Rifled Barrel Pressure Device for Crop Residue Processing
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Solution Overview
Problem
Current methods for processing crop residues into nutritional animal feed face challenges such as low digestibility, protein content, and inefficiencies in processing, particularly in developing regions like Africa and Asia, where crop residues are a significant livestock feed source, due to issues like waste disposal, economic viability, and the need for chemical treatments.
Innovation Solution
A pressure device with a rifled barrel and a popper device that applies shearing forces and increased pressure to crop residues, breaking down cellulose molecules into smaller proteins, achieving higher protein content without chemical additives, and allowing for the production of nutritional animal feed, flour, and alcohols through a process that involves chopping, water addition, and controlled temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If chemical treatment methods (NaOH, ammonia) are used to improve crop residue digestibility and protein content, then nutritional value increases, but waste disposal problems arise and processing costs increase
Solution Approach 1:
The patent replaces chemical treatment methods with a mechanical processing system consisting of a pressure cooker, mixer, and extruder. The mechanical extrusion process transforms crop residue into nutritious feed without requiring chemical additives like NaOH or ammonia, thereby eliminating waste disposal problems associated with chemical treatments while still achieving high protein content (365% increase) and improved digestibility.
2Reliability
If traditional Beckmann method with NaOH soaking is used, then digestibility increases two-fold, but dry matter loss reaches 25%
Solution Approach 1:
The mechanical extrusion process replaces the NaOH soaking method, achieving improved digestibility through mechanical breakdown of cellulose structure rather than chemical treatment. The extruder forces processed material through a die at high pressure, creating a dense, nutritious feed that is highly digestible without the 25% dry matter loss associated with chemical soaking and washing procedures.
3Productivity
If crop residue is treated with chemicals to improve nutrition, then animal intake increases, but processing complexity and farmer sophistication requirements increase
Solution Approach 1:
The patent employs a mechanical processing system (pressure cooker, mixer, extruder) that is simpler to operate than chemical treatment methods. The equipment requires no specialized knowledge of chemical concentrations, soaking times, or neutralization procedures. Farmers can achieve increased animal intake (365% protein increase) through straightforward mechanical processing, eliminating the need for sophisticated chemical handling skills.
4Object-generated harmful factors
If mechanical processing alone is used without chemical treatment, then waste disposal is simplified, but protein content and nutritional value remain insufficient
Solution Approach 1:
The patent uses parameter changes in the mechanical processing system to achieve high protein content. The pressure cooker cooks crop residue at elevated temperature and pressure, the mixer thoroughly combines and aerates the material, and the extruder forces it through a die at high pressure. These parameter changes (temperature, pressure, mechanical stress) transform the physical and chemical structure of crop residue, breaking down cellulose and increasing protein content by 365% without chemical additives, thereby simplifying waste disposal while improving nutrition.
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
The process significantly increases protein content by 365% and produces a nutritional feed that is palatable and digestible, eliminating the need for chemical treatments and improving the overall quality of crop residues, making it suitable for animal feed and potential human consumption.
Implementation Method 1
A pressure device with a rifled barrel and a popper device that applies shearing forces and increased pressure to crop residues, breaking down cellulose molecules into smaller proteins
Implementation Method 2
The increased surface area, provided by the rifling grooves, creates more friction between the crop residue and the barrel wall thereby increasing the internal temperature and pressure
Implementation Method 3
The pressure device with a rifled barrel and a popper device that applies shearing forces and increased pressure to crop residues
Data Source
AI summary
A pressure device has a rifled barrel, a rifled end cap, a section clamped to the barrel, a circular flange welded to a threaded male pipe connection, a plate with holes or a cone, a female cap receiving the plate and aligning the holes to the rifling in the barrel, and the flange threadily engaging the cap, securing the plate. The rifled barrel provides shearing, increased pressure, and higher temperatures upon the passing crop residue. The increased surface area of the rifling grooves increases temperature and pressure between the crop residue and the barrel wall. The rifling, when misaligned, creates a pressure chamber that further breaks down the molecules in the crop residue. The crop residue then enters a popper device. The pressure in the popper device forces the crop residue through the holes of plate or around an encased cone, relieving excess pressure and producing a nutritional animal feed.