Rice bran oil decolorizing system

Abstract

The invention belongs to the field of equipment monitoring, and particularly discloses and provides a rice bran oil decolorizing system which comprises a decolorizing agent supply unit, a grease pretreatment unit, a mixed decolorizing unit, a separation unit and a control system, the control system is based on dynamic optimization of an AI model, the lowest necessary carclazyte addition amount is accurately matched according to the real-time quality of feeding oil, automatic and intelligent decoloration is achieved in the whole process from adsorbent adding, temperature control to filtering and cleaning, and a circle of large-scale and intensive rice bran oil production is formed.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of oil processing, and relates to a rice bran oil decolorization system. BACKGROUND

[0002] The decolorization process is a key core link in the rice bran oil refining process, and its main purpose is to effectively remove various pigments, residual soapstock, trace metal ions and oxidative degradation products in oil by using the selective adsorption of adsorbents (mainly activated clay, sometimes supplemented with activated carbon). This process not only directly determines the final color and appearance clarity of the finished oil, but also is a prerequisite for ensuring the smooth progress of the subsequent deodorization process, improving the oxidative stability of the oil and prolonging the shelf life.

[0003] At present, the decolorization process commonly used in the domestic and foreign rice bran oil refining industry is still mainly based on the intermittent decolorization tank technology. Its typical operation process is as follows: the rice bran oil treated by the previous degumming and deacidification is transported to a normal pressure or reduced pressure decolorization tank equipped with stirring and heating devices, a predetermined amount of adsorbent is manually weighed and added by the operator according to experience, and stirring adsorption reaction is carried out at a certain temperature and time. After the reaction is completed, the oil-soil mixture is transported to a filtration system for solid-liquid separation to obtain decolorized oil.

[0004] Although this traditional technical solution has solved the problem of rice bran oil decolorization in a certain historical period, with the upgrading of industrial technology and the increasing demand for high-quality, low-cost and green manufacturing, its inherent technical limitations have become increasingly prominent, mainly in the following aspects: (1) Coarse adsorbent addition: the existing technology completely relies on the experience of the operator to manually control the addition amount of adsorbent, and cannot realize the rapid response and precise adaptation to the fluctuations of the feed oil quality (such as initial color and acid value). In order to ensure that the color of the decolorized oil meets the requirements, the production site often adopts the conservative strategy of "better safe than sorry", which leads to the long-term overuse of adsorbent. For example, the patent with the publication number CN204058420U uses the adsorption effect of the waste white soil filter cake layer for pre-decolorization. This not only directly increases the material procurement cost, but also causes significant loss of effective components of oil due to the high proportion of adsorbent adsorption and entrainment of oil, which directly reduces the refining yield and economic benefits.

[0005] (2) Product quality is unstable: the stirring mode of traditional decolorization tank is mostly simple paddle or anchor stirring, which is difficult to realize instantaneous, uniform and microscopic mixing of powder adsorbent and high viscosity oil in a short time. In practice, it is easy to appear adsorbent "clumping", "sedimentation" and "dead zone" of material, resulting in low utilization rate of effective specific surface area of adsorbent and poor mass transfer efficiency. At the same time, the inherent discontinuity of batch operation mode makes the actual reaction residence time of different batches of materials distributed discretely, eventually leading to large fluctuation of key quality indicators such as color and residual impurity content of decolorized oil between batches, and it is difficult to guarantee the uniformity and stability of the product.

[0006] (3) Low process automation level: the entire decolorization process is heavily dependent on the skill level and subjective judgment of the operator. For materials such as rice bran oil with complex raw material sources and fluctuating pretreatment conditions, the lag, inconsistency and subjective randomness of manual intervention make it difficult for the production process to run in the optimal process window continuously and stably, which restricts the further improvement of product quality and the fine management of production cost. SUMMARY

[0007] In view of this, in order to solve the problems raised in the background art, a rice bran oil decolorization system is proposed.

