopperalsocalledasilagechopperismainly
usedforsilageoncattlefarms.Themediumchopperisnormallysuitedtocuttingdry
strawandsilage,soitiscalledastrawsilagechopper.
Chopperscanbedividedintocylinderorflywheeltypes,accordingtothemodeof
cutting.Largeandmediumsizechoppersaregenerallyflywheeltypes,tofacilitate
throwingsilage,butthemajorityofsmallchoppersarecylindertype.Largeand
mediumchoppersareusuallyequippedwithroadwheelsforeasymovement,while
smallsizechoppersarenormallystationary.
Cylinderchoppers
Therearemanytypesofcylinderchopper.The93ZT100chopper(Figure611),made
byWulanhaoteLivestockMachineryFactoryinInnerMongolia,istakenasanexample
todescribethestructureofachopper.
Themachineconsistsprimarilyofmechanismsforfeeding,chopping,andthrowing,
withatransmission,aclutchandaframe.Theprinciplesofoperationareillustratedin
Figure612.
Themainpartsofthefeedmechanismareachainconveyor,pressingrollers,and
upperandlowerfeedrollers.Fortheupperfeedroller,springsareusedforpressure,
withacrossgrooveshaftcoupledwithacompactstructurefordriving.Thechopping
andthrowingmechanismisinoneunit,whichconsistsofamainshaft,abladerotor,
rotatingblades,athrowingvaneandstationaryblades.Gearteethare13,22,65or56.
Bychangingthegearused,thespeedcanbeadjustedtoobtainvariouscutting
lengths.
Figure611.93ZT1000strawchopper

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KEY:1.Frame2.Throwingcover3.Smallsinglegroovesheave4.
Bladesdisk5.Movableblade6.Changeablegear7.Wheeltension
clutch8.Suspensionbracket9.Feedinggroove10.Chain11.Large
singlegroovesheave12.Supportingplateformotor.
Figure612.Choppingactionofcylindertypestrawchopper

KEY:1.Upperfeedroller2.Cylinderblade.3.Stationarybottomblade4.
Lowerfeedroller.
Flywheelchoppers
FlywheelchopperoperationisillustratedinFigure613,showingafeedchain,upper
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andlowerfeedrollers,astationarylowerblade,acutterandathrowingfan.Thestraw
isfedviathefeedchainintothefeedrollers,pressedandmovedforwardbythem,then
cutintopiecesbythecombinationofupperandlowerblades,anditisfinallyblownby
thefantothestoragesiteorsilo.
Figure613.Choppingactionofthediskchopper

KEY:1.Feedroller2.Blade3.Disk4.Blowerfan5.Stationarybottom
blade6.Feedroller7.Feedchain
Figure614showstheoutlineofa93ZP1000strawchopperproducedbytheLiaoning
FengchengDonsfengMachineryFactory.Itsoutputis1000kg/hour,thelengthof
choppedpiecesare15mmor35mmandtherotaryspeedofthemainshaftis8000
rpm.Ithas2movableblades,apowersupplyof3kWfromanintegralmotor,weighs
110kg,anditsoveralldimensionsare95cmlong,98cmwideand140cmhigh.
Figure614.Structureofa93ZP1000typechopper

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KEY:1.Feedchannel2.Bowshapeframe3.Supportingframefor
rollers4.Handleforchangingposition5.Cover6.Outletforstraw7.
Connectingshaft8.Gearbox9.Chassis10.Movableblade11.Motor
frame.
Sometypesofstrawchoppers,theirtechnicalparametersandtheirmanufacturersin
ChinaareshowninTable62.

