Grain Ethanol Processing
The OptiShear jet cooker is designed for starch cooking, wet mill processing of starch, ethanol production and fructose and alcohol production. ProSonix's unique method of direct steam injection utilises internal steam modulation via an integral Pneumatic Actuator and variable position steam plug, to accurately meter the mass flow of steam, through choked flow conditions. 'Choked flow' is the phenomenon of accelerating a vapor to maximum velocity by creating a pressure differential through an engineered opening. By establishing choked flow, the steam mass flow can be metered to precisely control the heating of the liquid. This produces predictable results based on the position of the steam plug. Through a variable-area steam diffuser, steam flow is metered at the point where steam and liquid first contact and mix.
| How biomass works |
- Starch slurry processing is designed for starch slurries with solids concentration of up to 40%
- The OptiShear is well suited for all types of starch such as corn, potato, wheat, rice and cassava or tapioca
- High velocity steam and turbulent mixing injection via internally modulated steam control and variable position steam plug for vibration free operation
- Precise temperature control of +/- 1°F (-17.2°C) for reliable heating performance
- The OptiShear can be installed in any orientation and requires no floor space for installation
- Automatic or manual operation simplifies process integration
- Can be installed in any orientation. High temperature rise 250°F (121°C) in a single pass
- Materials of construction. Standard carbon steel or 316SS with optional wear coatings available for erosive slurry conditions
- Standard ANSI class connections (NPT threaded or RFF flanged) for 150 psig steam, with optional 300 psig available. Design standards- designed to ASME
Adjustable Slurry Gap Optimises Starch and Steam Mixing, Reducing Enzyme Use
In starch cooking, proper agitation or 'shear' is required to optimise the thermal effect of the steam on the starch particles. The OptiShear Jet Cooker is equipped with an adjustable Condensing Tube (CT). The adjustable CT can be positioned to vary the gap relative to the steam nozzle, creating a narrow slurry gap. This narrow gap between the CT and steam nozzle optimises the steam exposure to the thin ribbon of starch slurry as it enters the CT. By changing the position of the CT relative to the face of the steam nozzle, back pressure inside of the OptiShear can be optimised to reduce uncooked starch and enzyme usage.
Radial Slurry Flow
In the OptiShear design, the condensing tube and steam nozzle interface is truly coaxial, ensuring the starch slurry gap is uniform throughout the full 360° flow path. The tube rests on multiple bearing surfaces so there is no movement of the tube relative to the injector except to adjust the gap.
Advanced Drive System
The tube movement in the ProSonix heater to adjust the starch gap is accomplished using a threaded engagement. The tube is rotated and an external thread moves the tube towards or away from the injector (nozzle). Moving the tube in this way changes the orientation of the tube inside the heater, causing any wear spots of the tube to move as well. This has the beneficial effect of evening out the wear of the internal parts, extending their operating life.