[0008] The purpose of the present application can be achieved by the following technical solutions: a rice bran oil decolorization system, comprising: a decolorizing agent supply unit, comprising a silo for storing decolorizing agent and a weighing conveyor connected to the discharge port of the silo; an oil pretreatment unit, comprising a feed tank, a feed pump and a feed heat exchanger connected in sequence; a mixing and decolorization unit, comprising a mixer and a continuous decolorization tower; the feed inlet of the mixer is connected to the discharge outlet of the weighing conveyor and the discharge outlet of the feed heat exchanger, respectively, and the discharge outlet of the mixer is connected to the feed inlet of the continuous decolorization tower; the continuous decolorization tower is a vertical tower structure, and the tower is divided into multiple decolorization stages in series; each decolorization stage is provided with an independent stirring mechanism, an inclined oil liquid filter layer, a spraying device and a heating jacket wrapped around the decolorization stage.

[0009] a separation unit, comprising a decolorized oil pump, a vane filter and a polishing filter connected in sequence; the inlet of the decolorized oil pump is connected to the discharge outlet at the bottom of the continuous decolorization tower; a control system, which is signal connected with the weighing conveyor and the feed pump, and is used for controlling the conveying rate of the weighing conveyor according to the flow of the feed oil; the control system can independently adjust the proportion of decolorizing agent conveyed to each decolorization stage, and independently control the temperature of the heating jacket of each decolorization stage.

[0010] Preferably, the weighing conveyor is a loss-in-weight scale; and the mixer is a high-shear mixer.

[0011] Preferably, the inclined oil liquid filtering layer comprises a filtering screen and a shielding extraction plate; The stirring mechanism comprises a rotating shaft and stirring blades fixedly connected to the rotating shaft, and the rotating shaft penetrates through each layer of the inclined oil liquid filtering layer; The spraying device is arranged on one side close to the upper half page of the shielding extraction plate, the shielding extraction plate is arranged below the filtering screen, and the upper half page and the lower half page are symmetrically arranged on both sides of the rotating shaft, the lower half page can move in parallel along the direction of the filtering screen to selectively receive or leave the oil liquid filtered by the filtering screen, and the lower half page can be moved to the outside of the continuous decolorizing tower to carry out the filtered oil liquid so as to control the chroma data of the extracted oil liquid by the control system.

[0012] Preferably, the feed heat exchanger is a plate heat exchanger, and a hot medium inlet of the plate heat exchanger is connected with a hot decolorized oil pipeline output by the separation unit to realize heat recovery.

[0013] Preferably, the silo comprises a white silo and a carbon silo arranged side by side, and the discharge outlets of the white silo and the carbon silo are respectively connected to a mixed silo, and a weighing and conveying device is connected to the discharge outlet of the mixed silo. The control system is also signal-connected with the discharging devices of the white silo and the carbon silo, and the discharging devices are instructed to prepare the decolorizing agent with different mixing ratios according to different decolorizing levels.

[0014] Preferably, the control system further comprises an AI optimization module. The AI optimization module receives the chroma data from each decolorizing level. Based on the received chroma data and a pre-trained decolorizing effect prediction model, the AI optimization module independently outputs a decolorizing agent mixing ratio optimization setting value and a heating jacket temperature optimization setting value for each decolorizing level. The control system independently controls the discharging devices and the heating jackets of each decolorizing level according to the optimization setting values. Compared with the prior art, the present application has the following beneficial effects: (1) Through the linkage control of the loss-in-weight scale and the flow meter and the dynamic optimization based on the AI model, the system can accurately match the minimum necessary adsorbent addition amount according to the real-time quality of the feed oil, which completely changes the traditional extensive mode of “excessive addition”, directly saves the material procurement cost, and the integration of the plate heat exchanger realizes the efficient heat recovery between the hot oil after decolorization and the cold oil before decolorization, greatly reducing the steam consumption required for heating the feed oil to the operating temperature.

[0015] (2) Online high shear mixer ensures instantaneous and uniform mixing of adsorbent and oil, avoids clumping and dead zones, and makes every drop of oil have equal opportunity for bleaching. Continuous bleaching tower provides stable and consistent residence time, and can adjust adsorbent content and reaction temperature. The combination of the two makes the color index of the output bleached oil highly stable, with little difference between batches, effectively eliminating quality fluctuations.

[0016] (3) From adsorbent addition, temperature control to filtration and cleaning, the whole process is automated and intelligent. This not only reduces the dependence on skilled operators and reduces labor costs, but also fundamentally eliminates quality accidents and production fluctuations caused by human error, ensuring the reliability and traceability of production records. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the description of the embodiments. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0018] Figure 1 The structure and control principle of the present application are shown in the figure. Figure 2 The structure of the continuous bleaching tower of the present application is shown in the figure.