Grinders
Grindingmethodsandgrindertypes
Therearefourmaingrindingmethods:impacting,grinding,crushingandsawing(see
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Figure615).Impactingissuitableforhardandbrittlerawmaterials,suchasmaize
feedsawingisbetterforlargeandfragilefeedandcrushingandgrindingareusedfor
toughfeed.
Table62.Somechoppertypes,theirtechnicalparametersandmanufacturersin
China
Model

93ZP400
Straw

Type&
Speed
(rpm)
Flywheel

Cutting
length
(mm)

Power(kW)&
Capacity
(kg/hour)
0.75

Weight(kg)&Size
(lwhcm)
33

15,35
chopper
(Feima)
93ZP1000
Straw

900

400

705550

Flywheel

3.0

110

800

1000

9598140

Flywheel

4.0

115

15,35
chopper
(Feima)
93ZP1600
Straw

15,35
chopper
(Feima)
93ZQ400
Straw

800

0.75
5,7,15,
35

(1)

757

900

400

705550

Flywheel

7.511

200

1000
Flywheel 15,22,35,
50
700
Flywheel

1500

1529980

13.0

515

4000
10.0

450

9000
3.0

Flywheel
andveg.
chopper

(1)

35

2927

(1)

6300

(2)

6300

(2)

2532481773
1000

6106
chopper
9ZP1.6
Straw

1190

n.a.

16

chopper
PCC60
Silage

(1)

(1)

andveg.
chopper

chopper
(Feima)
9ZP4.0
Straw

730

1235
1600

Flywheel

(Feima)
9QF45
Silage

Price Maker
()

284177205

n.a.
15,20,35

Grass2000

(3)
n.a.

(Fenglei)
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Straw3000
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4.0
9DQ100
Silage

Flywheel

335
9,20,28,
60

chopper
(Wuye)

Straw2500

600

1680

(4)

1188

(5)

4100

(6)

15055126
7006500

93ZT1000
Straw
chopper

3.0

190

1000

17560110

13,26

(Xing'anling)
5.5
9Z4Straw

Cylinder

280
1520

chopper

Grass6000

1200

n.a.
Straw1500
n.a.

9Z8Straw

Flywheel
15,14

chopper
(Ximmu)
9ZCA1.0
Straw

Grass12000

(6)

600
Straw3000
3.0

Cylinder

195

13,26
chopper
775
9ZC6Straw Cylinder

1000
10.0

650
Flywheel

(7)

5700

(8)

17560110
1000

6,13,25
chopper
93ZP2500
Straw

800

Silage6000
7.5

250180195
320

2500

238134173

825
chopper
(Ximmu)

850

(9)

NOTE:n.a.=informationnotsupplied.
KEYTOMANUFACTURERS:(1)LiaoningFengchengDongfeng
MachineryPlant.(2)BeijingLinhaiAgriculturalandLivestockMachinery
Plant.(3)BeijingYanjingLivestockMachineryCo.(4)Shijiazhuang
AgriculturalandLivestockMachineryPlant.(5)InnerMongoliaWulanhote
LivestockMachineryPlant.(6)ShandongFeichengChopperPlant.(7)
HenanFugouScientificInstrumentPlant(MOA).(8)ShanxiXi'an
LivestockandMilkMachineryPlant.(9)XinjiangLivestockMachinery
Plant.
Manymillscombinedifferentmethods.Thosecommonlyfoundarehammer,fixed
head,clawandrollermills.Thehammermilliswellsuitedforstrawfeed.Therollermill
usesapairofopposedtoothedrollersthatrotatesimultaneouslyinoppositedirections
andatdifferentspeedstogrindthefeed.Rollermillsaremainlyusedforgrindingoil
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cakes.TheprinciplesofoperationareillustratedinFigure615(5).
Figure615.Grindingmethodsforfeed

Key:1.Impacting2.Grinding3.Pressing4,5.Sawing.
Hammermills
Hammermillsgrindmaterialbytheimpactofahighspeedrotaryhammer.Hammer
millsareeithertangentialfeedoraxialfeedtypes,accordingtotheirstructure.
Figure616showsthestructureofthe9FQ50tangentialfeedmillmadebythe
HongxingMachineryFactoryinJiangxiProvince.Themillcomprisesafeedingpart,a
grindingchamberandacollector.Thefeedingpartcomprisesafeedhopperanda
feedcontrolflap.Thegrindingchamberconsistsofarotarydisk,ahammer,aserrated
plateandascreen.Themajorpartsofthecollectorincludeafan,afeedconveying
tubeandacollectionhopper.
Fedfromthefeedhopperinatangentialdirection,thematerialisimpactedanddriven
tothegrindingchamberbytherotatinghammerswithhighspeed.Thematerialinthe
grindingchamberisfirstlyhitandgroundtosomeextentbyhammers,andthenthrown
athighspeedattheserratedplateandtheperipheralscreenfixedinsidethechamber
tobefurthergroundthroughimpactwiththeserratedplateandfrictionwiththescreen.
Figure616.Tangentialfeedgrinder

