xuat bia 100t l
TRANSCRIPT
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LI M U
Bia l loi ung c gas, c mi thm mt, giu gi tr dinh dng, c
cn thp, nhiu bt mn, c mi v c trng ca nguyn liu v cc sn phm phkhc to thnh trong qu trnh ln men. c bit CO2 bo ha c trong bia c tc
dng gii kht tc th, hn na vi hm lng cn thp s kch thch kh nng tiu
ha ca d dy.
V gi tr dinh dng: mt lt bia c hm lng trung bnh tng ng vi
25 gam tht b hoc 150 gam bnh m loi mt, hoc tng ng vi 500 kcal
bng 2/3 nng lng c cung cp t cng mt n v th tch sa. Ngoi ra trong
bia cn cha vitamin B1, B2, B5, B6, rt nhiu vitamin PP v cc axit amin cn thit
cho c th, cc cht khong v nguyn t vi lng khc. Chnh v vy t lu bia tr thnh th ung quen thuc c rt nhiu ngi a thch.
Hng nm, vic sn xut ung ni chung v bia ni ring ng gp vo
ngn sch nh nc vi nghn t ng. Do nhu cu v cht lng sn phm ngy
cng tng nn vic xy dng nhng nh my bia mi, hin i, thay th cho nhng
nh my nh, trang thit b lc hu va m bo tnh kinh t, va p ng c
nhu cu th trng v cht lng v gi c l cn thit.
Vi tinh thn , em quyt nh lm n tt nghip vi ti: Thit k
nh my sn xut bia nng xut 100 triu lt/nm. Hy vng qua bn n ny,
em s lm r c quy trnh cng ngh sn xut bia, cc yu t nh hng n quy
trnh sn xut, mt s ci tin cng ngh nng cao cht lng bia, v vic a cng
ngh p dng vo thc t sn xut. Nhm to ra mt sn phm c gi tr kinh t cao,
thc y nn kinh t pht trin.
Do cn mt s hn ch nht nh nn vic tnh ton thit k cn nhiu thiu
st. Knh mong c cc thy c ch bo thm n c hon chnh hn.
Em xin chn thnh cm n PGS.TS Tn Tht Minh cng ton th cc thyc trong b mn tn tnh hng dn, gip , to iu kin em hon thnh tt
bn n ca mnh.
Sinh vin thc hin
Lng Tun Anh
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PHN I
LP LUN KINH T
Ngy nay cng cng vi s pht trin ca ngnh cng ngh thc phm , cngngh sn xut bia cng ang pht trin mnh trn th gii vi tc pht trin hng
nm kh nhanh c v quy m cng nh sn lng.
I.1.1. TNH HNH SN XUT V TIU TH BIA TRN TH GII
Theo thng k cc nc Ty u c t l tiu th bia cao nht trn th gii.
Nh c, an mch tiu th nhiu hn 100 lt/ ngi/nm. Cc nc c, M c
sn lng hn 10 t lt/nm.Tuy nhin Chu Phi ch c mt s nc sn xut v tiu
th bia. Ngi ta thng k c 10 nc c sn lng v tiu th bia cao nht th
gii l: M, Trung Quc, c, Braxin, Nht Bn, Anh, Mexico, Ty Ban Nha, NamPhi, Italia. Chu cng ngh sn xut bia cng pht trin mt s nc nh
Trung Quc, Nht Bn, SingapoCc nc ang pht trin nh Lo, Campuchia,
Vit Nam...u c sn lng ngy cng tng v c tc tng trng khc nhau
mi nc. Trung bnh tc tng trng Chu l 8%/nm. Sn lng bia
Nht Bn, Trung Quc t 8 10 t lt/nm. Mc tiu th trung bnh Chu l 17
lt/ngi/nm. Nht Bn l 50 lt/ngi/nm, Singapo l 20 lt/ngi/nm,
Ngoi ra cn c cc nc khc cng pht trin nhanh v c sn lng ln nh Hng
Kng, Innxia, Malayxia ....
I.1.2. TNH HNH SN XUT V TIU TH BIA VIT NAM
Vit Nam l nc nm trong khu vc ng Nam c vng kh hu nhit i
nng m, ng dn c v th nhu cu tiu th ngy cng tng. Vi sn lng ln
nht l Thnh Ph H Ch Minh khong 300 350 triu lt/nm, sau n H
Ni 150 triu lt/nm. Hin nay mi xy dng thm cc nh my khc c sn lng
ng k nh: Nh my bia Chu, Heiniken...Nhiu Nh my p dng tin b
khoa hc k thut, s dng dy chuyn thit b hin i tng nng sut, nng caocht lng sn phm nhng vn khng p ng nhu cu ca th trng v cht
lng cng nh sn lng. V vy m cc cng ty nc ngoi, cng ty lin doanh
trn vo Vit Nam v chim lnh th ni a to ln s cnh tranh ln i vi
cc cng ty bia trong nc.
V mc tiu th bia Vit Nam nm 2000 l 8 lt/ngi/nm. Tng sn
lng l 700 triu lt/nm. D kin n nm 2005 mc tiu th trung bnh l 13
lt/ngi/nm, v n nm 2020 trung bnh l 20 lt/ngi/nm, vi tng sn lng
l 1700 triu lt/nm. Hin nay nn kinh t th trng ngy cng pht trin, i sng
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ca nhn dn ngy cng c nng cao, nhu dng p ng nhu cu ngy cng
cao ca ngi tiu dng, chng t ngnh sn xut bia ang c trin vng pht trin
trong tng lai khng xa.
V chng loi bia Vit Nam, hin nay ch yu vn l loi bia vng, bia en
th sn lng rt t v ch yu s dng trong bia nh hng. Bia vng ch yu sn
xut dng bia chai, bia lon v bia hi. Cc cng ty ang c th phn ln ti Vit
Nam nh cng ty bia H Ni 120 triult/nm, cng ty bia Si Gn 200
triult/nm, cng ty bia HUDA Hu, cng ty bia VIDA Vinh. Ngoi ra cu v
ung c bit l bia ngy cng tng. Bia tr ln quen thuc vi mi ngi,
mi la tui v mi gia inh. Chng loi bia cng rt a cc thnh ph ln nh H
Ni v Tp.H Ch Minh xut hin bia ti hay bia nh hng (nh hng bn bia
ti), vi nng xut thp nhng cht lng cao, p ng nhu cu ung bia chtlng cao cho mt b phn khch hng c thu nhp cao v snh v bia.
Trong vi nm gn y, kinh t pht trin, thu nhp bnh qun u ngi
tng cao, do a s ngi ung bia bt u quan tm n cht lng ca bia.
cc vng nng thn ch yu s dng bia chai v bia hi gi t 4 n 12 nghn
ng/lt. y l du hiu tt cho th trng cng nh trin vng pht trin sn xut
bia nc ta trong tng lai.
I.2. C S XY DNG NH MY SN XUT BIA TI KHU CNG
NGHIP I AN- TNH HI DNGI.2.1. CHN A IM XY DNG NH MY
Theo ngh quyt ca tnh y Hi Dng v pht trin cng nghip, tiu th
cng nghip. Tnh to iu kin thun li h tr, thu ht cc nh u t v cc
doanh nghip trong sn xut kinh doanh. Tnh lp cc khu cng nghip nh i
An ,Tn Trng. Khu cng nghip i An c tng din tch l 664 ha vi tng vn
u t khong 1800 t ng. Trong din tch khu I l 189,82 ha (170,82 ha t
cng nghip v 19 ha t khu dn c phc v cng nghip). Nm 2007 KCN m
rng khu II l 474 ha (trong din tch t cng nghip l 403 ha, din tch t
Khu dn c l 71 ha). Ti y s hnh thnh mt Khu lin hp cng nghip tiu
khu nh ng b v hin i, m bo h tng k thut gn lin vi h tng x
hi- KCN gn lin vi khu dn c v cc dch v phc v cho cng nhn v chuyn
gia lm vic trong KCN, ng thi lm tng sc hp dn thu ht cc nh u t
n y.
Sau 5 nm trin khai u t xy dng h tng KCN i An, n nay khu I c
31 d n vi din tch t cho thu chim ti 95%. Din tch t cng nghip khu IImi thc hin xong cng tc n b GPMB 209 ha v ang thc hin cc cng trnh h
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tng k thut. H thng h tng k thut KCN c u t xy dng ng b, v hin
i gm : h thng cp in, cp nc, thot nc, giao thng, thng tin lin lc, h
thng chiu sng, trung tm kho vn, an ninh, mi trng v cy xanh....