[0019] Explanation of figure numbers: 1-rotating shaft, 2-stirring blade, 3-heating jacket, 4-filtering screen, 5-shielding extraction plate, 6-spraying device. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present application will be described clearly and completely in the following by combining the drawings in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0021] As Figure 1 , the present application provides a rice bran oil bleaching system, comprising: a bleaching agent supply unit, including a silo for storing bleaching agent and a weighing conveyor connected to the discharge port of the silo; the weighing conveyor is a loss-in-weight scale, which is connected to the outlet at the bottom of the silo through a flexible connection, for continuously and accurately measuring and outputting the bleaching agent; an oil pretreatment unit, including a feed tank, a feed pump and a feed heat exchanger connected in sequence; the feed pump is a variable frequency centrifugal pump, and a flow meter is installed on the outlet pipeline of the pump; an online high shear mixer, including a rotating shaft and a plurality of stirring blades arranged on the rotating shaft; the rotating shaft is connected to the outlet of the bleaching agent supply unit through a flexible connection, and the stirring blades are arranged in the shape of a cone with the bottom of the cone being the outlet of the bleaching agent supply unit; the rotating shaft is connected to a motor through a transmission mechanism, and the motor is connected to a frequency converter; the frequency converter is connected to a computer through a communication interface; the computer is connected to a temperature controller through a communication interface; the temperature controller is connected to a heating jacket through a communication interface; the heating jacket is arranged on the rotating shaft; the computer is connected to a pressure controller through a communication interface; the pressure controller is connected to a filter screen through a communication interface; the filter screen is arranged on the rotating shaft; the computer is connected to a spraying device through a communication interface; the spraying device is arranged on the rotating shaft; the computer is connected to a continuous bleaching tower through a communication interface; the continuous bleaching tower is connected to a filter and cleaning unit through a communication interface; the filter and cleaning unit is connected to a bleached oil tank through a communication interface; the bleached oil tank is connected to a bleached oil pump through a communication interface; the bleached oil pump is connected to a bleached oil heat exchanger through a communication interface; the bleached oil heat exchanger is connected to a bleached oil storage tank through a communication interface; the bleached oil storage tank is connected to a bleached oil pump through a communication interface; the bleached oil pump is connected to a bleached oil pipeline through a communication interface; the bleached oil pipeline is connected to a bleached oil tank through a communication interface. The mixed decolorization unit comprises a mixer and a continuous decolorization tower; the mixer is a high-shear mixer, two feed inlets of the high-shear mixer are connected to the outlet of the loss-in-weight scale and the hot oil outlet of the plate heat exchanger through pipelines respectively, and the outlet of the high-shear mixer is connected to the feed inlet at the top of the continuous decolorization tower through a pipeline; the continuous decolorization tower is a vertical tower structure, and the tower is divided into multiple decolorization stages in series, each decolorization stage is provided with an independent stirring mechanism, an inclined oil liquid filtering layer, a spraying device 6 and a heating jacket 3 wrapped around the decolorization stage; The separation unit comprises a decolorized oil pump, a vane filter and a polishing filter connected in sequence; the inlet of the decolorized oil pump is connected to the outlet at the bottom of the continuous decolorization tower; the decolorized oil at the outlet of the polishing filter is divided into two paths, one path goes to the next section, and the other path returns to the hot medium inlet of the plate heat exchanger as a heat medium to preheat the feed cold oil; The control system adopts a distributed control system, is connected with the frequency converter, the flow meter and the loss-in-weight scale of the feed pump, and is used for controlling the conveying rate of the weighing conveying device according to the flow of the feed oil; the control system can independently adjust the proportion of the decolorizing agent conveyed to each decolorization stage, and independently control the temperature of the heating jacket 3 of each decolorization stage.

