A processing technology of fresh corn stalks after juice extraction and briquetting

Abstract

The application discloses a processing technology of fresh corn straw briquetting after juice extraction, relates to the technical field of straw processing and processing, and selects a press to extract juice from fresh corn straw twice, so as to obtain corn juice and corn straw after juice extraction. The obtained corn straw after juice extraction is conveyed to a height of 5-10 m by a belt conveyor, naturally falls to form a conical heap, and is naturally dried to obtain corn straw with a moisture content of 30-35%. The obtained corn juice is boiled to obtain industrial syrup. The obtained dried corn straw is put into a briquetting machine bin, and is pressed into a columnar or granular shape after two times of briquetting, so as to obtain straw blocks or straw particles. The processing technology of fresh corn straw briquetting after juice extraction replaces the operation of the original four machines, namely, a shredder, a pulverizer, a dryer and a dust remover. The dry straw after juice extraction is dried and briquetted into a columnar or granular shape, and is used as a clean fuel for gasification or combustion. Compared with the previous process, more than 70% of the power consumption can be saved.

Description

Technical Field

[0001] This invention relates to the field of straw treatment and processing technology, specifically a processing technology for pressing fresh corn stalks into blocks after juicing. Background Technology

[0002] The disposal of corn stalks after the autumn harvest has always been an important issue in agricultural production. Previously, corn stalks were typically crushed and then rotary tilled into the soil for return to the field. However, since the straw is not conducive to decomposition in winter, most farmers considered harvesting, drying, chopping, crushing, and dust removal from the stalks. However, this process has the following drawbacks: First, using a combined rotary shredder and pulverizer, with a total power of approximately 120KW and a capacity of 1.5~2t / h, results in low throughput due to the high moisture content of corn stalks. Furthermore, during the crushing process, damp stalks easily clog the pulverizer chamber, and the inclusion of fragments or metal parts damages the pulverizing blades, leading to frequent downtime for maintenance. Second, the dust generated during the pulverizing process is excessive and does not meet environmental protection requirements. To address the dust problem during the fly knife crushing process, technicians used an exhaust fan to draw the crushed material into a pipeline and transport it to a vortex feeder. This was supplemented by multi-stage vortex dust removal and finally, a large bag filter. Although this improvement met environmental protection requirements, the total power required during operation exceeded 220KW, the actual output was ≤2t / h, the accident rate was high, and the electricity cost was as high as 120 yuan / t, making it impossible to promote its large-scale use.

[0003] In addition, directly crushing fresh corn stalks is not only difficult and complicated, but also presents problems such as the large space required for drying the stalks and the difficulty in storing them. Furthermore, since fresh stalks contain a certain amount of sucrose, this sucrose has not been developed and utilized, resulting in a waste of resources.

[0004] The inventor's location is a national and provincial straw energy demonstration base. Since 1997, they have been dedicated to researching the comprehensive utilization of straw. The main goal proposed in 1997 was to collect, crush, and grind autumn-harvested corn stalks into blocks for use in domestic stoves or power plant boilers. Based on the demonstration base layout, they rented 20 acres of land and equipped it with the most advanced straw rotary cutting and crushing equipment in China, with a total power of about 120KW and an output of 1.5-2t / h. However, the equipment used was relatively dry, which easily clogged the crushing and cutting chamber. The mixing of fragments or iron parts damaged the crushing blades, causing frequent shutdowns for maintenance. The key issue was environmental protection measures, mainly due to excessive dust generated during the crushing process.

[0005] Later, based on the lessons learned in 1997, rotary cutting and crushing equipment was added; exhaust fans drew the crushed material from the flying knives into pipelines and transported it to the rotary feeder, with multi-stage rotary dust removal and then large bag filters. The total power exceeded 220KW, with an actual output of ≤2t / h. Its operation and use barely met environmental approval, but no official document was issued. The facility continued to operate intermittently for less than two months before being shut down, mainly due to the high accident rate. Electricity costs alone reached 120 yuan / t, and the amount of dry straw was small; drying wet straw was impractical and inefficient, making the electricity costs unbearable. Crucially, environmental protection remained the primary concern. In Northeast China, the solution was to operate within enclosed large factory sheds to comply with environmental regulations, but this resulted in harsh working conditions.

[0006] In 2013, the inventor began collecting harvested straw at a processing center, where it was first shredded (or chopped) and then crushed (using an integrated machine that shreds (or chops) the straw at the top and crushes it at the bottom). The crushed straw contained too much moisture to be compressed into blocks, so it had to be spread out over a large area or dried in the sun, which took up a lot of space, was inefficient, and had high operating costs. It was very difficult to process more than 20 tons of straw per day, even though it could not keep up with the demand for straw recycling. Summary of the Invention

[0007] To address the aforementioned problems, the present invention aims to provide a processing technology for briquetting fresh corn stalks after juicing. This technology utilizes a sugarcane press to extract juice from fresh corn stalks for sugar production, replacing the functions of a shredder, crusher, dryer, and dust collector—a four-in-one environmentally friendly briquetting (granulation) process. During the stalk harvesting season, fresh stalks are transported from the field to the briquetting station. After being extracted by a multi-stage press, the juice is steamed and boiled into industrial syrup. The dejuiced dry stalks are then processed into 25-35mm briquettes or 8-16mm pellets to become clean fuel for gasification or combustion, thus realizing an effective way to utilize stalks for energy.

[0008] To achieve the above objectives, the present invention employs the following technical solution:

[0009] A process for pressing fresh corn stalks into blocks after juicing includes the following steps:

[0010] ① Use a press to extract juice from fresh corn stalks twice to reduce the moisture content of the stalks, obtaining corn juice and corn stalk residue. The temperature of the corn stalk residue is 40-80℃ and the humidity is 41-47%.