Trong s 31 d n cp giy php trong KCN i An c 15 nh my i vo
sn xut, 9 nh my ang xy dng c bn v 7 nh my ang hon thin th tc
cp giy php xy dng; tng s vn u t ca cc d n trong KCN l 422 triu
USD; vn thc hin 250 triu USD; vn u t trung bnh 1 ha t l 4,7 triu
USD; s lng cng nhn s dng trong KCN khong 6.800 ngi, trong NL
a phng l 5.780 ngi, chim t l 85%. Hin nay KCN thu ht c nhiu
doanh nghip l cc tp ton ln c thng hiu ca cc quc gia trn th gii: M,
Nht, Php, c, Hn Quc, Trung Quc, Malaysia, i Loan v Vit Nam.
c xy dng theo tiu chun ca mt KCN sch, khng gy nhim mitrng, v vy ngoi nhim v trng tm l thu ht tht nhiu ngun vn FDI, KCN
i An lun hng ti s cn bng gia thu ht u t v bo v mi trng bn
vng, hin trong KCN xy dng nh my x l nc thi cng sut 2000
m3/ngy m phc v cho khu I.
Nhm to thun li hn cho cc nh u t v CBCNV lm vic trong KCN,
Cng ty C phn i An sn sng cung cp mt h thng dch v h tr hon ho
trong thi gian ngn nht vi chi ph hp l nht: t vn thnh lp doanh nghip v
cc th tc xin cp giy php u t; dch v t vn thit k v thi cng xy dng;dch v vn chuyn hng ha; Dch v kho tng cha tr hng ha; dch v bo
him, th tc hi quan xut nhp khu; h tr tuyn dng cng nhn; c khu nh
cho chuyn gia v cng nhn thu. KCN i An hp tc vi ngn hng Ocean Bank
thc hin h tr ti chnh cho cc nh u t thc hin d n xy dng nh
xng v thu t.
Ngoi li th v v tr u t v li th v thng mi, c s h tng ng b
hon chnh cng cc dch v hon ho, KCN i An cn hp dn cc nh u t bi
ni y c ngun nhn lc di do c th p ng ti a mi nhu cu s dng lao
ng ca cc nh u t.
n nh nhu cu sinh hot n cho cc chuyn gia v cng nhn ang
lm vic trong KCN, nm 2004 Cng ty C phn i An thc hin d n xy
dng Khu nh cho cc ch doanh nghip b tr thu cho cng nhn, chuyn
gia. Nhm p ng nhu cu pht trin ngun nhn lc phc v cho cc doanh
nghip trong KCN i An v cc KCN ln cn, hin Cng ty cng ang lp d n
xin xy dng trng cao ng o to ngh cho cng nhn.
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Nm 2008- mt nm kh khn ca nn kinh t Vit Nam do nh hng bin
ng ca kinh t th gii, v vy tc ng khng tt n n hot ng SXKD
ca cc nh u t ti Vit Nam. Tuy nhin do nm bt v ch ng c tnh hnh
nn mi hot ng SXKD ca KCN i An vn din ra bnh thng. T u nm
n nay ti KCN i An c 4 d n c cp giy php vi s vn ng k 120
triu USD. Mc tiu nm nay ca KCN i An l phn u duy tr hot ng
SXKD v m bo i sng thu nhp cho CBCNV.
Vi tinh thn on kt, ng sc ng lng, v ngi nh ln i An di
s ch o v gip kp thi ca cc cp lnh o tnh Hi Dng v nhn dn
vng D n, n nay KCN i An v ang to nn dng v v din mo mi cho
mnh v tr thnh tm im ca cc nh u t trong v ngoi nc - mt trung
tm cng nghip nh ca tnh Hi Dng. xy dng v pht trin KCN i An tr thnh mt KCN tp trung, hin
i v pht trin theo hng n nh, bn vng, Cng ty C phn i An mong
mun ng v Nh nc cn c nhng qui hoch chin lc v cc chnh sch n
nh lu di cc nh u t nc ngoi yn tm u t ti Vit Nam; cc doanh
nghip u t nh cho cng nhn v cc cng trnh phc v cho KCN cn c
vay vn u i; khi c ngun thu t cc doanh nghip nc ngoi cn c k hoch
dnh li mt phn chm lo i sng cho ngi dn ti khu vc chuyn c cu s
dng t nng nghip sang cng nghip v u t mt s cng trnh h tng kthut phc v cho KCN
I.2.2. IU KIN T NHIN V X HI
Din tch: 1662 Km2
V tr a l:
Hi Dng l mt trong 7 tnh, thnh thuc vng kinh t trng im pha
Bc, tip gip vi cc vng sau:
+ Pha ng gip Thnh ph Hi Phng
+ Pha ty gip tnh Hng Yn
+ Pha nam gip tnh Thi Bnh
+ Pha bc gip tnh Bc Giang
Kh hu:
Hi Dng nm trong vng nhit i gi ma, nhit trung bnh hng nm
l 23,30C, nhit cao nht ma h khng qu 24C, gi nng trung bnh hng
nm l 1524 gi, lng ma trung bnh hng nm 1.300 - 1.700 mm, m trung
bnh l 85 - 87%.a hnh:
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Hi Dng c chia lm 2 vng: vng i ni v vng ng bng. Vng
i ni nm pha bc tnh, chim 11% din tch t nhin gm 13 x thuc huyn
Ch Linh v 18 x thuc huyn Kinh Mn; l vng i ni thp, ph hp vi vic
trng cy n qu, cy ly g v cy cng nghip ngn ngy. Vng ng bng cn li
chim 89% din tch t nhin do ph sa sng Thi Bnh bi p, t mu m, thch
hp vi nhiu loi cy trng, sn xut c nhiu v trong nm.
iu kin x hiDn s & lao ng:
Dn s hn 1.703.492 ngi (theo iu tra dn s nm 2009).
Trong :
+ Mt dn s trung bnh: 1.044,26 ngi/km2.
+ Dn s thnh th: 324.930 ngi+ Dn s nng thn: 1.378.562 ngi
+ Nam: 833.459 ngi
+ N: 870.033 ngi
Hi Dng vn l mnh t c lch s lu i, giu truyn thng vn ha,
con ngi y giu truyn thng yu nc, cn c, chm ch, sng to v yu lao
ng, i ng lao ng di do, nhng c im trn l th mnh ca tnh Hi
Dng. Nh vy rt thun li khi s dng ngun nhn lc ti ch sn xut.
I.2.3. GIAO THNG VN TIGiao thng & c s h tng:
Tnh Hi Dng c h thng c s h tng kh hon chnh, to iu kin
thun li cho kinh t - x hi ca tnh pht trin.
+ H thng giao thng: gm ng b, ng thu, ng st; Phn b hp
l, giao lu rt thun li ti cc tnh.
- ng b: c 4 tuyn ng quc l qua tnh di 99 km, u l ng cp
I, cho 4 ln xe i li thun tin:
- ng st: Tuyn H Ni - Hi Phng chy song song vi quc l 5, p
ng vn chuyn hng ho, hnh khch qua 7 ga trong tnh.
Tuyn Kp - Bi Chy chy qua huyn Ch Linh, l tuyn ng vn chuyn
hng lm nng th sn cc tnh min ni pha Bc ra nc ngoi qua cng Ci
Ln, cng nh hng nhp khu v than cho cc tnh
- ng thu: vi 400 km ng sng cho tu, thuyn 500 tn qua li d
dng. Cng Cng Cu cng sut 300.000 tn /nm v h thng bn bi p ng v
vn ti hng ho bng ng thu mt cch thun li.
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H thng giao thng trn bo m cho vic giao lu kinh t t Hi Dng i
c nc v nc ngoi rt thun li.
I.2.4. NGUN NGUYN, NHIN LIU
nh my i vo vn hnh c th cn phi nhp nguyn liu t ni khc,
c th Malt i mch s c nhp t cng ty ng - Malt T Sn - Bc Ninh,
cch nh my 80 km, theo hng quc l 5 i H Ni. Cn nguyn liu thay th nh
my s nhp go t t Thi Bnh v cc tnh ln cn. Nhin liu cung cp cho l
hi hin nay ph bin l than v du. Vi nguyn liu than c u im chnh l r
tin, nhit lng ln, vn chuyn d dng, nhng gy bi, nhim mi trng v
tiu th vi lng ln. Cn du t th tuy c nhit lng ln, nhng t tin...
y em chn nguyn liu t l than sn xut hi. Than c vn chuyn t
Qung Ninh v a v nh my, hoc ch bng xe chuyn dng theo quc l 5.I.2.5. HIN TRNG SN XUT V TIU TH BIA TRN A BN TNH
Hin nay trn a bn tnh c mt nh my sn xut bia l cng ty c phn
bia H Ni Hi Dng vi sn lng 2005 l 9 triult/nm, tiu th khp cc
huyn trong tnh. Ngoi ra trn a bn tnh cn co mt s sn phm bia ca cc
cng ty khc v rt nhiu xng sn xut nh khp cc huyn trong tnh chim th
phn kh ln, cc xng ny c c im l sn xut theo nhu cu ca th trng,
ch yu sn xut vo ma h, v sn xut mt loi bia l bia hi, sn lng hng
nm ca cc c s ny cha thng k chnh xc c. V gi c, trn a bn tnhgi bia hi t 3.000 8.000/lt, bia chai t 5.000 25.000/lt, bia lon t 15.000
30.000/lt.