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KEY:1.Feedhopper2.Feedcontrol3.Swinginghammer4.Rotary
disk5.Smallserratedplate6.Peripheralscreen7.Largeserratedplate
8.Fan9.Feedgathering(collection)hopper.
Theprocessthenrepeatsuntiltheparticlespassthroughthescreenandare
dischargedfromthegrindingchamber.Theprocessinsidethegrindingchamber
includesthefunctionsofimpacting,shearingandkneading,whichimprovesthe
efficiencyofgrinding.Thefeedproductissuckedfromthedischargingdoortothe
conveyingtubebyafan,thenentersthecollectionhopper,andisfinallydischarged
fromthecollectionhopperafterthemealsettlesoutfromtheairstream.
Theaxialfeedmill(Figure617)differsfromthetangentialfeedmillinboththe
directionoffeedingandinprimarycuttingaction.Strawfedfromtheaxialfeedhopper
isfirstlychoppedintosmallpiecesbytheprimarycuttingmechanismfixedinfrontof
thegrindingchamber,andthesepiecesthenfallintothegrindingchamber.Thusthe
loadonthegrindingchamberisreducedandthefeedingcapabilityandefficiencyof
processingimproved.Theaxialfeedmillisespeciallysuitedtogrindingstrawwithhigh
moisturecontent.
Theadvantagesofthehammermillarehighproductivity,wideapplicationandfine
particleoutput.Itcanbeusedtomillmaize,concentratefeed,greengrassandvarious
strawswithhighmoistureandfibrecontent,soitisalsocalleda"grasspowdermiller."
However,energyconsumptionishigh.
Thefixedheadmilldiffersfromthehammermillinthatitsbladeisfixedtotherotary
diskratherthanconnectedtoitbyapin,soithasmuchhighergrindingcapacity.
Figure617.Axialfeedmill.A.OutlineB.Operation

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KEY:1.Motor2.Housing3.Ringscreen4.Hammer5.Primarycutter
6.Conveyingtube7.Feedcollection(gathering)hopper8.Discharging
doorandtube9.Fan10.Frame.
Clawmills
Clawmillshitandgrindmaterialwithclawsfixedinarotatingdisc,andaresuitablefor
concentrategrindingbecauseofcompactstructure,smallvolumeandlightweight.
Figure618illustratesthestructureofaclawmillwithitsfeeding,grindingand
dischargingparts.Thefeedingincludesafeedhopper,afeedcontroldoorandafeed
tube.Thegrindingpartconsistsofarotaryserrateddisk,astationaryserrateddiskand
aringscreen.Clawsarefixedontherotaryandthestationarydisksalternatively.The
dischargingpartisatubesituatedinthebottomofthemachine.
Afterflowingintothegrindingchamberfromthefeedhopperviathefeedingdoor,the
materialisimpacted,sheared,kneadedandgraduallyrubbedbyclawsintopowder.At
thesametime,theairflowformedbyhighspeedrotationoftherotaryserrateddisk
blowsthepowderoutthroughtheringscreen.
Figure618.Clawmill