[0011] ② The corn stalk residue obtained in step ① at a temperature of 40-80℃ is conveyed to a height of 5-30 meters by a belt conveyor and falls naturally to form a cone-shaped pile (hill) with a bottom diameter of 10-20 meters and a pointed top. Since the hill area is large enough, the belt conveyor can continuously scatter the residue at a temperature of 40-80℃ onto the surface of the hill at a height of tens of meters. During the scattering process, it is exposed to natural wind and sun. The residue fully releases the 40-80℃ heat and is partially dried naturally to obtain corn stalks with a moisture content of 30-35%.

[0012] The corn juice obtained in step ① is fed into an evaporator or a sugar boiling pot to boil sugar and obtain industrial syrup.

[0013] ③ The dried corn stalks obtained in step ② are put into the feed box of the briquetting machine and pressed into columnar or granular shapes through two briquetting processes to obtain straw blocks or straw pellets, which can be used as clean fuel for gasification or combustion.

[0014] Preferably, the columnar shape is a columnar shape with a diameter of 25-32 mm and a length of 30-150 mm, and the granular shape is a particle with a diameter of 8-16 mm.

[0015] Preferably, the specific steps for step ①, which involves using a press to extract juice from fresh corn stalks twice, are as follows:

[0016] Fresh straw is harvested from the field, loaded onto vehicles, and transported to the briquetting station. The fresh straw is then unloaded into the unpacking machine and conveyed to the first press via the bottom of the unpacking machine or a conveyor belt. During pressing, the sharp teeth of the upper roller cut into the groove at the root of the sharp teeth of the lower roller. Under pressure, the water in the fresh straw is squeezed out, and the shredding function is completed at the same time, resulting in the initial shredded fresh straw.

[0017] The fresh straw, which has been shredded during the initial pressing, is conveyed across the bridge to the next press. During pressing, the sharp teeth of the upper roller cut into the groove at the base of the sharp teeth of the lower roller. Under pressure, the moisture in the fresh straw is squeezed out and it becomes granular, thus completing the functions of crushing and dust removal.

[0018] Preferably, a longitudinally pointed-toothed roller press is used as the press for the first pressing. The longitudinally pointed-toothed roller press includes a frame, on which a fixed pressing roller, a bearing seat, a first sliding pressing roller, and a second sliding pressing roller are mounted. The first sliding pressing roller is equipped with a first sliding bearing seat and a first sliding pressing roller top screw. The second sliding pressing roller is equipped with a second sliding bearing seat and a second sliding pressing roller top screw. The first sliding pressing roller is connected to an auxiliary pressing roller, which is equipped with a bearing seat. A guide funnel plate is provided between the first and second sliding pressing rollers. The first sliding pressing roller is provided with pointed teeth.

[0019] In a further preferred embodiment, during assembly, the first sliding press roller, the second sliding press roller, and the fixed press roller are engaged with the sharp-angled teeth in a manner that is offset by half.

[0020] Preferably, straw blocks or straw pellets are used as fuel during sugar boiling. The distilled water at several tens of degrees Celsius is heated by heat exchange and becomes a distilled water product. During the cold season, the waste heat of the distilled water generated during sugar boiling is used for heating. The resulting industrial syrup is used as a feed additive or for processing ethanol or butanol.

[0021] Preferably, in step ①, a press is used to juice the fresh corn stalks twice. During the first and second juicing processes, a longitudinal pressing toothed roller press is connected in series with a transverse pressing toothed roller press.

[0022] Preferably, the residue from the secondary pressing process has been heated to 40-80℃ and is transported by belt for tens of meters to the surface of the hill. It contains 41-47% moisture. At a temperature of 40-80℃, the residue naturally releases some heat, which is also moisture. The 40-80℃ temperature is based on three years of operation results. It is feasible and consistent with theoretical calculations to reduce the humidity from 41-47% to 30-35%. With the addition of auxiliary blowing and sun drying (at a temperature of 15-25℃), it is easy to obtain corn stalk residue with a humidity of 30-35% in a few to tens of hours, and complete the functions of sun drying, chopping, crushing, drying and dust removal.

[0023] Preferably, corn stalk residue is pressed into briquettes using a two-machine system: taking a 2t / h briquette press as an example, two machines are connected in series to press and compact the residue, achieving a moisture content of around 30%. When the first machine operates at 4t / h, the high moisture content of the residue results in poorly formed, constantly steaming briquettes with a temperature exceeding 30℃, which are then fed into the second machine for pressing. The second machine, without internal friction heating, directly presses the residue. After three years of operation, the output remains at 4t / h, with an average of 2t / h. This demonstrates that the primary advantage lies in the heating of the semi-finished product formed by the first machine, which releases steam as it enters the second machine. This reduces the moisture content of the residue by more than 5%, resulting in well-shaped briquettes.

[0024] The present invention has the following advantages over the prior art:

[0025] The processing technology for pressing fresh corn stalks into briquettes after juicing, as described in this invention, replaces the operation of the original four machines: shredder, crusher, dryer, and dust collector. Fresh stalks are transported from the field to a briquetting station, where they are pressed through a multi-stage press to extract corn juice. This juice is then processed into industrial syrup through steaming and boiling. The dejuiced dry stalks are dried, pressed into columnar or granular shapes, and used as clean fuel for gasification or combustion, providing an effective way to utilize stalk energy. Compared to previous processes, this method can save more than 70% of electricity consumption, achieving a combination of low power consumption and dust-free environmental protection.

