F55 fructose syrup processing machine section-F42 high fructose syrup production line plant
F55 fructose syrup s production equipment
(1) starch milk slurry
The starch milk enters the starch milk adjustment tank from the starch production workshop, and monitors and automatically adjusts the starch milk flow, DS, pH value and enzyme flow indicators online. The adjusted starch milk is pumped to the liquefaction ejector.
(2) Jet liquefaction
The imported liquefied sprayer is used to instantly heat the material to 108 ～ 110 ℃ after steam spraying, which makes the starch milk gelatinize instantaneously and the viscosity decreases. After the starch milk and the enzyme maintain the preliminary function in the column, the temperature is reduced by flash evaporation in a flash tank to achieve the optimum liquefaction reaction temperature of the enzyme. The liquefaction reaction time is 90 to 120 min. The DE value after liquefaction is 12-18, the liquefied liquid is clear, and the protein floc is good.
Flash steam can be fully utilized as a heat source in the glucose evaporation section to achieve the purpose of comprehensive utilization of thermal energy for recovery of thermal energy.
(3) Saccharification
After flash evaporation, the liquefied liquid passes through the plate heat exchanger to precisely control the temperature and then enters the saccharification pH adjustment tank. The online automatic control adjusts the pH and adds an appropriate amount of enzyme to the saccharification tank for saccharification. The saccharification temperature is 55-60 ° C, and the saccharification time is 24-48h.
(4) Plate and frame filtering section
After saccharification, the solution is sent to a plate and frame filter to remove solid residues such as insoluble proteins. By filtering the turbid liquid and clear liquid of the saccharified liquid respectively in different plates and frames, the filtering efficiency is improved and the energy consumption is reduced. The dregs obtained after filtering can be used as animal feed after drying.
(5) Membrane filtration section
After the glucose saccharification solution pre-filtered through the plate and frame enters the membrane filtration system, glucose and water pass through the membrane surface under the action of pressure and are separated to form a dialysate; and the macromolecular substances in the material solution such as Proteins, fats, pigments, etc. are trapped by the membrane and cannot penetrate the membrane surface, forming a concentrated solution. After the concentrated solution is filtered through multiple membrane cores, a concentrated phase is formed, and the concentrated solution is returned to the pretreatment plate and frame and then filtered. The dialysate enters the next outcrossing process.
Imported roll membrane core, unique design for sugar liquid filtration, excellent performance, high temperature resistance, strong anti-pollution ability, more stable flux. The equipment runs continuously, with high degree of automation and automatic cleaning online.
(6) Ion exchange
The purpose of the divorce is to decolorize, deodorize and demineralize (organic and inorganic salts) to increase the temperature of boiling sugar.
The glucose outcrossing system uses a full-chamber bed process, countercurrent feed, two sets of operation, and one set of regeneration for standby. The whole system has high degree of self-control, high operating efficiency, and low consumption of regenerant. The sugar solution is colorless and transparent after the off-breeding, taste: no salty, no bitterness, no odor, no odor; pH value: 4.6 ～ 6.0, electrical conductivity ≤50us / cm.
(7) DE96 evaporation
Four-effect falling film evaporation system using falling film evaporation. Make full use of the waste steam produced by the first flash, second flash and third flash of liquefaction to further reduce energy consumption. The advanced performance of the device is: large concentration ratio, stable material concentration after evaporation; heat pump evaporation to save steam. The output glucose concentration is ≥45%, which meets the requirement of isomeric concentration.
(8) Heterogeneous
Immobilized isomerase was used to convert glucose to fructose to obtain F42 fructose syrup. By precisely controlling the pH, temperature, and the amount of magnesium sulfate and sodium metabisulfite added to the heterogeneous feed, the good activity of the isomerase can be maintained and the service life of the enzyme can be extended.
(9) F42 fructose ion exchange
Desalting F42 fructose syrup after isomerization (mainly removing MgSO4 and Na2S2O5 added during isomerization). The device adopts full-bed technology, runs countercurrently, operates in two groups, and regenerates in reserve. The system is equipped with sensors, flow meters and automatic control valve groups. The online monitoring and control devices operate with a high degree of automatic control, high operating efficiency and low consumption of regenerant. After disengagement, the sugar solution has a pH value of 4.0 to 5.0, an electrical conductivity of ≤20us / cm, and a light transmittance of ≥98%.
(10) F42 fructose concentration
The isomerized F42 fructose syrup is concentrated, and it is concentrated to 60%, and then enters a chromatographic separation section. The device is a four-effect falling film evaporation system using falling film evaporation. Large concentration ratio, stable material concentration after evaporation; heat pump evaporation to save steam. The output glucose concentration is ≥60%.
(11) Chromatographic separation
Chromatographic separation is a method of separating components of a mixture by utilizing the different migration speeds of the components in the separation resin. During the separation of F42 fructose syrup, fructose molecules bind to Ca2 + and are adsorbed by resin ions, with a long residence time; glucose molecules cannot bind to Ca2 + and have a short residence time. Therefore, using water as eluent can separate higher purity fructose from F42 fructose syrup.
The resin of the chromatographic separation device adopts imported homogeneous resin and uses the new generation sequential simulated moving bed (SSMB) technology to realize fully automatic operation. It has the advantages of low water consumption and high fructose recovery rate (F≥90%).
(12) F55 Fructose Mixed Bed Divorce
F42 fructose and chromatographically separated F90 fructose are mixed into F55 fructose in a mass ratio. The adsorption capacity of the ion exchange resin is used to further remove pigments, organic salts and inorganic salts in fructose, and reduce the conductivity. After the mixed bed is disengaged, the pH value of the syrup is 3.7 ～ 4.2, the conductivity is ≤10 us / cm, the light transmittance is ≥99.5%, the color is ≤10ICU, there is no abnormal smell, and the shelf life of the finished product is ≥12 months.
(13) Deodorization by filtration
A plate-type closed filter is used to decolorize and deodorize F55 fructose after demixing in the mixed bed, remove organic impurities in the sugar solution, and improve the light transmittance of the finished product. The filter has small volume, simple operation, automatic slag discharge, and does not consume filter paper and filter cloth, and consumes only a small amount of filter aid, so it has the advantage of low filtration cost.
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