Process using agriculture residue biomass for producing feed pellets

• US 8,551,549 B2
• Filed: 12/30/2011
• Issued: 10/08/2013
• Est. Priority Date: 05/08/2009
• Status: Active Grant

• Current Assignee: Pellet Technologies LLC
• Original Assignee: Pellet Technologies LLC
• Inventors: Zeeck, James Russell
• Primary Examiner(s): Goloboy, James
• Assistant Examiner(s): HINES, LATOSHA D
• Application Number:
  US13/341,319
• Publication Number:
  US 20120107472A1
• Time in Patent Office: 648 Days
• Field of Search: 445/00, 445/89, 446/34, 426/442
• US Class Current: 426/442
• CPC Class Codes: C10L 5/44 on vegetable substances
• CPC Class Codes: C10L 5/445 Agricultural waste, e.g. corn crops, grass clippings, nut shells or oil pressing residues
• CPC Class Codes: F23G 2900/50206 Pelletising waste before combustion
• CPC Class Codes: F23G 2900/55011 Detecting the properties of waste to be incinerated, e.g. heating value, density
• CPC Class Codes: F23G 5/033 comminuting or crushing
• CPC Class Codes: F23G 7/10 of field or garden waste or biomasses
• CPC Class Codes: F23K 1/00 Preparation of lump or pulverulent fuel in readiness for delivery to combustion apparatus
• CPC Class Codes: F23K 1/02 Mixing solid fuel with a liquid, e.g. preparing slurries
• CPC Class Codes: F23K 2201/10 Pulverizing
• CPC Class Codes: F23K 2201/20 Drying
• CPC Class Codes: F23K 2201/30 Separating
• CPC Class Codes: F23K 2201/50 Blending
• CPC Class Codes: F23K 2201/505 with additives
• CPC Class Codes: F23K 2203/103 Storage devices
• CPC Class Codes: F23K 2203/201 using pneumatic means
• CPC Class Codes: F23K 3/00 Feeding or distributing of lump or pulverulent fuel to combustion apparatus
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel

Abstract

A process is provided for creating feed pellets from agricultural residue material having substantially no food value, such as corn stover. The agricultural residue material is harvested and baled for transport to a storage and processing site. The baled agricultural residue material is then shredded and ground, and one or more chemical agents are added to depolymerize the fiber (lignin-carbohydrate) matrix of the agricultural residue material. Agricultural processing byproducts such as distiller'"'"'s solubles and dried distillers grains with solubles (DDGS) are added to the agricultural residue material, either before or after the chemical agents are added, to form a combined material. The combined material is then pelletized into feed pellets, which may be transported and stored for later consumption by animals. The process produces a nutritionally enhanced material which is more easily digested than existing feed rations.

Claims

1. A process for utilizing agricultural crop residue material for feed production comprising:

harvesting agricultural crop residue material selected from a group consisting of corn stover, soybean stubble, and sorghum residue;

bailing the harvested material;

shredding the baled material;

grinding the shredded material;

adding one or more chemical agents to depolymerize fiber in the material;

adding nutritional supplements to the ground and shredded material before or after the chemical agent has been added to form a mixture; and

pelletizing the mixture into feed pellets.

2. The process of claim 1 wherein the mixture is pelletized without the use of binding additives.

3. The process of claim 1 wherein the mixture is pelletized without use of dedicated drying equipment.

4. The process of claim 1 is continuous.

5. The process of claim 1 wherein the chemical agents and nutritional supplements are combined and processed with the residue material using an auger mixer with a vertical auger system, at least one twin screw vertical mixer, and an extruder.

6. The process of claim 1 wherein the pelletized material has a density of 35-40 pounds per cubic foot.

7. The process of claim 1 wherein the agricultural residue material is corn stover.

8. The process of claim 1 wherein the pellets have a durability index of at least 95.

9. The process of claim 1 wherein the pellets have a moisture content of approximately 10%.

10. The process of claim 1 wherein the material is depolymerized without adding fresh water.

11. The process of claim 10 wherein shredding and grinding steps each include the active movement of air to convey the material.

12. The process of claim 1 further comprising wetting the mixture before pelletizing for die temperature control and lubrication.

13. The process of claim 1 further comprising pneumatically separating rocks, metal, and other heavy particles from the material prior to shredding.

14. The process of claim 1 further comprising cooling and drying the pellets using ambient air.

15. The process of claim 1 wherein the pellets are formed by extruding the mixture through a die.

16. The process of claim 1 wherein the material is ground to a density of 6-8 pounds per cubic foot.

17. The process of claim 1 wherein excess mixture beyond the pelletizing capacity is reconveyed for use in the pelletizing step.

18. The process of claim 17 further comprising storing excess ground material in a bin for use in the pelletizing step.

19. The process of claim 1 wherein the residue material is substantially free from natural hinders.

20. The process of claim 1 wherein the mixture is fed in a continuous manner to keep the die operating at capacity without surging.

21. The process of claim 1 wherein the mixture is fed under a constant flow into a die for pelletizing.

22. The process of claim 21 wherein a conveyor feeds the pellet manufacturing ingredients into a material conditioner wherein water is added before delivery to the die, and the conveyor returns excess material to a storage bin for future delivery to the die.

23. A process for utilizing agricultural crop residue material for feed production comprising:

collecting the crop residue material selected from a group consisting of corn stover, soybean stubble, and sorghum residue;

reducing the material size;

then

chemical treating the material to increase digestibility of the material by animals; and

mechanically treating the material to increase digestibility of the material by animals.

24. The process of claim 23 wherein chemical treatment includes the addition of calcium oxide and/or sodium hydroxide to the material.

25. The process of claim 24 further comprising the addition of nutritional supplements to the treated material to increase the food valve of the supplements and material.

26. The process of claim 24 further comprising pelletizing the treated material into pellets for animal feed.

27. The process of claim 24 wherein the mechanical treatment includes mixing the material in a mixer.

28. The process of claim 23 wherein the material is stover.

29. The process of claim 23 wherein the cutting step includes air-assisted shredding and grinding.

30. The process of claim 23 wherein the treatment steps are performed without adding water to the material.