I.2.6. CHN NNG SUT
Th trng tiu th ch yu ca nh my hng ti l th trng H Ni y
l mt trong nhng ni tiu th bia nhiu nht nc, ch sau thnh ph H Ch
Minh ngoi ra nh my cn cung cp bia cho cc tnh ln cn nh: H Nam, Ninh
Bnh, Ha Bnh, Bc Ninh, Hi Phng
Vi c tnh ca bia v nhu cu nc gii kht ngy cng cao cng vi a
im t nh my thun li th vic sn xut bia s em li hiu qu kinh t cao.
iu ny chng t thit k mt nh my bia nng sut 100 triu lt/ nm l hon
ton c kh thi, chc chn s em li hiu qu kinh t cao cung nh to vic lm
cho mt lng cng nhn kh ln v tng ngun thu nhp cho ngn sch nh nc.
Nh my c thit k vi nng sut 100 triu lt bia/nm, c cu sn phm
30% bia chai v 70% bia hi. Nng dch ng trc ln men l 11,40S ng vi
bia chai, v 100
S ng vi bia hi. S dng nguyn liu thay th l go vi t l thayth l 30% cho tng lng go v malt s dng.
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Lng bia chai sn xut trong mt nm l: 30% 100 = 30 (triu lt)
Lng bia hi sn xut trong mt nm l: 70% 100 = 70 (triu lt)
Do nc ta nm trong khu vc nhit i gi ma, min Bc kh hu c 4
ma rt khc nhau v vy m nhu cu tiu th bia cc ma cng khc nhau. Ma h
do thi tit nng nc nn nhu cu s dng bia cao, trong khi ma ng do thi tit
lnh nhu cu v bia gim. Do nh my phi c k hoch sn xut mt cch hp
l lng bia sn xut ra tiu th ht trnh lng ph.
Bng k hoch sn xut ca nh my
Tnh cho qu c cng sut hot ng ln nht, trung bnh mi thng sn xut
25 ngy. Nng sut ln nht mt thng: 27000000 : 3 = 9000000 (lt)
Nng sut ln nht mt ngy: 9000000 : 25 = 360000 (lt)
Trung bnh mi ngy nu 6 m, mi m sn xut ra: 360000:6= 60000 (lt
bia).
Qu I II III IV
Bia chai, lon (triu lt) 15 12 12 15
Bia hi (triu lt) 8 15 15 8Tng nng sut (triu lt) 23 27 27 23
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PHN II
CHN V THUYT MINH DY CHUYN CNG NGHNh my c thit k sn xut loi bia vng, gm hai loi chnh l bia
chai v bia hi. sn phm c cht lng tt, th phi t tiu chun, cng nghtin tin, thit b hin i.
II.1. THNH PHN V CC CH TIU LA CHN NGUYN LIU.
II.1.1. CH TIU CHT LNG MALT I MCH .
Malt i mch l nguyn liu chnh trong sn xut bia, thnh phn v cht
lng ca malt c nh hng ln n mu sc, hng v, kh nng to bt v
bn sinh hc cho bia. Malt c sn sut t i mch m mm, sy kh, sau
tch mm s thu c malt kh dng cho sn xut. Cc ch tiu nh gi nh sau:
Ch tiu cm quan : Mu sc ca malt: vng rm hoc vng snh v c nh, hnh dng v kch
thc ca cc ht phi ng u.
V ngt nh, mi hng c trng, khng c mi l, khng ln tp cht, t
l cho php 0,5% ht gy, v v tp cht khckhng qu 1%.
Ch tiu vt l:
Khi lng hectolit (100lt): 60 kg .
Khi lng 1000 ht: 35,0 g. Kch thc: 2,5 2,8m.
cng: 50.000 55.000g.cm/g.
Hnh tho vt ct: trng c 94%.
Ch tiu ho hc.
m : 7,0%.
Thi gian ng ho : 10 20pht.
Hm lng cht ho tan: 76 %.
Hiu sut chit > 76%.
Ch s Kolback: K= 35 45 %
(K=(m ho tan)/(tng s hp cht nit ho tan)).
Hot lc Ditaza: 150 250 WK.
II.1.2. GO (NGUYN LIU THAY TH)
Go c cha nhiu tinh bt, s dng nhm thay th mt phn malt i mch
nhm thu c nhiu cht ho tan, gim gi thnh sn phm.
Ch tiu cm quan . Go c mu trng trong.
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Kch thc ng u khng mi mt, khng c mi b kht, t l ht mc,
hng, sn
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Nhng cht khc: 26,0%.
Cao hoa l dng dch chit hoa houblon c c, thnh phn nh sau:
-Axt ng: 30,0%.
-Axt ng: 6,0%.
Nha mm: 4,0%.
m: 30,0%.
Cht khc: 30,0%.[8].
II.1.4. NC
Nc l mt trong nhng nguyn liu chnh sn xut bia hm lng nc
trong bia chim 80 99%. V vy cht lng nc l mt trong nhng yu t quyt
nh n cht lng ca bia.
Nc l mt dung dch long ca cc loi mui dng ion. Nhm cation thchim nhiu nht l: Ca2+, Mg2+, H+, Na+, K+, Mn2+, Al3+, cn nhm anion ch yu
l: OH-, HCO32, CO32-, SO42. Hm lng cc mui trong nc khc nhau nn nh
hng ca chng i vi cng ngh l khc nhau.
Trong Fe l nguyn t nh hng mnh nht ti cht lng bia. Xc tc
phn ng oxy ho trong bia lm gim bn keo, gy c cho sn phm, st cn
gy v l, mi tanh, Mn lm cho bia ng, Ca2+, Na+, Mg2+ lm cho bia c v cht phi
tiu chun.
Vy trc khi a vo sn xut, nc phi c x l t yu cu cho sn xut:
pH c tnh axt nh pH = 6 7.
cng t mm n trung bnh.
Hm lng mui cacbonat khng qu 50mg/l.
Hm lng mui Mg khng qu 100mg/l.
Hm lng mui clorua t 75 150mg/l. Hm lng CaSO4 t 150 200mg/l.
Hm lng Fe2+< 0,3 mg/l.
Hm lng Mn2+< 0,05mg/l.
Hm lng CO32-< 50 mg/l.
NH3 v mui NO2 : khng c.
Vi khun E.coli: khng c.
Kim loi nng: khng c.
Vi sinh vt khng qu: 100 t bo /ml.
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x l nc c th dng h thng trao i ion, lng trong v lc, lm mm
nc v ci to thnh phn sinh hc ca nc.
II.1.5. NM MEN.
Chng nm men s dng: Saccharomyces Carlbergensis, y l loi nm
men ln men chm, c nui cy nhn ging t ng thch nghing, sau nhn
ging sn xut.
c im hnh thi v sinh l:
Hnh dng trn hoc van: kch thc (4 8)x(5 10) (m).
Sinh sn bng phng php ny chi, to gi si, to bo t.
Ym kh ty tin, ln men ru, khng ng ha nitrt.
II.1.6. CC NGUYN LIU PH
a, Ch phm enzim. Ch phm enzym Termamyl 120L.
y l loi ch phm - amylaza c sn xut t vi sinh vt c dng
ph bin trong cc nh my sn xut ru cn t tinh bt, nh my sn xut bia.
Enzym ny thu phn tinh bt mi lin kt -1,4 glucozit trong phn t amyloza
v amylopectin. V vy tinh bt s chng b phn gii thnh dextrin tan trong nc.
Nhit ti u l: 90 95C. iu ny rt thun li cho dch ho tinh bt
go v nhit h ho go l 86C.Hm lng s dng: 0,1% so vi nguyn liuthay th.S dng enzym nhm mc ch:
Tng hiu sut thu hi cht ho tan.
Tng t l nguyn liu thay th, gim gi thnh sn phm.
Ch phm enzym Cereflo 200L
y l tn thng mi ca enzym -glucanaza hot ng ti u pH=5,5
6,0, nhit 50 60C c tc dng lm gim nht ca dch ng, tng hiu
sut lc, tng kh nng trch ly cc cht vo trong dch ng. V vy a ngay qu
trnh ny vo u qu trnh ng ho nng 0,06% so vi nguyn liu thay th.
b, Cc nguyn liu ph khc.
Axit lactic: iu chnh pH= 5,3 5,5 khi ng ho.
Cc ho cht dng v sinh ty ra thit b, chai, thng cha, ng ng
nh: HNO3, NaOH, nc v trng, nc P3 cha trong cc thng CIP.
Bt tr lc Diatomit, vi lc, nc sch v sinh
Khng kh v trng, mui CaCl 2 , axt H 2 SO 4
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II.2. CHN DY CHUYN CNG NGH.
Chn dy chuyn cng ngh l mt trong nhng khu kh khn nht trong
cng vic thit k. Mt dy chuyn cng ngh phi va ph hp vi trnh k
thut hin i li va pht huy ti a ngun lc lao ng, nhng phi m bo hiu
qu kinh t cao nht v gi thnh h nht vi cht lng tt nht. y l khu quan
trng quyt nh n cht lng sn phm v hiu qu kinh t ca nh my do
em xin a ra nhiu phng php ti u cho qu trnh.