[0026] To verify the advantages of pressing straw instead of crushing, drying, and electricity consumption, the following comparison was made: The original rotary cutter and crusher blows in the material through a blower, removes dust through the blower, and then removes dust again through a large cloth bag to produce fuzzy straw fragments with a moisture content of ≤25%. After repeated pressing by rollers in the briquetting machine, the electricity consumption is more than 130 kWh / t per ton of briquetting.

[0027] Compared with the original technology, which involves rotary cutting and crushing, the weight of corn stalks after juicing and pressing is 90-130 kg per stalk. However, the weight of corn stalks after juicing and pressing is 180-260 kg per stalk. The corn stalks after juicing and pressing are smaller in volume and have a higher weight ratio, which is the reason why pressing the briquettes saves electricity and increases the yield.

[0028] A comparison of the productivity of repeated briquetting processing was conducted using a briquetting machine with a rated output of 1.5 t / h. The output results for the two types of raw materials were as follows: ① Rotary cutting and crushing materials reached 0.9-1.5 t / h (normal), and repeated (secondary) briquetting reached 1.5-2.1 t / h; ② Pressed materials reached 1.8-2.4 t / h, and repeated briquetting reached 3.6-4.8 t / h. The pressed raw materials were compact and free of fibrous material, resulting in a significant increase in briquetting output, while electricity costs were reduced by exactly half.

[0029] The comprehensive utilization of straw for energy has been carried out by the state for more than 20 years, but the results are not obvious. The reasons are that problems such as straw drying and removal from the field, processing equipment and crushing technology, environmental protection, cost, and the short interval between autumn harvest and autumn planting restrict development. The invention of this invention, patent number ZL201210215366.1, produces gas in a pure oxidizer to drive a gas-fired internal combustion generator to generate electricity. The fresh straw produced as raw material is compressed into blocks and reacts very well in pure oxygen oxidization. The composition of the produced gas is basically stable at H2=40-49%, CO=27-35%, CO2=20-25%, CH4=3-5%, O2≤0.9%, N2≤3-4%, gas cleanliness≤20mg / m³, calorific value 2400-2600 kcal / m³, and gas production per ton is 1200-1300 m³.

[0030] This invention relates to a process for processing fresh corn stalks into briquettes after juicing. The first press performs primary pressing, followed by a second press. The juice is collected and sent to a sugar-boiling workshop. After juicing, the stalk material is in flake form with a tested moisture content of 41-47%. It is first conveyed by a 20-meter belt conveyor to a height of 6 meters before naturally falling. After several days of continuous pressing, it forms a conical pile with a bottom diameter of over ten meters and a pointed top. After hundreds of tons of pressing, the moisture content of the pile can be reduced to as low as 34-45% through natural space and time, eliminating the need for air drying, sun drying, and oven drying. The material can then be continuously fed into the briquetting machine's hopper by a single trolley. The briquetting machine has a production rate of 1.8-2.4 t / h for one pass and 3.6-4.8 t / h for two passes. This process ensures that fresh straw is removed from the field without touching the ground, avoiding the drying and sun-drying processes that could affect autumn planting. The pressing station's press produces raw liquid at the bottom and straw and flaky material at the top. This completely eliminates the need for rotary or flying-cut crushing and achieves dust-free operation. Pressing extracts the juice without requiring a drying or sun-drying system. The raw liquid is a valuable ingredient for sugar production. The fresh straw, pressed without touching the ground, produces flaky material with very little soil content, resulting in well-formed briquettes. The process is energy-efficient and has a higher calorific value than air-drying. Attached Figure Description

[0031] Figure 1 This diagram illustrates the connection of the presses in series during the two-stage juicing process; I, II, and III represent the first, second, and third stages of pressing, respectively.

[0032] Figure 2 for Figure 1 A schematic diagram of the longitudinal press in the middle; Figure 3 for Figure 2 View from direction A;

[0033] Figure 4 for Figure 1 Schematic diagram of a double-roll press for medium-sized steel mills; Figure 5 for Figure 4 A-direction view. Implementation

[0034] The purpose of this invention is to provide a processing method for pressing fresh corn stalks into blocks after juicing, which is achieved through the following technical solution:

[0035] A process for pressing fresh corn stalks into blocks after juicing includes the following steps:

[0036] ① Use a press to juice the fresh corn stalks twice to reduce the moisture content of the stalks, obtaining corn juice and the juiced corn stalks. The moisture content of the juiced corn stalks is 41-47%.

[0037] ② The corn stalks obtained from juicing in step ① are conveyed to a height of 5-10 meters by a belt conveyor and then naturally fall to form a cone-shaped pile with a bottom diameter of 10-20 meters and a pointed top. They are then naturally dried to obtain corn stalks with a moisture content of 30-35%.

[0038] The corn juice obtained in step ① is fed into an evaporator or a sugar boiling pot to boil sugar and obtain industrial syrup.

[0039] ③ The dried corn stalks obtained in step ② are put into the briquetting machine's feed box and briquetting them twice to form columnar or granular shapes, which can then be used as clean fuel for gasification or combustion.

[0040] This invention discloses a processing technology for pressing fresh corn stalks into briquettes after juicing. This technology replaces the four processes of sun-drying, shredding, crushing, drying, and dust removal required for pressing fresh corn stalks into briquettes (granules) by immediately pressing them into juice without letting them fall to the ground. Based on integrated technology, dozens of combine harvesters are deployed from townships and villages, covering dozens of acres per machine, hundreds of acres or even thousands of acres per machine, with 2-3 times the number of transport vehicles, achieving large-scale production. The briquettes are ultimately processed into cylindrical blocks with a diameter of φ30-35mm. This process utilizes both new and clean energy sources, ensuring timely pressing of the stalks without letting them fall to the ground, thus facilitating efficient and mechanized agricultural harvesting.

