Aquafeed producers are losing about $4 to $10 per ton of product produced in terms of lost production, higher energy consumption and lowered product quality. These losses can be recovered by substituting a more effective moisture (MC) sensing and control technology for currently used traditional MC sensing and control.

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January | February 2013
Profitable aquafeed moisture control
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2. FEATURE
Profitable aquafeed
by John Robinson, president, Drying Technology Inc, USA
A
quafeed producers are losing wider the MC variation the lower the target after contact with the wet product and the
about $4 to $10 per ton of mean MC must be to prevent production of production rate or evaporative load (S). The
product produced in terms of wet product. Consequently, use of currently model solved the two main problems with
lost production, higher energy consump- available control technology forces manu- MC sensing and control by producing. Firstly,
tion and lowered product quality. These facturers to over dry their products which a rugged, reliable ‘inside-the-dryer’ moisture
losses can be recovered by substituting causes significant costs in terms of lower sensor; and secondly, a new and powerful
a more effective moisture (MC) sensing production, higher energy usage, and poorer control algorithm that precisely adjusts the
and control technology for currently used quality. Figure 1 illustrates the effect of poor set point for evaporative load changes.
traditional MC sensing and control. MC sensing and control on MC variation.
The control solution A new type of MC sensor
Losses caused by poor MC sensing and Figure 2 describes how the Delta T MC
The control problem control may be recovered if the MC vari- sensor continuously measures the MC of
Two main problems prevent traditional ation (standard deviation) is reduced such aquafeed inside the harsh environment of a
MC sensing and control technology from that the mean MC can be maximized with- dryer while it is being dried with a belt dryer.
being effective. Firstly, the lack of timely and out exceeding the upper specification limit As illustrated by Figure 2, patented Delta
accurate MC data upon which to base con- (USL). Fortunately, a solution for poor MC T technology invented a new type MC
trol action (poor MC sensing). Secondly, the sensing and control was supplied by the deri- sensor that can be installed ‘inside-the-
inability to correctly adjust for evaporative vation of a MC sensing and control model dryer’ which reduces the dead time (time
load changes entering with the feed. from first principles. The Delta T model: to detect a disturbance entering with the
Figure 1 shows a typical normal MC dis- feed) by at least 30 percent. Since dead
tribution curve produced by traditional MC MC = K1(ΔT)p – K2/Sq time is directly proportional to the product
sensing and control technology. The curve is standard deviation, use of this ‘inside-the-
relatively wide as a result of the effect of high relates the product MC exiting a dryer dryer’ sensor reduces the standard deviation
MC standard deviation. It is obvious that the to the temperature drop (ΔT) of hot air at least 30 percent below that achieved by
Figure 1: Typical MC distribution
curve produced by poor MC
sensing and control Figure 2: Delta T ‘inside-the-dryer’ MC sensor
32 | January - february 2013 Grain &feed millinG technoloGy

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Innovations for a better world.

4. FEATURE
FEATURE
tive load entering the lower operating costs,
means longer uptime, dryer with the feed.
less expenses on maintenance and spares,
Proprietary methods are used in adapting the
model to the dryer and product. makes the
and half the energy usage. This
whole unloading process more economical
Application of Delta T to especially
and environmentally sustainable,
aquafeed the added demurrage costs to
considering manufacture
vessels above-mentioned reduction in stand-
The if a pneumatic system breaks down.
ard deviation enablesoperates at lowerto be
Lastly, the Bargolink the target MC noise
increased by 0.5 not generate lower frequen-
levels and does percent to as much as 1.25
percent without fear of systems whoseprod-
cies than pneumatic producing wet loud
uct which might mold volumes maystorage.
droning and changing in transit or consti-
Figure health hazard.
tute a 4 shows schematically how reducing
the Already three customers the China,
standard deviation enables in mean
MC to and France have been convinced
Croatia be increased by shifting the Delta T
Figure 3: Delta T reduces dead time on belt dryer curvethey can benefit the upper + 3Bargolink.
that rightward until from Bühler’s standard
deviation points (USL) ofBargolink offers an
Altogether, Bühler’s both curves coincide.
The difference in mean MCs represents effi-
investment-friendly, highly flexible and the
use of currently used MC sensing methods. downstream of the dryer and analyzed by a economic gain for unloading systems used for
cient solution from using Delta T technology.
It should be noted that use of raw Delta T laboratory instrument. inland water transportation in the genuine
data will not work—it must be processed For the above conditions, the Delta T Buhler manufacturing quality combined with
Results and conclusions
by the model before use. Figure 3 illustrates accomplishes dead time reductions of 30 per- best in class components. additional water
From 10 to 25 lbs of
the advantage of reducing dead time for cent and 53 percent below that for the mois- can be safely sold with the product per ton
aquafeed drying. ture meter method and the laboratory MC of product produced without exceeding the
Three possible locations are shown for sample method respectively. The standard upper specification limit using this new tech-
installing the MC sensor. Dead time for each deviation reductions would also be reduced nology. ThenforMatIon: aquafeed manu-
More I return to the
installation point is the time it takes for the 30 percent and 53 percent respectively. Bühler GmbH
facturer is $4 to $10 per ton of product for
individual MC method to detect a change in a wholesale productCH-9240, Uzwil, Switzerland
Grain Logistics, price of $800 per ton.
evaporative load entering with the feed. The A new MC control algorithm Tel: +41 719 551111
In addition, energy savings of approximately
lowest dead time is 14 minutes for the Delta As a result of its theoretical basis, the four to seven 719 553949
Fax: +41 percent possible. The Delta T
Email: grain-logistics@buhlergroup.com
T sensor inside the dryer; the next lowest Delta T technology provides a new control has been successfully applied in the US for
Website: www.buhlergroup.com
dead time is 20 minutes for a MC meter algorithm that enables precise calculation of MC sensing and control of many products,
located at the dryer exit; the longest dead the set point necessary to maintain the target including aquafeed using a Beltomatic con-
time is 30 minutes for MC samples taken MC in spite of frequent changes in evapora- veyor dryer.
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Ann A5 victam 0212.indd 1
January - february 2013 | 17
January - february 2013 |15:37:04
21/02/12 33

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