[0022] Preferably, as shown in Figs. 1 and 2, the inclined oil liquid filtering layer comprises a filter screen 4 and a shielding extraction plate 5; The stirring mechanism comprises a rotating shaft 1 and stirring blades 2 fixedly connected with the rotating shaft 1, and the rotating shaft 1 penetrates through each layer of the inclined oil liquid filtering layer; The spraying device 6 is arranged on one side close to the upper half page of the shielding extraction plate 5, the shielding extraction plate 5 is arranged below the filter screen 4, and the upper half page and the lower half page are symmetrically arranged on both sides of the rotating shaft 1, the lower half page can move in parallel along the direction of the filter screen 4 to selectively receive or leave the oil liquid filtered by the filter screen 4; the lower half page can be moved to the outside of the continuous decolorization tower to take out the filtered oil liquid, so that the control system extracts the chroma data of the oil liquid; The spraying device 6 is installed on the side surface, which avoids the problem of uneven spraying of the traditional top layer, because when the top layer is sprayed, the adsorbent will be relatively concentrated directly below the spraying device, and when the side surface is sprayed, the adsorbent will be relatively concentrated at the upper end of the inclined oil liquid filtering layer and will penetrate to the lower layer along the slope.

[0023] Preferably, the feed heat exchanger is a plate heat exchanger, and the hot medium inlet of the plate heat exchanger is connected with the pipeline of the hot decolorized oil output by the separation unit to realize heat recovery.

[0024] Preferably, the bin comprises a white bin and a carbon bin arranged side by side, and the outlets of the white bin and the carbon bin are connected to a mixing bin, and the weighing conveying device is connected with the outlet of the mixing bin.

[0025] Preferably, an online colorimeter is installed on the pipeline between the plate heat exchanger and the high-shear mixer to detect the initial color of the feed oil in real time. The control system is connected to the online colorimeter and is pre-programmed with basic control logic. For example, when the initial color is detected to be higher than the standard range, the control system will automatically increase the preset clay addition ratio (e.g., from 2% to 2.2%); conversely, when the initial color is lower, the addition ratio will be automatically reduced (e.g., from 2% to 1.8%). This "feedforward" control based on feed quality enables the system to have preliminary adaptive ability, stabilizing the quality of finished oil when the feed fluctuates, and avoiding excessive use of clay when the feed is good.

[0026] Preferably, the control system further includes an AI optimization module, which can be integrated into the host computer of the control system or communicate data with the DCS as a separate server. The workflow of the AI optimization module is as follows: 1. Data collection and model input: The AI optimization module continuously collects real-time process parameters from the control system, including but not limited to: initial color from the online colorimeter, feed oil flow from the flowmeter, actual adsorbent ratio from the loss-in-weight scale, temperature of each layer of the decoloring tower from the temperature sensor, and color data of the oil after reaction; 2. Measurement prediction: The AI optimization module 501 has a pre-trained decoloring effect prediction model; the model is trained with historical production data using the XGBoost algorithm; the model receives the above real-time parameters as input and outputs a predicted value: predicted decoloring oil end color; 3. Multi-objective optimization and decision-making: The AI optimization module 501 takes "achieving the lowest clay consumption and the smallest oil adsorption loss under the premise of ensuring the predicted color (C_out_pred) meets the standard" as the optimization goal; A multi-objective optimization algorithm (e.g., NSGA-II) runs inside the module to search within the feasible range of adsorbent addition ratio (R) and decoloring temperature (T), and solve the optimal operating point that can simultaneously meet the above multiple objectives, i.e., obtain the optimized clay addition ratio set value (R_opt) and the optimized decoloring temperature set value (T_opt); 4. Instruction issuance and execution: The AI optimization module 501 issues R_opt and T_opt to the control system, which then adjusts the control instruction to the loss-in-weight scale according to R_opt and adjusts the steam regulating valve of each heating jacket of the continuous decoloring tower according to T_opt, so that the system runs in the optimal operating condition.

[0027] Working principle: The feed pump and the silo add oil and adsorbent according to the preset ratio, enter the high-shear mixer, are mixed fully, and then enter the continuous decoloring tower for full reaction. The continuous decoloring tower has a three-layer structure, each layer has an independent stirring mechanism, an inclined oil liquid filtering layer, a spraying device 6 and a heating jacket 3 wrapped around the decoloring layer, after the oil liquid reaches the preset reaction time, the oil liquid and the precipitate are layered, the shielding extraction plate 5 of the inclined oil liquid filtering layer slides down, due to the inclined design of the inclined oil liquid filtering layer, the oil liquid can pass through the filter screen 4 to enter the next layer; at the same time, the oil liquid taken out with the shielding extraction plate 5 flows into the sampling device outside the continuous decoloring tower, the control system extracts the chroma data of the oil liquid through image recognition, and then judges the adsorption effect of the oil liquid according to the trained decoloring effect prediction model, if the expected reaction effect is not reached, the control system controls the decoloring agent supply unit to adjust the adsorbent content in the continuous decoloring tower. After the oil liquid completes the adsorption reaction, high-quality decolorized oil is obtained through the separation unit.