II.2.1. NGHIN NGUYN LIU.
a. Nghin go (nguyn liu thay th ): ta cn hiu sut ha tan cao nht, v
qu trnh thy phn go trit nht do vy cn nghin go cng nh cng tt.
y ta chn phng php nghin ba.
b. Nghin malt.C ba phng php nghin chnh:
Phng php nghin th: c nghin lun khng qua qu trnh ngm
hay ry nc.
u im: l p dng c cho mi phn xng sn xut t nh n ln, t
th cng n t ng, cht lng ca bia kh tt.
Nhc im : v malt d b nt, gy nh hng xu n mi, hng v ca
bia nh hng xu n qu trnh lc sau ny. Phng php nghin m : Malt trc khi vo my nghin c phun m
b sung 2% m bng nc si, hi hoc nc m 600 C.
u im: V malt c bo ton trng thi sau khi nghin, to iu kin
cho lc d dng hn (nu lc y bng), mt khc vic phun m lm trng n cc
dng keo ca ni nh, thun li cho qu trnh cng ngh sau ny.
Nhc im: thit b phc tp, tn km nhiu v chi ph, khng cho php
nghin cc ht c kch thc khc nhau.Vic phun nc trc khi nghin khng qu
1 2h nu phun lu hn m khng a vo nu d nhim vi sinh vt. Phng php nghin t : Malt c a vo cng vi nc theo t l
nht nh trong my nghin.
u im: rt ngn c thi gian lc b cn 80% 90% (do rng ca
khi b tng ln), t rt ngn thi gian thao tc.
Nhc im: thit b phc tap, u t ban u ln.
Qua vic phn tch trn em quyt nh chn nghin theo phng php
nghin m.
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II.2.2. NU V NG HA NGUYN LIU
Nh my sn xut Bia c s dng nguyn liu thay th, do vy quy trnh
ng ha y em chn theo phng php hn hp, l phng php nu c s
dng nguyn liu thay th, trong qu trnh nu nguyn liu thay th c b sung 10%
Malt lt, v b sung ch phm en zim.
u im: Dch c duy tr ti nhiu mc nhit thch hp cho cc enzim
hot ng khi s dng nguyn liu thay th, do hiu sut ng ha tng, to
dinh dng y cho nm men pht trin, s hi ha gia cc thnh phn trong
bia c m bo.
Nhc im: un si nhiu ln dn n ha tan cc cht khng c li cho
cht lng ca bia sau ny ngoi ra cht lng cm quan cng b nh hng.
Phng php ny tn hi, tn thit b, chu k nu ko di,u t ban u ln.II.2.3. LC DCH NG
C hai thit b lc rt ph bin hin nay l thit b lc khung bn v thit b
lc y bng (thng lc).
a, My lc khung bn:
u im:
V lc di p lc ca bm nn thi gian lc nhanh, cht lng tt, dch
lc trong, dng c nhiu nguyn liu thay th.
Nng sut n nh, cht lng khng ph thuc vo cht lng malt.
Lng nc ra b t.
Th tch my b do gim din tch nh xng.
Nhc im:
Dng nhiu lao ng c bp (phi tho lp,v sinh)
Nguyn liu cho mt m nu phi ln.
Kh t ng ha, bo dng chi ph cao.
b, My lc y bng: u im:
V sinh d dng,chi ph bo dng t, nng sut ln.
Cch nhit tt hn.
Nhc im:
Vn u t ban u ln.
Din tch phn xng ln.
Cht lng bia ph thuc vo cht lng malt.
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Lng nc ra b nhiu, dch lc khng trong lm.
Qua phn tch trn em quyt nh chn thit b lc y bng.
II.2.4. UN SI DCH NG VI HOA HOUBLON
Qa trnh nu dch ng vi Hoa Houblon nhm mc ch trch ly cc cht
ng, tinh du thm, polyphenol, cc cht cha Nit v cc thnh phn khc ca
Hoa Houblon. Lm ng t protein, tng bn keo ca dch ng, n nh thnh
phn sinh hc ca bia, tiu dit vi sinh vt, c c mt phn dch ng n nng
thch hp, to mu v hng v c trng cho bia. t cc mc ch trn ta
cn un Hoa nhit cao, cng si mnh. Do em chn thit b hnh tr c
bu cp nhit trung tm dng ng truyn nhit, v s dng hi gia nhit cho ni
un hoa.
II.2.5 LN MEN DCH NGLn men nhm chuyn cc loi ng, dextrin... c kh nng ln men thnh
ru, CO2 v cc sn phm khc. C hai phng php ln men l ln men theo
phng php c in v ln men theo phng php hin i.
Phng php c in :
Theo phng php ny dch ng sau khi un hoa c ln men trong cc
phng lnh hoc hm lnh, gm hai giai on ln men chnh v ln men ph, hai
giai on ny din ra trong hai thit b khc nhau.
u im: Thit b n gin, d thao tc, d ch to, c hng v m ,cht lng tt.
Nhc im: Thi gian ln men di, tn hao nhiu lnh, tn hao nhiu dch
ng khi chuyn t ln men chnh sang ln men ph.
Phng php ln men hin i:
Ton b qu trnh ln men din ra trong mt thit b. Thit b c cu to dng
thn tr y cn, c khoang lnh bn ngoi iu chnh nhit , c lp bo n
cch nhit bn ngoi. Nhit ca qu trnh ln men cao hn so vi phng phpln men c in.
u im: Thi gian ln men rt ngn hn so vi phng php ln men c
in, lng dch ng hao ht khng ng k khi chuyn i gia hai giai on
ln men chnh v ln men ph. Hiu sut s dng thit b cao, iu kin v sinh v
trng tt, kh nng t ng ha cao v t tn lnh.
Nhc im: Do nhit ln men cao nn c nhiu sn phm ph, cht
lng ca bia km hn so vi phng php ln men c in.
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Theo phng php ny th cc chng nm men hay c dng thuc loi
Saccharomyses Calrbergebcis, ln men chm.
Qua phn tch trn em chn ln men theo phng php hin i, vi thit
b thn tr, y cn, ln men theo phong php ln men chm vi chng nm men l
Saccharomyces Calrbergebsis.
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S CNG NGH SN XUT BIA
Malt
Ngh.m
.Ho
H.houblon
Ngh.kh
BLc(1at)
Nu hoa
L.xoy
L.nhanhOxy(7mg/l)
Go
Ngh.ba
H ho
Enzim(0,04%)
axt
B
Menging
N.gingCp I
Lm.chnh(8ngy)
CO2
Enzim(0,04%)
R.MenRt menLm.ph(12ngy)
Lc Bia
Malt lt
N.gingCp II (10%)
M.thi
B
Enzim(0,04%)
axt
S NU - NG HA
Cn
Ra b
N c(5:1)
nh l ng nh l ng
N c(5:1)
Bu cha
X lMen st(1%)
X l
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Malt
Ngh.m
.Ho
H.houblon
Ngh.kh
BLc(1at)
Nu hoa
L.xoy
L.nhanhOxy(7mg/l)
Go
Ngh.ba
H ho
Enzim(0,04%)
axt
B
Menging
N.gingCp I
Lm.chnh(8ngy)
CO2
Enzim(0,04%)
R.MenRt menLm.ph(12ngy)
Lc Bia
Bo ho CO2
Chai K.tra Chit Chai Chit Bock
S.Phm
K.tra
D.Nhn
Thanh Tr ngHi
Malt lt
N.gingCp II (10%)
M.thi
CO2
B
Bn
s l n men bia
Enzim(0,04%)
axt
S NU - NG HA
Cn
Ra b
N c
(5:1)
nh l ng nh l ng
N c
(5:1)
Tng tr
RaRa
Xut xng
Bu cha
X lMen st(1%)
X l
K.tra
II.3. THUYT MINH DY CHUYN CNG NGH
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II.3.1. NGHIN NU - NG HA NGUYN LIU
Nguyn liu nhp v c a vo xylo cha v bo qun iu kin thch
hp. Khi a vo nu nguyn liu c nghin theo m vi khi lng xc nh ca
mt m, sau dng gu ti v vt ti a nguyn liu vo ni h ha v ng ha
theo t l cho trc. V nu c s dng nguyn liu thay th do vy trong qu trnh
h ha em c s dng 10% malt lt nhm tng cng hot lc enzim cho ni h
ha. Lng malt lt ny c nghin theo ch nghin kh, cn malt dng trong
ni ng ha th c nghin theo ch nghin m c phun hi nc trc khi
nghin t 1 n 2h sao cho m trong malt tng 2% m.
Tin hnh nu:
Trc tin cp nc 450C vo ni h ha vi t l: nc:nguyn liu bng
5:1, bt cnh khuy. Sau tin hnh xung bt go +10% malt lt, tip theo bsung ch phm enzim Termamyl 120L 0,04% so vi lng nguyn liu, b sung
axt H 3 PO 4 v CaSO 4 v gi nhit ny trong 30 pht. Sau tin hnh nng
nhit khi dch ln 860C v gi trong 30 pht ha tan tinh bt v dch ha mt
phn tinh bt di tc dng ca enzim -Amilaza. Tip nng nhit ca khi
dch ln n si, v gi y t 25 n 30 pht nhm ha tan hon ton tinh bt,
sau chuyn sang ni ng ha kt thc qu trnh nu.