[0041] The press is preferably made of two press rollers with a diameter of 0.6~1.2 meters connected in series. The first press has a power of 100~300kw for primary pressing and desiccation, and the second press has a power of 100~400kw for secondary pressing to reduce the moisture content of the straw to below 43%. The straw is then transported by belt conveyor to a height of more than ten meters and scattered in the stacking space for more than ten hours, where 5~15% of the moisture is naturally evaporated and reduced to below 35%. Then the straw is fed into two pressing and forming machines with a power of 200~400kw, and the pressing process is completed through two pressing processes.

[0042] During the autumn harvest in rural communities, corn is harvested in designated areas and directly loaded into vehicles or separated using combine harvesters. The straw is chopped inside the machine and discharged into the vehicles, preventing it from touching the ground and eliminating the need for drying before pressing into briquettes. The briquetting station serves as the collection center for this invention in rural areas. The process of pressing straw into juice can perfectly replace dust-free chopping (shredding). After pressing, the straw residue has a moisture content of ≤43%. It is then conveyed by a conveyor belt to a height of over ten meters, naturally falling to form cone-shaped mounds. After more than ten hours of resting, the moisture content evaporates further to below 40%, allowing for direct briquetting.

[0043] This invention provides a processing technology for pressing fresh corn stalks into blocks after juicing. This process eliminates the steps of sun-drying, drying, cutting (tearing), crushing, and dust removal, achieving high output, labor saving, electricity saving, and low accident rate. It fundamentally solves the problem of fresh stalks not falling to the ground or leaving the field, achieving large-scale, highly mechanized, labor-saving, cost-saving, and environmentally friendly results. This creates an effective way for the comprehensive utilization of fresh corn stalks.

[0044] This invention discloses a processing technology for pressing fresh corn stalks into briquettes after juicing. This technology changes the cumbersome traditional method of processing stalks, which involves laying them on the ground, air-drying them, then shredding, crushing, dust removal, and finally drying them again before pressing them into briquettes. The new process uses a sugarcane press for initial pressing, followed by a second high-intensity press to extract corn juice (syrup concentrate) with a sugar content of 8-15%. This juice is then concentrated into industrial syrup or sugar. The pressing process replaces air-drying, shredding, crushing, drying, and dust removal. The extracted stalk residue, with a moisture content of 30-46%, is formed into granules. With increased density, the moisture content can be controlled at 35-50%, allowing for direct and repeated pressing into briquettes. This residue can be used as biomass fuel or gasification feedstock, and high-temperature pyrolysis produces high-quality gas for use in gas-fired internal combustion engine cogeneration, domestic applications, kilns, and gas-fired boilers.

[0045] The present invention provides a processing method for pressing fresh corn stalks into blocks after juicing, which replaces shredders, crushers, dust collectors, and dryers to achieve the goal of pressing into blocks (granules) while being environmentally friendly and energy-saving. The steps are as follows:

[0046] ① Harvest fresh straw from the fields and promptly remove it from the fields to the pressing (block) station.

[0047] ② Fresh straw is unloaded into the dismantling machine or material yard at the pressing (block) station. It is then conveyed or carried into the first pressing machine through the bottom of the dismantling machine. When the paired pressing rollers press, dozens of sharp teeth (ribs) on the upper roller deeply cut into the grooves at the base of the sharp teeth (ribs) on the lower roller. Under the strong pressure, the straw is squeezed out and the water (juice) is released. After collection, it is boiled into syrup. At the same time, the functions of tearing (chopping) and dehydrating (juicing) fresh straw are completed.

[0048] ③ The fresh straw shredded by the first press is conveyed to the next press (roller) through a steel comb bridge. The paired press (roller) rollers have dozens of sharp teeth (ribs). The sharp teeth (ribs) of the upper press roller cut deeply into the groove at the root of the sharp teeth (ribs) of the lower press roller, pressing with strong pressure. During the cutting process, water (juice) is squeezed out. At the same time, the functions of crushing the fresh straw into fine particles of ≤200mm by the steel comb and dehydrating (juice) the fresh straw are completed.

[0049] ④ Through the functions and effects of ② and ③; when the fresh straw contains 50-70% water (juice), it is pressed instead of shredding, cutting (crushing), and pressing to remove juice (air drying). After being dropped from a high altitude by a belt conveyor and naturally volatilized again, the water content drops to 30-48%, and it can be directly fed into a briquetting machine to produce columns with a diameter of Ф25-35mm and a length of 30-200mm (called straw briquettes).

[0050] ⑤ By adding a heavy-duty twin-roll mill to replace the second sharp-tooth (ribbed) roll, the water (juice) content of fresh straw can be reduced to 15-46% through repeated pressing. Alternatively, the flue gas from the heating boiler used for evaporating syrup can be used for drying, so that the straw can be directly fed into the pellet mill to produce cylindrical pellets (called straw pellets) with a diameter of Ф8-16mm and a length of 30-100mm.

[0051] ⑥ After the corn juice is extracted through ②③ and boiled into syrup in an evaporator or sugar boiling pot, it enters the sugar base industry chain. Priority is given to sugar boiling and ethanol processing to make the fresh corn stalks dry and fully utilized, thereby improving efficiency.