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KEY:1.Mainshaft2.Stationaryserrateddisk3.Rotaryserrateddisk4.
Ringscreen5.Doortocontrolmaterialinputrate6.Feedtube.
Factorsinfluencingtheeffectsofgrinding
(i)Typeofmaterialtobeground.Thegrindingoutputwiththesameenergy
consumptiondiffersaccordingtorawmaterial.Outputwithcerealfeedishigherthan
withroughage.Withascreenholediameterof1.2mmandamoisturecontentbelow
15percent,theoutputinkg/kWis4560formaizeandsorghum1722forchaff1216
forsweetpotatovines812formaizestover712forsorghumstover610forlegume
strawand34formaizecobs(2mmscreenholediameter).
(ii)Moisturecontent.Thehigherthemoisturecontent,thelowertheoutputandthe
poorertheenergyefficiency.Generally,moisturecontentshouldnotbehigherthan15
percent.
(iii)Rotaryspeedofmainshaft.Eachtypeofmillhasarangeofrotaryspeedsfor
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themainshafttoobtainhighoutputandlowenergyconsumptionforeachfeed.Ifthe
rotaryspeedistoolow,thegrindingcapacityisdecreasedandfeeddischargeis
hampered,soproductivityisalsoreduced.Incontrast,iftherotaryspeedistoohigh,
idleenergyconsumptionisincreased,aswellaswear,tearandvibration,andthetotal
energyconsumedishigher.ThelinespeedforhammermillsmadeinChinainrecent
yearsisabout7090m/sec.
(iv)Feedrate.Ifthefeedrateistoohigh,groundfeedcannotbedischargedfromthe
grindingchamberatthesamerate,whichresultsinclogging,whichaffectscapacity.In
contrast,ifthefeedingrateistoolow,themillingcapacityisnotfullyusedand
efficiencydecreases.
ThemainmilltypesmadeinChinaarelistedinTable63.

Kneadingmachines
Thekneadingmachineisanewkindofstrawprocessingtechniquedevelopedin
China,combiningchoppingwithgrinding.Themachineprocessesresidues,especially
maizestover,intothinthreadsegmentsof819cm,completelydestroyingitsnode
structure.Palatabilityisgreatlyimproved,andtheintakeoftheentirecropisalso
increasedto95percentfromtheoriginal50percent.Thestructureofthekneading
machineisshowninFigure619.Inoperation,therotor,diameter40cm,rotatesata
highspeed(2856rpm)driving16hammersarrangedin4groups,whichimpactthe
strawfedcontinually.Atiltedserratedplate,whoseteetharearrangedhelicallyand
withchangeableheight,and6stationarybladesarefixedtotheconcaveplateofthe
machine,inordertokeeptheimpactedstrawmovinginaxiallywiththehelpofafan.
Takingthe9RC40kneadingmachine,madebytheBeijingLinhaiAgriculturaland
LivestockMachineryPlant,asanexample:thepowersupplyis7.513kW(the
machinecanalsobedrivenby8.8211.0kWfromafourwheeldrivetractor)andthe
outputofmodelIisupto1000kg/hour,with2000kg/hourfrommodelII.
Thekneadingmachinecanincreasestrawutilizationconsiderablysimplybyphysical
processinganditiswellsuitedformaizestover,whichalreadyhashighnutrientvalue.
Energyconsumptionishigh,1to2timesthatofanormalchoppingmachineofthe
sameoutput,becausethefinalparticlesarefiner.Becausestrawcanalsobesoftened
duringensilageorammoniation,thischoppercanmeetanimals'requirementswhen
theydonotdirectlyeatstraw.
ThemaintypesandtechnicalparametersofthekneadingmachinesmadeinChinaare
showninTable64.
Table63.CharacteristicsofsomegrindersproducedinChina
ModelandType*

9FQ40BFeed
mill(Fenglei)[H]
9QF50BFeed
mill(Fenglei)[H]
6FC308AFeed
mill[Fixedhead]
9FQ4020Feed
mill[H]

Speed
Output Capacity Power Weight(kg) Price Maker
RotorD
Maize Maize (kW)
Size
()
(mm)
Straw Straw
(lwhcm)
Screen (kg/kWh) (kg/hour)
(mm)
3800rpm
95
800
7.5
150
790
(1)
400
22
160
837990
3250rpm
95
1300
13.0
240
1600 (1)
500
20
260
10710699
3800rpm
n.a.
600
5.5
120
760
(2)
308

7556120
n.a.
n.a.
1000 7.511
170
850
(2)

908981

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9F45AHigh
efficiencyfeed

3600rpm

90

900

130
10.0

mill(Fengshou)
[H]
9F36Feedmill

4501.2

30

4500rpm

300

8887105

1000

85

n.a.
(Fengshou)
9FQ4020Straw

3602

280

3770rpm
Mill(Fengshou)

4002.0
3600rpm

900
200
1090

n.a.
mill[H]
9FS45AFeed

2
3200rpm

mill[C]
93FC50Straw

(3)

850

(3)

998981
7.511

200
905781

1297

(4)

11

n.a.

n.a.