Tin hnh ng ha:
Khi ni cho bt u si ta bt u tin hnh thao tc ni ng ha. Bm
nc 450C vo ni ng ha theo t l nc:nguyn liu bng 5:1, sau bt cnh
khuy, tip theo cho ton b lng malt cn li vo ni ng ha, b sung axit
H2SO4 , CaCl2 v enzim Cereflo 200L. Ngm y trong 30 pht sau chuyn
mt phn dch cho sang ni ng ha sao cho ni ng ha t nhit l 520C
gi y trong 25 pht to iu kin cho enzim proteaza hot ng vi mc ch
m ha. Tip theo bm ht lng cho bn ni h ha sang ni ng ha, lc ny
nhit y t 60 61 0 C sau ta tng nhit ni ng ha ln 63 0 C v gi
y trong 20 pht nhm to iu kin cho enzim - Amilaza hot ng nhm
phn ct tinh bt v dextrin thnh maltoza v cc sn phm ph khc, Tip theo
nng nhit ln 730C v gi y trong 20 pht to iu kin cho enzim -
Amilaza hot ng nhm phn ct tinh bt v cc cht cao phn t thnh cc dextrin
v cc sn phm ph khc. Cui cng nng nhit ca khi dch ln 750C v gi
y cho n khi ng ha hon ton (Kim tra bng cch th mu vi dung dch
It ), thng mt 25 30 pht th kt thc qu trnh ng ha.
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70
8090
100
10 30 60 90 120 150 180 210 240 270
45
86
4552
6372 75
100
S N u V N G H a
Nhit C
Thi gian(pht)
10203040
5060
II.3.2. LC DCH NGTrc khi lc dch ng, ni lc c v sinh sch s v c hm nng,
sau b sung nc nng 76 780C ngp li lc t 1 1,5cm ui ht khng
kh, tip theo bt cnh khuy, dng bm chuyn ht khi dch t ni ng ha
sang ni lc , sau khi bm xong tip tc khuy o thm 10 pht na th lng 15 20 pht, tip theo m van dch chy vo bnh trung gian. Ban u dch cn c
ta phi hi lu dch tr li ni lc, khi nhn qua knh quan st thy dch trong ta
ng van hi lu li m van sang ni nu hoa v bt bm cm bin cho hot ng.Lc cho n khi b mt lp dch cch lp b t 2 3cm ta tin hnh dng qu trnh
lc chnh v chuyn sang qu trnh ra b. Ra b bng nc nng 780C khong 3
ln cho n khi nng ng trong b < 2% th kt thc qu trnh lc.
II.3.3. UN SI DCH NG VI HOA HOUBLON
Sau khi bm dch ng t thng lc sang ni un hoa, trong qu trnh
bm cn phi cung cp hi vo ni un hoa n khi bm ht dch lc sang th
dch trong ni nu hoa cng va si. Khi si c 5 pht ta cho ton b cao hoa
vo ni nu hoa, sau khi si c 30 pht ta cho 80% lng hoa vin, khi si
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c 90 pht b sung tip 20% lng hoa vin cn li. Qua trnh un hoa kt
thc sau 110 pht un si.
Qu trnh un hoa m bo ch si vi cng mnh, hay l si bng,
t yu cu ta s dng hi nc c p sut t 2,5 -3kg/cm2. Cng khng nn
cho ni si qu mnh lm tro dch ra ngoi.
II.3.4. LNG XOY V LM LNH DCH NG
Sau khi un hoa xong ta chuyn dch ng vo ni lng xoy theo phng
tip tuyn vi thnh thng to thnh dng lng xoy, cn v cc cht khng tan chu
tc dng ca lc hng tm s xoy vo gia thng v lng xung y thng. Thi
gian cn thit ly dch ra khi thng l 30 40 pht, dch c ly qua ba van.
Sau khi ly ht dch ta tin hnh thu b v v sinh thit b.
Sau khi lng xong ta phi a dch ng v nhit thch hp cho qu trnhln men l t 12 140C. Dch ng c bm vo my lnh nhanh kiu tm bn
hai cp, cp I dng tc nhn l nc thng, cp II dng tc nhn lm lnh l
Glycol c nhit -40C. Sau khi ra khi my lnh nhanh dch ng c b sung
oxy v trng n nng 6-8 mg/lt th a vo tank ln men v tin hnh ln men
dch ng.
II.3.5. LN MEN DCH NG
a, Chun b men ging:
Chng nm men s dng l SaccharomycesCarlbergensis, l dng nm menchm. Nm men ging c th nhp t ngun nm men thun khit cc c s vi
sinh, hay c th ti s dng men sa.
Nui cy men ging :
Chng nm men thun khit c nhp v dng ng thch nghing, ban
u ta cy sang ng nghim 10 ml, tip theo ta chuyn sang bnh tam gic 100ml,
nui 20 25 0C trong 20 24 h, sau chuyn sang bnh 1 lt nui 20 250C
trong 24 h, tip theo chuyn sang bnh 10 lt nui 20 25 0C trong 16 18h, v
chuyn sang thit b nhn men ging cp I, trong thit b ny dch ng c
thanh trng, v h nhit n 20 0C , dch ng c sc oxy v trng 3h mt ln
v mi ln trong 15 pht, p sut nui cy trong thit b l 0,8 1,0 at, sau khong
thi gian 14 16h ta kim tra nng t bo, nu t t l 80 triu t bo/mldch th
chuyn n thit b nhn men ging cp II. Trong thit b nhn men ging cp II,
dch ng cng c thanh trng nhng c lm ngui n nhit 16 0C , cc
iu kin nui cy khc cng ging nh trong thit b nhn men ging cp I. Sau 10
14h ta mang kim tra vi sinh vi cc ch tiu nh: ng u kch thc, lng
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t bo nm men /ml dch phi t (1,5 2)x108 t bo/ml dch, t bo cht < 5%, t
bo ny chi > 60%, t bo cha Glycogen > 70%,...Nu t cc tiu chun trn ta
s chuyn men ging sang tank ln men vi t l 10% men ging so vi tng th
tch dch ng ca mt tank.
Phng php x l v hot ha nm men ti s dng:
Sa men sau khi rt t tank ln men ta dng ry tch cn lng, tip theo
ra nm men bng nc lnh v trng 1 20C trong thit b ra men. Khi ra tin
hnh sc nc t di ln sau lng v gn b xc nm men trn b mt, tin
hnh ra khong 4 5 ln th c. n y ta c th mang nm men ti s dng
hoc hot ha nm men i vi nm men yu, sau mang s dng hoc c th
mang bo qun. Nm men ti s dng c t l 1% so vi tng th tch dch ng
ca mt tank. Trong trng hp nm men b nhim tp:
Sau khi rt sa men xong a vo thit b ra men, dng H 2 SO 4 1%, h pH
xung 2,9 3,3. Ngm men trong 40 pht, sau mang trung ha bng NaHSO 3
1%, cho n khi pH= 4,5 5,0, khuy trong 10 pht, sau ra li bng nc v
trng 1 20C khong 4 5 ln.
Hot ha nm men:
a nm men vo thit b hot ha, tip theo b sung dch ng vi nng 4 5 lt dch ng /1lt dch nm men. Sau khong 4 5 h, sau khi kim tra vi
sinh nu s lng t bo ny chi t yu cu v nng cn khong 0,3% th kt
thc qu trnh hot ha.
b, Tin hnh ln men dch ng trong tank ln men :
Dch ng sau khi lm lnh nhanh xong c nhit l 14 0 C, c bm vo
tank ln men, sau khi bm xong m u tin ta a ton b men ging vo theo t
l men ging 10% so vi tng th tch dch ng ca mt tank ln men. Trn thn
ca tank ln men c o lnh s dng tc nhn l Glycol, xung quanh c lp bo n duy tr nhit trong giai on ln men chnh t 12 140C, iu chnh van thu
hi CO2 duy tr p sut bng 0,7 at. Trong qu trnh ln men chnh lun kim tra
nhit , p sut, nng ng, nng cn....khi nng ng cn khong 2,5 3,00Bx th kt thc qu trnh ln men chnh. iu chnh lu lng lnh sao cho
nhit trong tank ln men h t t xung 50C trong vng 18 24 h. Sau khong thi
gian trn tin hnh rt sa men v mang sa men i x l. Tip theo h tip nhit
trong tank ln men xung 0 20C, iu chnh p sut trong tank khong 1,0 at, sau
khong 8-10 ngy tng p sut ca tank ln men ln 1,3 1,5 at, cho n khi kt
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thc qu trnh ln men. Qu trnh ln men ph kt thc khi nng ng st trong
dch khong 2,0 2,8 0 Bx.