[0052] ⑦ The above-described ③④⑤ integrates the four mechanical functions of existing shredders, crushers, dryers, and environmental dust collectors into one unit, effectively replacing the existing shredders, crushers, dryers, and environmental dust collectors for fresh straw shredding, crushing, and dehydration (juice extraction) during pressing. The pressing rollers utilize radially machined sharp-angled teeth (ribs); cutting replaces shredding, shearing replaces crushing, and dehydration (juice extraction) during pressing replaces drying. This saves electricity, simplifies equipment, saves fuel during drying, and eliminates dust and noise sources. The extracted juice is used to process industrial syrups, ethanol, butanol, and other products. Its output reaches 5t / h, 10t / h, 20t / h, and 50t / h, enabling large-scale factory processing. Within a rural area, harvesting, shredding, crushing, drying, and dust removal are completed in approximately 45 days. Simultaneously, the straw juice is concentrated into syrup, eliminating pollution issues and producing only distilled water. The dried straw residue (granules) after pressing is processed into pellets, multiplying economic benefits and laying the foundation for exhausting straw and realizing energy utilization.

[0053] Preferably, the pressing machine is a combination of two structures and performances: a pressing machine with sharp-angled teeth (ribs) and a heavy-duty double-roller 22 or 23 pressing machine with sharp-angled teeth (ribs). The pressing machine uses the strong pressure of dozens of sharp-angled teeth (ribs) of the pressing rollers to extract fresh straw juice (dehydrated (juice)). Then, heavy-duty rolled steel structure rollers are added to process the sharp-angled teeth (ribs) rollers to make strong high-pressure pressing to reduce the straw moisture (juice) content to ≤45%, or to compress it into granules of ≤50mm for use as fuel.

[0054] Preferably, the rollers 22 and 23 of the heavy-duty twin-roll mill are modified with sharp-angled teeth (ribs) 24 to repeatedly press the straw under high pressure. The moisture content is ≤35%. The straw is cut into ≤200mm pellets and flakes by comb plates 25 and 26, which reduces the cost of converting straw into fuel by several times.

[0055] Preferably, a yellow silage combine harvester is used (or a modified version) to feed silage by feeding shredded straw into transport vehicles for further pressing and juicing. After juicing, the straw residue is conveyed by a belt conveyor to a height of over ten meters to air dry naturally for more than ten hours, piling it into cones tens of meters high. The moisture content is below ≈35% (and can reach ≤35% after loosening), allowing it to be directly pressed into shaped raw materials, eliminating the need for further drying, shredding, or crushing. Drying or air drying in a dryer also requires a complex dust removal system.

[0056] Preferably, the juice extracted from fresh corn stalks immediately after cutting and removing them from the field contains 6-15% sugar, achieving harvesting without touching the ground, realizing large-scale mechanization, large-scale harvesting, and timely dehydration of the stalks into storable raw materials. Fresh corn stalks refer to harvested yellow silage stalks. The stalks harvested from mature corn contain 10%-50% moisture, that is, the juice (water) is extracted in a timely manner after harvesting and separating the corn.

[0057] Ideally, the autumn harvest and autumn planting are only a short time apart. Removing fresh straw from the field avoids mutual interference, while extracting juice from the fresh straw for sugar production adds added value and lays the foundation for the comprehensive utilization of corn straw. This process, which involves both juice extraction and sugar production, also produces straw residue that can be directly pressed into briquettes (pellets) without the need for drying, shredding, crushing, drying, or dust removal. The resulting briquettes (pellets) can be used as clean fuel or for efficient power generation and heating in gasified internal combustion engines. They are also high-quality domestic fuel or a primary ingredient in silage feed.

[0058] Pressing, replacing shredding, crushing, and sun-drying, fundamentally solves the decades-old problem of environmental constraints on the comprehensive utilization of straw. The equipment boasts a high degree of automation, saving labor and energy while maintaining a good working environment that meets environmental requirements. Fresh straw is removed from the field; primary pressing replaces shredding; repeated pressing replaces crushing; juice extraction replaces drying (sun-drying); and static pressure from the press rollers replaces dust removal for straw briquettes (granules), achieving clean, low-energy consumption, and mechanized operation. This fundamentally addresses the limitations of straw sun-drying (air-drying), shredding, crushing, drying, dust removal, and briquette (granule) processing that hinder comprehensive straw processing and utilization.

[0059] Fresh straw, after being removed from the field and juiced, can be used as straw feed. After storage, it becomes a high-quality feed with a long shelf life, fundamentally solving the difficulties in feed replacement and storage for cattle, sheep, ducks, geese, and rabbits. The fresh straw in this invention refers to corn and sorghum straw produced during the harvest season, which can be processed into reeds, grasses, branches, bark, leaves, and plant stems, and does not contain any iron-containing waste.

[0060] Fresh corn stalks are removed from the field and sent to a pressing (block) station to extract juice containing 6-15% sugar. This juice is then fed into an evaporator or boiling pot to produce industrial syrup, primarily used as a feed additive or in the processing of ethanol, butanol, and other products. During the boiling process, distilled water at several tens of degrees Celsius is heated through heat exchange to become distilled water. To ensure the complete utilization of fresh stalks, boiling is prioritized to increase the production of dry sugar, thus significantly increasing economic value. Furthermore, increasing the production of dry sugar from fresh stalks further reduces the amount of stalk residue, resulting in substantial economic benefits.

[0061] With a limited time gap between autumn harvest and autumn planting, removing fresh straw from the field avoids mutual interference. Extracting juice from the fresh straw for sugar production adds added value and lays the foundation for the comprehensive utilization of corn straw. This process, which involves both juicing and sugar production, produces straw residue that can be directly pressed into briquettes (pellets) without the need for drying, shredding, crushing, drying, or dust removal. The resulting briquettes (pellets) can be used as clean fuel, or for efficient power generation and heating in gasified internal combustion engines. They also serve as high-quality fuel for domestic use or as a primary source of green fodder. During the cooler season of sugar production, the waste heat from distilled water can be used for heating, effectively and inexpensively utilizing thermal energy again.