(5)

11

n.a.

n.a.

(5)

8000

(6)

1200

(6)

1800

(6)

700

(7)

1320

(8)

780
n.a.

3437rpm

780

170
7.511

95
25

(3)

7599114

1100
n.a.

n.a.
[H]
9FQ40Feed
mill[H]
9F45AFeed

7.5

865

134

1519

Mill(Hongxing)

15
5003

78

706

18410595

3730rpm

130

1000

180

[H]
9FQ4020Feed
mill(Hongxing)

7.6
4002

22

165

n.a.

3440rpm

69

884

488

[H]
9FQ50Feed
mill(Hongxing)

13
5001.2

13.7

175

15661210

250

125

[H]
9F371Feed
4000rpm
mill(Lingfeng)

n.a.
3701

7.5
50

697068

850

200

[H]
9F500Feed
3250rpm

>125

mill(Dongyue)

11
5003.5

>20

400

15497154

[H]
9F400Feed
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3000rpm

>142

600

mill(Dongyue)

150
7.5

[H]
93Fc650Straw

1100

4003.5

>25

250

14999146

2500rpm

107

800

n.a.
11

Mill(Xinmu)[H]

6504

46.8

560

(8)

(9)
215712741505 3200

NOTES:*Typesare[H]=hammer[C]=claw.n.a.=informationnot
provided.
KEYTOMANUFACTURERS:(1)BeijingtonnexianGrinderPlant.(2)
ShanxiHuguanFarmMachineryPlant.(3)InnerMongoliaNingchen
GeneralMachineryPlant.(4)LiaoningFengchenMachineryPlant.(5)
HelongjiangAnqingFarmandLivestockPlant.(6)JiangxiStateRunning
HongxingMachineryPlant.(7)GangxiHoxianAgriculturalMachinery
Plant.(8)ShandongTaishanFarmandLivestockMachineryPlant.(9)
XinjiangLivestockMachineryPlant
Figure619.Illustrationofkneadingmachinestructure

KEY:1.Smoothplate2.Hammerrotor3.Unequalheightteeth4.
Stationaryblade.
Table64.CharacteristicsofsomekneadingmachinesinChina
Modelandtype*

93RC40StrawKneading
Machine[H]
93RC40StrawKneading

Rotor
Power kg/kWh Weight(kg)
(mm)
(kW)
Size
Speed(rpm) Capacity
(lxwxh
(kg/hour)
cm)
400
7.510
120
100
2500
1000
13712669
400
7.513
130

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(.)

1640

(1)

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n.a.
Machine[H]

2610

K6750StrawKneading

500

2000

n.a.
n.a.
1400
n.a.

n.a.

2000
Chopping
900

9RSL50Multifunction
feed

1722
1500
5.510

2800

(4)

1800

(4)

1500

(5)

n.a.

(6)

750

(7)

3200

(8)

16050122
n.a.

700

1323783

7.5

195

Tearing2000
KneadingMachine[H&B]

(3)

n.a.
n.a.

n.a.
Machine[H&B]

2000

15366127

n.a.
Machine[H&B]
9RS0.7StrawKneading

(2)

n.a.
n.a.

Machine[H&B]
9RS1.5StrawKneading

2500

n.a.
5000

21554150

7.5

160

n.a.
9RC40StrawKneading
n.a.
Machine[H]
9FRQ40BStrawKneading

1000
n.a.

Machine[D]
93F45StrawKneading

n.a.

450

n.a.

n.a.
n.a.
n.a.
n.a.
600

4
50

Machine[H]

2500

200

18080105

NOTES:*machinetypesare[D]=disc[H]=hammer[H&B]=hammer
andblade.
n.a.=informationnotsupplied
KEYTOMANUFACTURERS:(1)LiaoningFengchenMachineryPlant.
(2)BeijingLinhaiFarmandLivestockMachineryPlant.(3)Helongjiang
AchenHuajianuyMetalStructurePlant.(4)InnerMongoliaChifeng
GeneralLivestockPlant.(5)HelongjiangAndaLivestockMachineryPlant.
(6)HelongjiangAchenandMechanicalElectricalEquipmentPlant.(7)Jilin
JutaiFarmToolPlant(8)ShanxiXianLivestockandMilkEquipment
Plant.