II.3.6 LC BIA
Sau khi kt thc qu trnh ln men, ta tin hnh lc bia. Thit b lc em dng
my lc Nn, c dng bt tr lc l Diatmit. Qu trnh lc tin hnh nh sau: Ban
u ha bt tr lc sau bm vo my lc nn ph bt tr lc, tip theo bm
bia vo lc. Qua knh quan st nu thy bia cn c ta hi lu li my lc nu
dch lc trong m van a bia non sang b phn sc kh CO 2 . Bia v CO 2 qua
thit b ny s c iu chnh lu lng nhm bo ha lng CO 2 i vi tng
loi bia khc nhau. Vi bia hi nng l 3,5 4,0g CO 2 /lt bia hi, vi bia chai
nng l 4,5 5,0g CO 2 /lt bia. Thit b bo ha c dng Bugi (kiu phun), bia v
kh CO2 c phun trn ln vo nhau trong xilanh, sau i qua mng zczc nhm
tng kh nng tip xc gia hai lu th, t tng kh nng ha tan ca CO2 vo
trong bia. Tip theo qu trnh bo ha ta a bia vo tank tng tr trong 24h trc
khi mang chit vo chai.
II.3.7. PHN XNG HON THIN
a, Chit bock.
Trong chit bock th bia khng cn phi b sung CO2 m phi m bo ba
yu cu sau: Rt y th tch thng bock.
Rt khng si bt.
Hao ph bia t nht.
Chit bock theo nguyn tc ng p vo cc bock th tch cha 25lt ,50 lt,
100 lt.
b, Hon thin bia chai.
Chai em chit phi tiu chun:
V sinh sch s.
Bia em chit chai cng c c sn xut khc so vi bia hi.
My chit lm vic theo nguyn tc ng p c u im:
Hn ch c bia tip xc vi khng kh.
Bia khng b tro bt, t tn hao CO2
Chit rt nhanh ng nh mc.
T ng ho hon ton.
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Qu trnh chit chai c thc hin theo dy chuyn sau
Bia T.phm
Chit Chai
Dp Nt
Kim Tra
ThanhTr ng
Dn Nhn
ChaiChit Bock
Bock Bia Bock
Bia Chai Thnh Phm
s quy t r nh Hon Thin Bia
Lm Kh
Ra chaiRa Bock
Chai phi c sn xut t loi thu tinh trong sut mu nu sm, hoc mu
xanh trnh tc ng ca phn ng quang ho gy nh hng xu n cht lng
sn phm.
Ra chai: Mc ch dit ht vi khun, cn bn, kim tra cht lng chai,
trc khi a vo chit.
Khi ra chai i qua cc b phn ca h thng my ra: Kim tra cht lng
chai, ra ln lt nhit 35 0 C, 65 0 C , 35 0 C, nc lnh 8 0 C.
Cch tin hnh ra chai: Ngm nc nng 350 C.
Ngm xt 65 0 C, 1,5%, phun xt vo chai.
Phun nc nng 65 0 C .
Ngm nc m 35 0 C.
Ngm nc lnh 8 0 C.
Sau khi ra chai song a qua b phn sy v qua b phn kim tra loi
b cc chai khng t yu cu. Sau chai theo bng chuyn a n b phn chit
chai theo nguyn l ng p. Mt bnh xe hnh sao s gt tng chai mt vo a qua
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pt tng. Trong qu trnh chuyn ng quay pt tng y chai ln ng mc v c
u cao su chp cht v chai tip tc quay khi qua ht mt vng th qu trnh chit
bia vo chai kt thc. Ging nh my chit, my dp nt chuyn dch theo mt
hng theo khun dp v dp tng nt vo ming chai. ng vo thi im th
pttng ln xung ng cht vo chai.
Tc dp nt bng vi tc chit. Sau giai on dp nt l giai on soi chai
bng my soi t ng loi b nhng chai v, chai lch nt, chai khng trong hay cha
t bt k mt tiu chun no. Sau th theo bng ti ti my thanh trng.
Thanh trng.
Mc ch: Di tc dng ca nhit 60 65oC, trong thi gian t 15 20
pht, cc t bo nm men, cc vi sinh vt sng b tiu dit hoc b lm yu i, tng
thi hn s dng v cht lng cho sn phm.Ch thanh trng: Dng hi ra nhit cho nc, sau dng nc thanh
trng cho bia. Nhit thanh trng l 60 650C.
Sau khi thanh trng th lm ngui chai n nhit thng v c x kh
bng kh nn v tin hnh hon thin sn phm.
Dn nhn v xp kt.
Trc khi dn nhn phi x kh v lau sch chai.
Nhn phi t tiu chun: Ghi tn nh my bia sn xut, ng k cht lng,
ngy, thng sn sut, thi hn s dng do nh nc cp. c bit hnh thc nhnphi c trang tr p, bt mt.
Chai sau khi dn nhn c xp vo kt v xut xng v a n ni tiu
th.
Yu cu ni bo qun bia: Kho m bo thong, sch, thng gi v chiu
sng tt. Khng lm nh hng n cht lng bia trong sut qu trnh bo qun.
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PHN III
TNH CN BNG SN PHM
III.1 Tnh cn bng sn phm cho bia hi
n gin ta tnh cn bng sn phm cho 100 lt bia thnh phm. Trongqu trnh sn xut, tn tht cc cng on l khng th trnh khi nn trong trong
qu trnh tnh ton ta u phi tnh n lng tn tht tng cng on. Lng tn
tht ph thuc vo nhiu yu t nh cht lng nguyn liu, ch cng ngh thit
b. Cc ch s yu cu i vi nguyn liu chnh cho sn xut bia l:
Bng 3.1: Cc ch s yu cu i vi nguyn liu chnh cho sn xut bia
Ch s Malt Go
m % 5% 13% ho tan 80% 85%
T l nguyn liu 70% 30%
Bng 3.2: Tn tht tnh theo % ca tng cng on sn xut l
Qu trnh Tn tht
Nghin
Nu, ng ho, lcNu hoa
Lng xoy
Lm lnh nhanh
Ln men chnh ph
Lc bia
Bo ho CO2
Chit bock
Chit chai
0,5% so vi trng lng nguyn liu
2% so vi cht kh10% lng dch do nc bay hi
2,5%
0,5%
4% so vi lng dch
1%
0,5%
1%
4%
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III.1.1. Tnh lng bia v dch ng qua cc giai on
Qu trnh chit bock tn tht 1%. Vy lng bia trc khi chit bock l:
100 : (1- 0,01) = 100 : 0,96 = 101,01 (l).
Qu trnh sc CO2 tn tht 0,5%. Lng bia sau khi lc l:101,01 : (1- 0,005) = 101,52 (l)
Qu trnh lc bia tn hao 1%. Lng bia trc khi lc l:
101,52 : (1- 0,01) = 102,55 (l)
Qu trnh ln men chnh v ph tn hao 4%. Lng dch ng a vo ln
men: 102,55 : (1- 0,04) = 106,82 (l)
Qu trnh lng trong v lm lnh tn hao 3%. Lng dch a vo lng xoy:
106,82 : (1- 0,03) = 110,12 (l)
Khi lm lnh th tch dch ng co 4%. Th tch dch ng 100 oC trckhi lng v lm lnh l:
110,707 : (1- 0,04) = 114,70 (l)
Dch ng 100Bx 20oC c khi lng ring d20/20= 1,039 (kg/l). Vy
khi lng dch ng sau qu trnh un hoa 200C l:
110,12 x 1,039 = 114,4(kg)
Lng cht chit c trong dch ng 100Bx l:
114,4 x 0,10 = 11,44(kg)
Qu trnh nu, lc tn hao cht chit 2%. Lng cht chit cn thit l:
11,44 : (1- 0,02) = 11,67(kg)
III.1.2. Tnh nguyn liu cho 100 lt bia 100Bx
Gi lng malt cn dng l M, lng cht chit thu c t M kg malt l:
M x 0,995 x 0,95 x 0,8 = 0,756 M
Lng go cn dng l 0,3/0,7, lng cht chit thu c t go l:
M x 0,3/0,7 x 0,995 x 0,87x 0,85 = 0,315M
Tng lng cht chit l:0,756M + 0,315M = 1,071M = 11,67(kg)
Lng malt cn dng l:
M = 11,67/ 1,071 = 10,9 (kg)
Lng go cn dng l:
10,9 x 0,3/0,7 = 4,67 (kg)
III.1.3. Tnh lng men ging.
Lng men ging nui cy tip vo trc khi ln men chnh l 10% so vi
lng dch a vo ln men l:
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106,82 x 0,1 = 10,68 (l)
Lng men sa tip vo trc khi ln men chnh l 1% so vi lng dch
a vo ln men.