[0062] Fresh straw is removed from the field, and initial pressing replaces chopping, repeated pressing replaces pulverizing, and juice extraction replaces drying (air drying). Static pressure from the pressing rollers replaces dust removal for straw briquettes (granules), achieving clean, low-energy consumption, and mechanized operation. This fundamentally solves the problem of straw drying (air drying), shredding, pulverizing, drying, dust removal, and briquetting (granulation) restricting the comprehensive processing and utilization of straw.

[0063] The straw residue after fresh straw is removed from the field and juiced is stored as high-quality feed that can be stored for several years after being dried or slightly dried. This solves the problem of feed continuity and storage for cattle, sheep, rabbits, etc. at the source. At the same time, the boiled syrup is preferred to be used to replace grains at a rate of 3-10% to create a high-calorie premium feed.

[0064] The present invention will be further described below with reference to specific embodiments. Example

[0065] A process for pressing fresh corn stalks into blocks after juicing includes the following steps:

[0066] ① Use a press to juice the fresh corn stalks twice to reduce the moisture content of the stalks, obtaining corn juice and the juiced corn stalks. The moisture content of the juiced corn stalks is 41-47%.

[0067] ② The corn stalks obtained from juicing in step ① are conveyed to a height of 5-10 meters by a belt conveyor and then naturally fall to form a cone-shaped pile with a bottom diameter of 10-20 meters and a pointed top. They are then naturally dried to obtain corn stalks with a moisture content of 30-35%.

[0068] The corn juice obtained in step ① is fed into an evaporator or a sugar boiling pot to boil sugar and obtain industrial syrup. Straw blocks or straw pellets can be used as fuel during the sugar boiling process. The distilled water at tens of degrees Celsius becomes a distilled water product after heat exchange during the sugar boiling process. During the cold season, the waste heat of the distilled water generated during the sugar boiling process is used for heating. The industrial syrup obtained is used as a feed additive or for processing ethanol or butanol.

[0069] ③ The dried corn stalks obtained in step ② are put into the feed box of the briquetting machine and pressed into columnar or granular shapes through two briquetting processes to obtain straw blocks or straw pellets, which can be used as clean fuel for gasification or combustion.

[0070] The columnar shape mentioned above has a diameter of 25-32 mm and a length of 30-150 mm, while the granular shape has a diameter of 8-16 mm.

[0071] Step ① involves using a juicer to extract juice from fresh corn stalks twice. The specific steps are as follows:

[0072] Fresh straw is harvested from the field, loaded onto vehicles, and transported to the briquetting station. The fresh straw is then unloaded into the unpacking machine and conveyed to the first press via the bottom of the unpacking machine or a conveyor belt. During pressing, the sharp teeth of the upper roller cut into the groove at the root of the sharp teeth of the lower roller. Under pressure, the water in the fresh straw is squeezed out, and the shredding function is completed at the same time, resulting in the initial shredded fresh straw.

[0073] The fresh straw, which has just been crushed, is conveyed across a bridge to the next press. During the pressing process, the sharp teeth of the upper roller cut into the groove at the base of the sharp teeth of the lower roller. Under pressure, the moisture in the fresh straw is squeezed out and it becomes granular. Example

[0074] A processing technology for pressing fresh corn stalks into briquettes after juicing, which replaces the existing shredding, crushing, dehydration, dust removal, and briquetting processes with chopped corn stalks, saving 70% of electricity and integrating environmental protection, specifically includes the following steps:

[0075] ① The fresh straw in the field is harvested, loaded into vehicles, and transported to the briquetting station;

[0076] ② Fresh straw enters the briquetting station and is unloaded into the unpacking machine. It is then conveyed to the first press by the bottom of the unpacking machine or by a trolley. When the paired press rollers press, dozens of sharp teeth on the upper roller deeply cut into the grooves at the base of the sharp teeth on the lower roller. The strong pressure squeezes the straw and squeezes out the water, while simultaneously tearing (chopping) and dehydrating the fresh straw.

[0077] ③ The fresh straw that has been shredded by the first press is transferred to the next press through a bridge. The pair of press rollers with dozens of horizontal sharp teeth have the sharp teeth of the upper press roller deeply cut into the groove at the root of the sharp teeth of the lower press roller, and press with strong pressure to squeeze out the water again and become granules. At the same time, the functions of crushing and dehydrating fresh straw are completed.

[0078] ④ Through the functions and roles of ② and ③; when the moisture content of fresh straw is 50-70%, it is reduced to 30-45% after being cut (shredded) and pressed to dehydrate it, and can be directly fed into a briquetting machine to produce cylindrical blocks with a diameter of Ф25-35mm and a length of 30-200mm (called straw briquettes).

[0079] ⑤ By adding a heavy-duty steel rolling mill or a high-powered press based on the functions described in ③ and ④, the moisture content of fresh straw can be reduced to 15-30%. It is preferable to use the flue gas discharged from the syrup boiling boiler for drying, so that it can be directly fed into the pellet mill to produce cylindrical pellets with a diameter of Ф8-16mm and a length of 30-100mm (called straw pellets).

[0080] ⑥ Extract the juice from the corn stalks through steps ④ and ⑤, then boil it in a boiler to make syrup for sale.