Kneadingandcuttingmachines
Kneadingandcuttingmachinemodels9LRZ80(Figure620)and9RZ60(Figure6
21)weredesignedbytheNonconventionalFeedInstitute,ChinaAgricultural
University.TheypassedappraisalbyMOAin1998.Theappraisalsaidthatthe
machineswereaninnovationinChina,withworldleadingperformance.
Figure620.Type9LRZ80kneadingmachine

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Kneadingandcuttingmachinescombinecutting,kneadingandmixinginoneoperation.
Maizestover,wheatandricestraw,beanvineandtubervinecanbeprocessedto
threadlikesoftmaterial.
Thefuturedevelopmentsoftheseriesincludethereplacementofthecuttingbladesin
thechopperbyrunningbladesandtheincorporationofahammerinthekneading
machineandofamixingrotorinthemixer.Therearenow16runningbladesand6
setsoffixedblades.Changingthenumberofrunningbladesandfixedbladeswillalter
thecuttinglengthandsoftness.Thematerialwillbethrowntotheinnerregionofthe
cylinder,andwillbechopped,cutandkneadedtothreadlikeform.Whentubersand
concentratearefedintothemachinetogether,materialwillbecutandmixed.
Figure621.Type9RZ60kneadingmachine

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Thenewserieshasthefollowingadvantages:
Thenewaxlestructureincreasesthefeedingcapacity.
Intheworkingcylinder,therunningandthefixedbladeswillcutandkneadat
sametime,sothatenergycanobviouslybereduced.
Bysimplychangingbladenumbers,differentlengthsandsoftnesscanbe
obtained.Itissuitableforgreenanddrymaterials,andespeciallyforwetand
toughmaterial(suchaspalmnutshell,reeds,andchastetreetwigs).
Itissuitableformaizestoversilage.Theprocessedmaterialcanbecompacted
easily.Withoutnodesremaining,thewholestalkcanbeeatenbytheanimal.
The9LRZ80isappropriateforlargefarms.Itrequiresapowersourceof2230kW,
andhasacapacityof68t/hour,andanoutputof0.39tonne/kWh.Itsnodebreaking
efficiencyis99percent.
The9RZ60kneadingandcuttingmachinecanbeequippedwitha15kWelectrical
motor.The9RZC60hasan18hpdieselengine.Bothhaveanoutputof34t/hour,
andaresuitableformediumsizedfarms.
Table65.Specificationsofkneadingandcuttingmachines
9LRZ80

9RZ60

22

1115

With1440%moisture

35

23

With4070%moisture

68

34

Power(kW)
Productivity(t/hour)

Gradeofprocessedmaterial
<50mm

ca78%

50100mm

ca20%

>100mm

ca2%

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Nodebreakingefficiency

>99%

Comparedtoachopper,the9LRZ80cansave2160kWhand1080workdaysfor
processing6000tonneofgreenstalks.Totalsavingsareabout3000.

Pelletingequipment
Afterbeinggroundintomeal,havinghadconcentratesandothernutrientelements
added,strawmakesacompletefeed,andcanbepressedbyapelletingmachine.The
pelletedfeed,containingallnutrients,increasespalatabilityandintake,andatthesame
timedecreasesfeedwasteandreducesfeedingtime.However,thecostofequipment
forpelletprocessingishigh.Themachineconsistsofapelletingdevice,asteam
generator,anoilandmolassesdoser,acoolingdevice,aseparatorandasieve.
Therearetwotypesofpelleters:diskdieandringdiepelleters.
Diskdiepelleter
SeveraldiskdiepelletershavebeenmadeinChina.Figure622showsadiskdie
pelleter,comprisingascrewconveyor,agearbox,astirrerandapelletingdevice.The
screwconveyor,whoserotaryspeedisadjustable,ismainlyusedtocontrolthe
chargingrate.Thestirrersituatedundertheconveyorstirsthematerial,admitting
steamthroughasideholetoheatandcookthematerialwhileitistransferredtothe
pelletingdevice.Insidethediethereare2to4pressrollersandadiskwithmanyholes
(showninFigure623).Inoperation,thediskrotatesataspeedof210rpm.After
fallingontothediskdie,thecookedmealisdistributedevenlybyaspadeandforced
throughtheroundholesofthediebythepress.Thecylindricalpelletsfromthedieare
thencutintopieces1020mmlongbyabladeunderthedisk.Diskpressescanbe
classifiedintothreetypes:movabledie,movablerollerandmovabledieandroller
types.Holediameterinthediecanbe4,6or8mm.Thediameteroftherollerranges
from160to180mm.
Figure622.Pelleterwithdiskdie