106,82 x 0,01 = 1,068 (l)
III.1.4. Tnh lng b malt v go
Tng lng cht kh ca malt v go l:
10,9 x 0,995 x 0,95 + 4,67 x 0,995 x 0,87 = 14,35 (kg)
Tng lng b kh bng tng lng cht kh go v malt tng lng cht
chit go v malt:
14,35- 11,67 = 2,68 (kg)
Tnh lng b m:
- m ca b l 80%- Lng b m l: 2,68 : 0,2 = 13,4 (kg)
- Lng nc trong b l: 13,4 2,68 = 10,72 (kg)
III.1.5. Tnh lng nc dng trong qu trnh nu v ra b.
a. Tnh lng nc dng trong ni h ha
Qu trnh h ha t l (bt go + 10% malt lt) : nc = 1:5. Lng nc
cho vo ni h ha:
(4,67 + 4,67 x 0,1 ) x 5 = 25,69 (lt)
Lng nc c sn trong nguyn liu ni h ha l:4,67 x 0,995 x 0,13 + 0,467 x 0,995 x 0,05 = 0,63 (kg)
Vy tng lng nc + bt cho vo ni h ha l:
6 x ( 4,67 x 0,995 + 0,467 x 0,995) = 30,66 (kg)
Qu trnh un si si bay hi 5% vy lng dch trong nui h ha l:
30,66 x 0,95 = 29,13(kg)
b. Tnh lng nc dng trong ni ng ha:
Qu trnh ng ha t l malt: nc = 1:5. Lng nc cho vo ni ng
ha: (10,9 4,67 x 0,1) x 5 = 52,17 (kg)
Tng lng nc cho vo ni ng ha v ni h ha l:
52,17 + 25,69 = 77,86 (l)
Lng nc c sn trong nguyn liu l:
(10,9 4,67 x 0,1) x 0,05 x 0,995 = 0,52 (kg)
Khi ng ha a ton b dch t ni h ha sang, khi tng lng dch
trong ni ng ha l:
(10,9 4,67 x 0,1) x 6 + 29,13 = 91,73 (kg)Qu trnh ng ha bay hi 4% vy lng dch cn li l:
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91,73 x 0,96 = 88,06 (kg)
Lng nc trong dch trc khi lc l:
88,06 - 14,35 = 73,71 (kg)
Lng nc trong dch sau khi un hoa ( nng dch ng 100Bx) l:
110,12 x (1- 0,10) = 99,1 (kg)
Khi un hoa lng nc bay hi 10% nn lng nc un dch trc khi
un hoa
99,1 : (1- 0,1) = 110,11 (kg)
Tnh lng nc ra b
Vnc trc lc + Vnc ra b = Vnc trong b + Vnc trong dch nu hoa
Vnc ra b = Vnc trong b + Vnc trong dch nu hoa - Vnc trc lc
Vnc ra b = 10,72 + 110,11 - 73,71 = 47,12 (kg) = 47,12 (l)III.1.6. Tnh cc nguyn liu khc
a. Tnh hoa houblon
Chn bia hi c ng l 18 BU. Vy 100 lt bia c ng l 18 BU c
lng cht ng l:
100 x 18 = 1800 (mg) - axit ng
Gi hiu sut chit cht ng l 30% nn lng cht ng cn dng l:
1800 : 0.3 = 6000 (mg) - axit ng
T l cao hoa : hoa vin = 20 : 80- Chn cao hoa 45 % - axit ng
- Hoa vin thm 7% - axit ng
- Hoa vin ng 8% - axit ng
Chn t l hoa vin ng : thm = 40 : 60. Cao hoa chim 20%:
100% = 6000 (mg) - axit
20% = X ?
X = 20 x 6000 : 100 = 1200 (mg) - axit ng
Khi lng cao hoa cn dng l:
45% = 1200 (mg) - axit ng
100% = Y?
Y = 100 x 1200 : 45 = 2666,7 (mg) cao hoa
Lng hoa vin l: 6000 1200 = 4800 (mg) - axit ng
Cht ng trong hoa vin ng l: 4800 x 40 : 100 = 1920 (mg) - axit ng
Lng hoa vin ng l: 1920 x 100 : 8 = 24 000 (mg) hoa vin ng
Cht ng trong hoa vin thm l: 4800 1920 = 2880 (mg) - axit ng
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Lng hoa vin thm l: 2880 x 100 : 7 = 41143 (mg) hoa vin thm
b. Tnh lng ch phm emzim
Ta s dng ch phm enzim termamyl 120L t l 0,1% so vi nguyn liu
thay th l go. Vy lng ch phm cn dng l:
4,67 x 0,001 = 0,00467 (kg)
S dng enzym Maturex b sung vo dch ng sau khi lm lnh vi lng
0,02 g/l. Lng dch ng sau khi lm lnh l 106,82 lt, vy lng enzym cn dng:
106,82 x 0,02 = 2,14 (g)
c. Tnh bt tr lc diatomit:
Lng bt tr lc cn dng ty thuc vo cht lng bt, thit b lc v b
mt lc.
Thng thng c 1000 lt bia cn 0,73kg bt lc. Vy lng tr lc cho 100lt bia cn dng l:
0,73 : 10 = 0,073 (kg) = 73 (g)
III.1.7. Tnh cc sn phm ph
a. Tnh lng b hoa houblon
Lng cht khng ha tan trong hoa vin l 60%, b hoa c m l 80%,
cao hoa c lng b khng ng k nn b qua:
24000 + 41 143 = 65142 (mg) hoa vin
Lng b hoa s l: 651432 x 0,6 : (1- 0,80) = 195426 (mg) = 195,4 (g)Cn lng: c 100 kg nguyn liu c khong 1,75 kg cn lng c m 80%
( thng lng xoy). sn xut 100 lt bia cn lng nguyn liu l:
10,9 + 4,67 = 15,57 (kg)
Vy cn lng c m 80% c khi lng l:
15,57 x 1,75 : 100 = 0,27 (kg)
b. Tnh lng sa men:
C 100 lit bia cho 2 lt sa men c m 80% trong lng sa men c
ti s dng l 1% so vi lng dch a vo ln men l 1,068 lt sa men.
Lng men sa ti s dng sn xut ra 100 lt bia l 1,068 lt.
Phn cn li lm thc n gia sc chim:
2 - 1,068 = 0,932 (l)
c. Tnh lng CO2 thu hi
Theo phng trnh:
C12H22O11 + H2O 4 C2H5OH + 4 CO2
C 342 gam maltora to thnh 176 gam CO2
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Lng dch trc khi ln men (dch 100Bx dch c d = 1,039)
106,82 x 1,039 = 110,98 (kg)
Lng cht chit trong dch ln men c ng 11,4S l:
110,98 x 0,10 = 11,098 (kg)
Coi ton b lng ng ln men l maltoza, hiu sut ln men trong qu
trnh ln men chnh l 55% nn lng CO2 thu c l:
11,098 x 0,55 x 176 : 342 = 3,14 (kg)
Lng CO2 bo ha trong bia non l 2 g CO2/ lt bia
102,55 x 2 = 205,1 (g) = 0,2051 (kg)
Lng CO2 thot ra l: 3,14 0,205 = 2,935(kg)
Lng CO2 thu hi ch t 70%
2,935 x 0,7 = 2,055 (kg) 20oC th 1 m3 CO2 nng 1,832 kg. Suy ra th tch CO2 bay ra l:
2,055 : 1,832 = 1,12 (m3)
Lng CO2 cn bo ha thm t 3,5g/l bia sau bo ha l:
3,5 x 101,01 2 x 101,52 = 150,5 (g)
Th tch CO2 cn bo ha thm l:
150,5 : (1,832 x 1000)= 0,082 (m3)
III.2. Tnh cn bng sn phm cho bia chai
III.2.1. Tnh lng bia v dch ng qua cc giai onQu trnh chit bia chai tn tht 4%. Lng bia bo ha CO2 l:
100 : (1- 0,04) = 100 : 0,96 = 104,17(l)
Qu trnh sc CO2 tn tht 0,5%. Lng bia sau khi lc l:
104,17 : (1- 0,005) = 104,690 (l)
Qu trnh lc bia tn hao 1%. Lng bia trc khi lc l:
104,690 : (1- 0,01) = 105,75 (l)
Qu trnh ln men chnh v ph tn hao 4%. Lng dch ng a vo ln men:
105,75 : (1- 0,04) = 110,16 (l)
Qu trnh lng trong v lm lnh tn hao 3%. Lng dch a vo lm lnh l:
110,16 : (1- 0,03) = 113,56 (l)
Khi lm lnh th tch dch ng co 4%. Th tch dch ng 100 0C trc
khi lng v lm lnh l:
113,56 : (1- 0,04) = 118,29 (l)
Dch ng 12Bx 20oC c khi lng ring d20/20= 1,048 (kg/l). Khi
lng dch ng sau qu trnh un hoa 200
C l:113,56 x 1,048 = 119 (kg)
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Lng cht chit c trong dch ng 120Bx l:
118,29 x 0,12 = 14,19 (kg)
Qu trnh nu, lc tn hao cht chit 2%. Lng cht chit cn thit l:
14,19 : (1- 0,02) = 14,5 (kg)
III.2.2. Tnh nguyn liu