[0081] ⑦ The above-described ③④⑤ integrates the four functions of shredding, crushing, and dehydrating fresh straw into one unit, effectively replacing the existing shredder, crusher, dryer, and environmental dust removal equipment. The pressing roller utilizes a radially machined, sharp-angled toothed mechanism to simultaneously cut instead of shredder, shear instead of crusher, and dehydrate instead of dryer, saving electricity and fuel while eliminating dust and noise sources. The extracted juice is used for processing industrial syrups, ethanol, butanol, and other products. Its output reaches 5t / h, 10t / h, 20t / h, and 50t / h, enabling large-scale factory processing. Within a rural area, shredding, crushing, drying, and dust removal can be completed in approximately 25 days. Simultaneously, the extracted straw juice is concentrated into syrup, eliminating pollution issues. Processing the dried straw into pellets after pressing significantly increases economic benefits, laying the foundation for straw energy utilization. Example

[0082] The steps are the same as in Example 2, except that a longitudinal pressing toothed roller press is used in series with a transverse pressing toothed roller press during the first and second pressing processes, such as... Figure 1 As shown, a longitudinal heavy-duty press is used, utilizing the powerful pressure exerted by dozens of sharp teeth on the press rollers to extract juice from fresh straw (dehydration). Specifically:

[0083] like Figures 2-3 As shown, the longitudinal pointed-angle toothed roller press is used as the press for the first pressing of juice. The longitudinal pointed-angle toothed roller press includes a frame 1, a fixed pressing roller 2, a bearing seat 7, a first sliding pressing roller 3, and a second sliding pressing roller 4. The first sliding pressing roller 3 is equipped with a first sliding bearing seat 8 and a first sliding pressing roller set screw 13. The second sliding pressing roller 4 is equipped with a second sliding bearing seat 9 and a second sliding pressing roller set screw 12. The first sliding pressing roller 3 is connected to an auxiliary pressing roller 10. The auxiliary pressing roller 10 is equipped with a seat 6. A guide funnel plate 5 is set between the first sliding pressing roller 3 and the second sliding pressing roller 4. The first sliding pressing roller 3 is provided with pointed teeth 11.

[0084] Each pressing roller is machined with pointed teeth 11 with a spacing of 8mm, 10mm, and 12mm. The tooth root width and tooth height (depth) are equal to the spacing between rows. During assembly, the first sliding pressing roller 3, the second sliding pressing roller 4, and the fixed pressing roller 2 engage with the pointed teeth in a staggered manner, meaning that the pointed teeth of the upper roller penetrate deep into the root of the pointed teeth of the lower roller to form a cutting and pressing action, causing the straw to be pressed and cut (shredded). At the same time, the strong pressing force squeezes out the water, completing the shredding and dehydration.

[0085] The auxiliary pressing roller 10 mainly uses sharp-angled teeth 11 to mesh well with the sliding pressing roller 3, so as to feed the material evenly and powerfully. The fixed pressing roller 2, the first sliding pressing roller 3, the second sliding pressing roller 4 and the auxiliary pressing roller 10 are driven by the gear tooth setting to form a longitudinal meshing tangent and operate synchronously, so that the fresh straw is pushed forward longitudinally to be shredded.

[0086] Furthermore, such as Figures 4-5 As shown, after the second pressing, a modified roll 22 from a first heavy-duty twin-roll mill and a modified roll 23 from a second heavy-duty twin-roll mill are added. The modified roll 22 from the first heavy-duty twin-roll mill and the modified roll 23 from the second heavy-duty twin-roll mill have second sharp teeth 24. The strong high pressure repeatedly presses the straw, and the moisture content ≤35% is cut into ≤20mm flakes and formed into fuel by the first comb plate 25 and the second comb plate 26, so that the cost of converting straw into fuel is reduced by several times.

[0087] Furthermore, the press rollers are radially machined with sharp-angled teeth 11, which can be symmetrical or asymmetrical triangular, or trapezoidal teeth can also be used. When the double-paired press rollers rotate longitudinally and interlock, the straw is longitudinally fed into the interlocking sharp-angled teeth, where it is torn apart within the sharp-angled spacing, resulting in concentrated pressing. Under pressure, the straw is compressed, and the moisture inside the straw is removed during the compression process. The interlocking sharp-angled teeth control the straw within the interlocking space, compressing and tearing it. The fresh straw is compressed and dehydrated, and the tearing is completed simultaneously. This sugarcane press, connected in series, integrates fresh straw juicing, shredding, crushing, dehydration, and environmental protection. It uses heavy-duty double-roll mill rollers 22 and 23 with sharp-angled teeth 24, applying high pressure to repeatedly press the straw. With a moisture content ≤35%, the straw is cut into ≤20mm flakes by comb plates 25 and 26 to form fuel, significantly reducing the cost of converting straw into fuel.

[0088] The present invention provides a processing method for pressing fresh corn stalks into blocks after juicing, which utilizes two types of pressing rollers with different diameters:

[0089] (a) Standard type

[0090] For straw processing capacities of 5t / h, 10t / h, and 15t / h, the diameter of the press rollers is 300~600mm.

[0091] (ii) Heavy

[0092] ① For straw processing capacities of 20t / h, 40t / h, and 60t / h or above, the diameter of the press rollers is 600~1000mm.

[0093] ②According to ①The press rollers are arranged vertically, and the first pair of rollers are arranged in a triangular pattern with dimensions of 30mm, 50mm, etc., for compression, shredding, and dewatering.

[0094] ③As described in ②, the sharp corner teeth of the second pressing roller are 15mm, 25mm, etc., and are used for compression, shredding, and further dehydration.

[0095] A third step can be added for compression molding and dehydration.

[0096] The last section consists of modified rolls 22 and 23 from the first heavy-duty twin-roll mill, both of which are sheared, pointed-toothed press rolls used to cut straw into granular sizes of 3-10mm, 20mm, 30mm, 40mm, etc.