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KEY:1.Screwconveyor2.Steaminlet3.Stirrer4.Press5.
Wormwheelbox6.Motor.
Figure623.Operationofthediskdie

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Ringdiepelleter
Theringdiepresshasbeenwidelyusedinengineering.Figure624isanillustrationof
itsoperation.Themainpartsareascrewconveyor,astirrer,apelletingdeviceanda
drivemechanism.Thescrewconveyor,whoserotaryspeedcannormallybechanged
graduallyintherangeof0150rpm,isusedtocontroltheloadingrate.Asideopening
tothestirringchamberallowssteamtobeinjected.Inthestirringcompartment,the
mealismixedwithoversaturatedhighpressuresteam.Sometimesoil,molassesand
otheradditivesareaddedduringmixing.Whenidealconditionscannotbemet,water
canbeusedinsteadofsteam,butinthiscasemixingispoor,outputisdecreased,and
energyconsumptionandfrictionareincreased.
Themixedmealgoesintothepelletingdevice,whichconsistsofaringdieand
pressingrollers.Inoperation,theringdierotates,makingtherollersturnandpressthe
materialthroughthecylindricalholesoftheringdie.Thecylindricalpelletsrotatewith
theringdie,andarecutbyablade.Thelargertheholediameter,thehighertheoutput
ofthemachineandthelowertheenergyconsumption.Holediameterisdeterminedby
animalrequirements.
Figure624.Operationofapelleterwithringdie

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KEY:1.Srewconveyor2.Stirrer3.Steamorairinlet4.Ringdie5.
Rollers6.Cutter.
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Waferingmachineryforroughage
Wafersareabouttentimesthesizeofpellets.Thewaferingmachinemadebythe
GuangdongHuadaMachineryFactorycanmakerectangularwafers2525mmor30
30mm,andalsocylindricalwafersof830mmindiameter.Thedensityvariesfrom
0.6to1.0g/cm3,andthebulkweightfrom0.4to0.6tonne/m3.Theoutputis6001000
kg/hour.Fiveoperatorsareneeded.
The93KWH40wafererandthe93KWHcompletewaferingsethavebeendeveloped
bytheJiangxiHongxingMachineryPlant.Therotaryspeedofthemainpressshaftis
167rpm,theoutputis300600kg/h,andthepowerneeded37kW.Thewhole
system'senergyneedsare62.5kW.
Aftermillingandadditionofconcentrates,chemicaladditivesandotherminerals,the
strawiswaferedtoincreasenutrientvalue,intakeanddigestibility.Thewaferedfeedis
notonlyeasytotransport,tostoreandtofeed,butalsoveryconvenientformarketing
duetoitshighdensity.
Thewaferingprocessisshowninaflowchart(Figure625).Aftersizereduction
(chopping,grinding)toaspecifiedsize,controlledbythescreenholes,roughagesuch
asricestraw,wheatstraw,maizestover,bulrushandsunflowerstemistransportedby
forcedairtothecyclone(2)andthentothebufferingbin(3).Thematerialfromthebin
(3)isconveyedviaadoublescrewconveyor(4)andarationingconveyor(5)tothe
mixer(8),wherechemicaladditivesandconcentratesareaddedseparatelyat
prescribedratesfromhoppers(6and7).Atthesametime,waterandsteamarealso
addedtothemixer.Theuniformlymixedmaterialfallstothewaferingmachine(11)to
bemadeintocubes.Thecubesaretransferredtoahorizontalcooler(13),andthen
droptothepackingmachine.

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