[0028] The above is only an example and description of the concept of the present application. Those skilled in the art can make various modifications or supplements to the described specific embodiments or use similar ways to replace, as long as they do not deviate from the concept of the present application or exceed the scope defined by the present application, which shall belong to the protection scope of the present application.

Claims

1. A rice bran oil decolorizing system characterized by comprising: The application relates to a decoloring system for oil, comprising: a decoloring agent supply unit comprising a bin for storing decoloring agent and a weighing conveyor connected to a discharge port of the bin; an oil pretreatment unit comprising a feed tank, a feed pump and a feed heat exchanger connected in sequence; a mixing and decoloring unit comprising a mixer and a continuous decoloring tower; the feed ports of the mixer are connected to the discharge ports of the weighing conveyor and the feed heat exchanger respectively, and the discharge port of the mixer is connected to the feed port of the continuous decoloring tower; the continuous decoloring tower is a vertical tower structure, and the tower is divided into multiple decoloring stages connected in series; each decoloring stage is provided with an independent stirring mechanism, an inclined oil liquid filtering layer, a spraying device and a heating jacket wrapping the decoloring stage; a separation unit comprising a decoloring oil pump, a vane filter and a polishing filter connected in sequence; the inlet of the decoloring oil pump is connected to the discharge port at the bottom of the continuous decoloring tower; a control system connected to the weighing conveyor and the feed pump to control the conveying rate of the weighing conveyor according to the flow of the feed oil; the control system can independently adjust the proportion of the decoloring agent conveyed to each decoloring stage and independently control the temperature of the heating jacket of each decoloring stage.

2. The rice bran oil decolorizing system according to claim 1, characterized by The weighing conveyor is a loss-in-weight scale; and the mixer is a high-shear mixer.

3. The rice bran oil decolorizing system according to claim 1, wherein The inclined oil liquid filtering layer comprises a filter screen and a shielding extraction plate; the stirring mechanism comprises a rotating shaft and stirring blades fixedly connected to the rotating shaft, and the rotating shaft penetrates through each layer of the inclined oil liquid filtering layer; the spraying device is arranged on one side close to the upper half page of the shielding extraction plate, the shielding extraction plate is arranged below the filter screen, and the upper half page and the lower half page are symmetrically arranged on both sides of the rotating shaft; the lower half page can move in parallel along the direction of the filter screen to selectively receive or release the oil liquid filtered by the filter screen; the lower half page can be moved to the outside of the continuous decoloring tower to take out the filtered oil liquid so that the control system extracts the chroma data of the oil liquid.

4. The rice bran oil decolorizing system according to claim 1, wherein The feed heat exchanger is a plate heat exchanger, and the heat medium inlet of the plate heat exchanger is connected to the pipeline of the heat-decoloring oil output by the separation unit to realize heat recovery.

5. The rice bran oil decolorizing system according to claim 1, wherein The bin comprises a white bin and a carbon bin arranged side by side, and the discharge ports of the white bin and the carbon bin are connected to a mixing bin; the weighing conveyor is connected to the discharge port of the mixing bin; the control system is also connected to the discharge devices of the white bin and the carbon bin, and the discharge devices are instructed to prepare the decoloring agent with different mixing proportions for different decoloring stages.

6. The rice bran oil decolorizing system according to any one of claims 1 to 6, characterized by, The control system further comprises an AI optimization module; the AI optimization module receives the chroma data from each decoloring stage; based on the received chroma data and a pre-trained decoloring effect prediction model, the AI optimization module independently outputs the optimized setting values of the mixing proportion of the decoloring agent and the temperature of the heating jacket for each decoloring stage; the control system independently controls the discharge devices and the heating jackets of each decoloring stage according to the optimized setting values.

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