[0097] When a three-roller straw press is used to press straw, with a feed rate of 90 kg per cycle, the average juice yield is:

[0098] After the first press, 90kg of corn stalks were pressed into 36kg; after the second press, 36kg of corn stalks were pressed into 32kg. This translates to at least 600-700kg of sugar solution per ton of fresh stalks. When the moisture content of the corn stalk fragments is ≤39% as measured by an electronic hygrometer, it can be used for briquetting.

[0099] This invention employs a series combination of multiple presses to process fresh corn stalks into briquettes after juicing. The pressing process perfectly replaces shredders, crushers, dryers, and dust removal equipment, ensuring timely entry of fresh stalks into briquettes or granules. Simultaneously, the stalks are crushed and shredded, resulting in uniformly finely chopped dry stalks. In other words, the process of stalk shredding, crushing, drying, and dust removal has been completely transformed, utilizing pressing to extract juice while repeatedly crushing and shredding the stalks into granules for easier briquetting or granulation. The extracted juice, containing 8%-13% sugar, can be used to make sugar or ethanol, replacing cassava, dried melon, and grains, effectively reducing grain consumption and costs by 50%.

Claims

1. A processing method for pressing fresh corn stalks into blocks after juicing, characterized in that: Includes the following steps: ① Use a press to extract juice from fresh corn stalks twice to reduce the moisture content of the stalks, obtaining corn juice and corn stalk residue. The temperature of the corn stalk residue is 40-80℃ and the humidity is 41-47%. The first and second juicing processes are carried out using a longitudinal pressing sharp-toothed roller press connected in series with a transverse pressing sharp-toothed roller press. ② The corn stalk residue obtained in step ① is conveyed to a height of 5-30 meters by a belt conveyor and falls naturally to form a cone-shaped pile with a bottom diameter of 10-20 meters and a pointed top, called a hill. Since the hill area is large enough, the belt conveyor continuously scatters the residue at a temperature of 40-80℃ onto the surface of the hill. During the scattering process, it is exposed to natural wind and dried. The residue fully releases the 40-80℃ hot steam and is partially dried naturally to obtain corn stalks with a moisture content of 30-35%. The corn juice obtained in step ① is fed into an evaporator or a sugar boiling pot to boil sugar and obtain industrial syrup. ③ The dried corn stalks obtained in step ② are put into the briquetting machine hopper and pressed into columnar or granular shapes after two rounds of briquetting to obtain straw blocks or straw pellets, which can be used as clean fuel for gasification or combustion. A longitudinally pointed-tooth roller press is used as the press for the first pressing. The longitudinally pointed-tooth roller press includes a frame (1), a fixed pressing roller (2) is set on the frame (1), a bearing seat (7), a first sliding pressing roller (3), and a second sliding pressing roller (4). The first sliding pressing roller (3) is equipped with a first sliding bearing seat (8) and a first sliding pressing roller top screw (13). The second sliding pressing roller (4) is equipped with a second sliding bearing seat (9) and a second sliding pressing roller top screw (12). The first sliding pressing roller (3) is connected to an auxiliary pressing roller (10). The auxiliary pressing roller (10) is equipped with a seat bearing (6). A guide funnel plate (5) is set between the first sliding pressing roller (3) and the second sliding pressing roller (4). The first sliding pressing roller (3) is equipped with pointed teeth (11). During assembly, the first sliding press roller (3), the second sliding press roller (4) and the fixed press roller (2) are engaged with each other by half the angled teeth.

2. The processing method for pressing fresh corn stalks into blocks after juicing, as described in claim 1, is characterized in that: The columnar shape has a diameter of 25-32 mm and a length of 30-150 mm, and the granular shape has a diameter of 8-16 mm.

3. The processing method for pressing fresh corn stalks into blocks after juicing, as described in claim 1, is characterized in that: Step ① involves using a juicer to extract juice from fresh corn stalks twice. The specific steps are as follows: Fresh straw is harvested from the field, loaded onto vehicles, and transported to the briquetting station. The fresh straw is then unloaded into the unpacking machine and conveyed to the first press via the bottom of the unpacking machine or a conveyor belt. During pressing, the sharp teeth of the upper roller cut into the groove at the root of the sharp teeth of the lower roller. Under pressure, the water in the fresh straw is squeezed out, and the shredding function is completed at the same time, resulting in the initial shredded fresh straw. The fresh straw, which has been shredded during the initial pressing, is conveyed across the bridge to the next press. During pressing, the sharp teeth of the upper roller cut into the groove at the base of the sharp teeth of the lower roller. Under pressure, the moisture in the fresh straw is squeezed out and it becomes granular, thus completing the functions of crushing and dust removal.

4. The processing method for pressing fresh corn stalks into blocks after juicing, as described in claim 1, is characterized in that: Straw blocks or straw pellets are used as fuel during sugar boiling. The distilled water from the sugar boiling process is used for heating after heat exchange and becomes a distilled water product. When the sugar boiling is in the cold season, the waste heat of the distilled water is used for heating again. The resulting industrial syrup is used as a feed additive or for processing ethanol or butanol.

5. The processing method for pressing fresh corn stalks into blocks after juicing, as described in claim 1, is characterized in that; During the secondary pressing process, the residue is heated to 40-80℃ and is transported by belt to the surface of the hill. It contains 41-47% moisture. At a temperature of 40-80℃, the residue naturally releases some heat, which is also moisture. With the addition of auxiliary blowing and drying, corn stalk residue with a moisture content of 30-35% is obtained, and the functions of drying, chopping, crushing, drying and dust removal are completed.

6. The processing method for pressing fresh corn stalks into blocks after juicing, as described in claim 1, is characterized in that; The corn stalk residue is pressed into briquettes using a two-machine system.

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