Enzyme Granulate Production via Localized Injection Heating
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Solution Overview
Problem
Existing methods for producing enzyme granulates face challenges such as high dust content, non-uniform temperature distributions, and low enzyme activity yield, leading to inefficient production and quality issues like high inactive carrier material content and poor roundness factors.
Innovation Solution
The method involves supplying heated processing gas mainly in the injection region of the apparatus, using a geometrical design that enhances particle circulation and uniform wetting, and controlling temperature conditions to reduce residence time and improve enzyme activity yield, resulting in enzyme granulates with low dust content and higher active enzyme percentages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spray drying is performed to improve enzyme stability, then enzyme stability is improved, but the product contains high dust content and requires large apparatus volumes
Solution Approach 1:
The patent employs spray drying, a phase transition process where liquid enzyme formulation is atomized and rapidly dried through contact with hot air, transforming the liquid enzyme into dry granulate particles. This phase transition from liquid to solid powder form improves enzyme stability while the controlled drying process manages dust generation
Solution Approach 2:
The patent introduces an intermediary classification system with gravity sifters and air classification separators that separate dust particles from the enzyme granulates. These intermediary devices act as mediators between the spray drying process and the final product, removing harmful dust while preserving the stable enzyme granulates
2Object-generated harmful factors
If multi-stage drying systems are used to reduce dust content, then dust content is reduced, but the granulates have poor roundness factor and break easily
Solution Approach 1:
The patent replaces traditional mechanical classification systems with an air classification system where granulates are separated from dust using air streams. This substitution of mechanical handling with pneumatic separation reduces mechanical stress on granulates, preventing breakage and maintaining strength while still achieving dust removal
Solution Approach 2:
The patent creates a controlled air environment in the classification system that gently separates particles based on density and size. This inert pneumatic environment avoids the mechanical contact and friction that would otherwise cause granulate breakage, maintaining structural integrity while removing dust
3Manufacturing precision
If conventional fluidized bed process is used with uniform gas distribution, then uniform drying is achieved, but enzyme activity yield is low due to non-uniform temperature distributions
Solution Approach 1:
The patent applies local quality by providing concentrated heating in the injection region where liquid enzyme is introduced, rather than uniform heating throughout the fluidized bed. This localized thermal treatment ensures that the enzyme formulation receives optimal drying conditions at the point of injection, improving enzyme activity yield while maintaining uniform overall drying through particle circulation
Solution Approach 2:
The patent employs preliminary action by pre-heating the processing gas before it contacts the enzyme formulation in the injection region. This preliminary heating ensures that the enzyme particles receive optimal drying conditions from the outset, preventing temperature shocks that would reduce enzyme activity while maintaining uniform drying through subsequent particle circulation
4Manufacturing precision
If longer residence time is used in fluidized bed, then drying completeness is improved, but enzyme inactivation increases and productivity decreases
Solution Approach 1:
The patent applies the skipping principle by rapidly drying the enzyme formulation in the injection region through concentrated heating and intense particle-gas contact. This rushing through the drying process achieves complete drying in shorter residence time, preventing enzyme inactivation that would occur with prolonged exposure to high temperatures, while maintaining productivity
Solution Approach 2:
The patent employs dynamics through continuous particle circulation between the injection region and the fluidized bed. This dynamic system allows particles to receive concentrated heating briefly in the injection region, then cool and circulate back, achieving complete drying through repeated cycles rather than prolonged static exposure, thus maintaining enzyme activity while ensuring drying completeness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach produces enzyme granulates with reduced dust content, improved enzyme activity, and controlled grain size distribution, enhancing storage stability and production efficiency while maintaining high active enzyme content and low moisture levels.
Implementation Method 1
supplying heated processing gas mainly in the injection region of the apparatus
Implementation Method 2
supplying heated processing gas mainly in the injection region of the apparatus
Data Source
AI summary
A method for producing enzyme granulates, the resulting enzyme granulates, and their use in formulations, e.g., for animal feed, food, washing means, rinsing means, and/or for pharmaceutical purposes and the like. The enzyme granulates show, in particular, a high relative percentage of active enzymes, certain grain sizes, good storage stability, especially small roundness factor, and/or low residual moisture percentage as well as preferably additional specific properties. According to the invention, the enzyme granulates are produced by linking the thermal conditions in the spray zone and the temperature conditions in the remaining region of the fluidized bed. In the process according to the invention, this is achieved in that the supply of heated processing gas is realized for drying exclusively in the injection region. The reliable supply of particles in the injection region is realized through the special geometrical shape of the apparatus under the use of gravity. Through the addition of inert particles as nuclei material for cores, the absolute content of enzyme activity of the enzyme granulate can be controlled.