Gi lng malt cn dng l M, lng cht chit thu c t M kg malt l:
M x 0,995 x 0,95 x 0,8 = 0,756 M
Lng go cn dng l 0,3/0,7, lng cht chit thu c t go l:
M x 0,3/0,7 x 0,995 x 0,87x 0,85 = 0,315M
Tng lng cht chit l:
0,756M + 0,315M = 1,071M = 14,5(kg)
Lng malt cn dng l:M = 14,5/ 1,071 = 13,54(kg)
Lng go cn dng l:
13,54 x 0,3/0,7 = 5,80(kg)
III.2.3. Tnh lng men ging
Lng men ging nui cy tip vo trc khi ln men chnh l 10% so vi
lng dch a vo ln men l:
110,16 x 0,1 = 11,0(l)
Lng men sa tip vo trc khi ln men chnh l 1% so vi lng dcha vo ln men. 110,16 x 0,01 = 1,1 (l)
III.2.4. Tnh lng b malt v go
Tng lng cht kh ca malt v go l:
13,54 x 0,995 x 0,95 + 5,80 x 0,995 x 0,87 = 17,82(kg)
Tng lng b kh bng tng lng cht kh go v malt tng lng cht
chit go v malt:
17,82- 14,5 = 3,32 (kg)
Tnh lng b m:
- m ca b l 80%
- Lng b m l: 3,32 : 0,2 = 16,6 (kg)
- Lng nc trong b l: 16,6 3,32 = 13,28(kg)
III.2.5. Tnh lng nc dng trong qu trnh nu v ra b
a. Tnh lng nc trong dng trong ni h ha
Qu trnh h ha t l (bt go + 10% malt lt):nc = 1:5. Lng nc cho
vo ni h ha:(5,80 + 5,80 x 0,1 ) x 5 = 31,9 (l)
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Lng nc c sn trong nguyn liu ni h ha l:
5,80 x 0,995 x 0,13 + 0,58 x 0,995 x 0,05 = 0,78(kg)
Vy tng lng nc + bt cho vo ni h ha l:
6 x ( 5,80 x 0,995 + 0,58 x 0,995) = 38,1(kg)
Qu trnh un si si bay hi 5% vy lng dch trong nui h ha l:
38,1 x 0,95 = 36,2(kg)
b. Tnh lng nc dng trong nui ng ha:
Qu trnh ng ha t l malt: nc = 1:4. Lng nc cho vo ni ng
ha: (13,54 5,8 x 0,1) x 4 = 51,84(kg)
Tng lng nc cho vo ni ng ha v ni h ha l:
31,9 + 51,84 = 83,74 (l)
Lng nc c sn trong nguyn liu l:(13,54 5,8 x 0,1) x 0,05 x 0,995 = 0,645(kg)
Khi ng ha a ton b dch t ni h ha sang, khi tng lng dch
trong ni ng ha l:
(13,54 5,8 x 0,1) x 5 + 36,2 = 101(kg)
Qu trnh ng ha bay hi 4% vy lng dch cn li l:
101 x 0,96 = 96,96(kg)
Lng nc trong dch trc khi lc l:
96,96 17,82 = 79,14(kg)Lng nc trong dch sau khi un hoa (nng dch ng 120Bx)
113,56 x (1- 0,12) = 100(kg)
Khi un hoa lng nc bay hi 10% nn lng nc un dch trc khi
un hoa: 100 : (1- 0,1) = 111,11(kg)
Tnh lng nc ra b:
Vnc trc lc + Vnc ra b = Vnc trong b + Vnc trong dch nu hoa
Vnc ra b = Vnc trong b + Vnc trong dch nu hoa - Vnc trc lc
= 13,28 + 111,11- 79,14 = 45,25(kg) = 45,52 (l)
III.2.6. Tnh cc nguyn liu khc
a. Tnh hoa houblon
Chn bia chai c ng l 21 BU. Vy 100 l bia c ng l 21 BU c
lng cht ng l:
100 x 21 = 2100 (mg) - axit ng
Gi hiu sut chit cht ng l 30% nn lng cht ng cn dng l:
2100 : 0.3 = 7000 (mg)
- axit ng
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T l cao hoa : hoa vin = 20 : 80
- Chn cao hoa 45 % - axit ng
- Hoa vin thm 7% - axit ng
- Hoa vin ng 8% - axit ng
Chn t l hoa vin ng : thm = 40 : 60. Cao hoa chim 20%:
100% = 7000 (mg) - axit
20% = X ?
X = 20 x 7000 : 100 = 1400 (mg) - axit ng
Khi lng cao hoa cn dng l:
45% = 1400 (mg) - axit ng
100% = Y?
Y = 100 x 1400 : 45 = 3111,1 (mg) cao hoaLng hoa vin l: 7000 1400 = 5600 (mg) - axit ng
Cht ng trong hoa vin ng l: 5600 x 40 : 100 = 2240 (mg) - axit ng
Lng hoa vin ng l: 2240 x 100 : 8 = 28000 (mg) hoa vin ng
Cht ng trong hoa vin thm l: 5600 2240 = 3360 (mg) - axit ng
Lng hoa vin thm l: 3360 x 100 : 7 = 48000 (mg) hoa vin thm
b. Tnh lng ch phm emzim
Ta s dng ch phm enzim termamyl 120L t l 0,1% so vi nguynliu thay th l go. Vy lng ch phm cn dng l:
5,80 x 0,001 = 0,0058 (kg)
S dng enzym Maturex b sung vo dch ng sau khi lm lnh vi
lng 0,02 g/l. Lng dch ng sau khi lm lnh l 110,16 lt, vy lng enzym
cn dng:
110,16 x 0,02 = 2,203 (g)
c. Tnh bt tr lc diatomit:
Lng bt tr lc cn dng ty thuc vo cht lng bt, thit b lc v b
mt lc.
Thng thng c 1000 lt bia cn 0,73kg bt lc. Vy lng tr lc cho 100
lt bia cn dng l: 0,73 : 10 = 0,073 (kg) = 73 (g)
III.2.7. Tnh cc sn phm ph
a. Tnh lng b hoa houblon
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Lng cht khng ha tan trong hoa vin l 60%, b hoa c m l 80%,
cao hoa c lng b khng ng k nn b qua:
48000 + 28000 = 76000 (mg) hoa vin
Lng b hoa s l: 76.000 x 0,6 : (1- 0,80) = 228.000 (mg) = 0,228 (kg)
Cn lng: c 100 kg nguyn liu c khong 1,75 kg cn lng c m 80%
( thng lng xoy). sn xut 100 lit bia cn lng nguyn liu l:
13,54 + 5,80 = 19,34 (kg)
Vy cn lng c m 80% c khi lng l:
19,34 x 1,75 : 100 = 0,34 (kg)
b. Tnh lng sa men:
C 100 lt bia cho 2 lt sa men c m 85% trong lng sa men c
ti s dng l 1% so vi lng dch a vo ln men l 1,068 lt sa men.Lng men sa ti s dng sn xut ra 100 lt bia l 1,068 lit.
Phn cn li lm thc n gia sc chim: 2- 1,1016 = 0,9 (l)
c. Tnh lng CO2 thu hi:
Theo phng trnh:
C12H22O11 + H2O 4 C2H5OH + 4 CO2
C 342 gam maltora to thnh 176 gam CO2
Lng dch trc khi ln men (dch 120Bx dch c d = 1,048)
110,16 x 1,048 = 115,44 (kg)Lng cht chit trong dch ln men c ng 120 Bx l:
115,44 x 0,12 = 13,85 (kg)
Coi ton b lng ng ln men l maltoza, hiu sut ln men trong qu
trnh ln men chnh l 55% nn lng CO2 thu c l:
13,85 x 0,55 x 176 : 342 = 3,92 (kg)
Lng CO2 bo ha trong bia non l 2 g CO2/ lt bia
105,75 x 2 = 211,5 g = 0,2115 (kg)
Lng CO2 thot ra l: 3,92 0,2115 = 3,709 (kg)
Lng CO2 thu hi ch t 70%: 3,709 x 0,7 = 2,596 (kg)
200C th 1 m3 CO2 nng 1,832 kg. Suy ra th tch CO2 bay ra l:
2,596 : 1,832 = 1,42 (m3)
Lng CO2 cn bo ha thm t 5g/l bia sau bo ha l:
5 x 104,17 2 x 104,69 = 311,47 (g)
Th tch CO2 cn bo ha thm l:
311,47 : (1,832 x 1000)= 0,17 (m3
)
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Bng 2.3: Cn bng sn phm cho bia hi ln men nng dch ng 100Bx
TT Cc thnh phnn
v
100 lt60.000 l
(1 m)
360.000 l
(1 ngy)
46 triu lt
(1 nm)
1 Malt Kg 10,9 6540 39240 5014000
2 Go Kg 4,67 2802 16812 2148200
3 Hoa vin 5 % g 42 25200 151200 19320000
4 Hoa vin 8% g 24 14400 86400 15360000
5 Cao hoa g 2,7 1620 9720 1242000
6 Nc cho ni h ha Lt 25,69 15414 92484 11817400
7 Nc cho ni ng ha Lt 52,17 31302 187812 23998200
8 Nc ra b Lt 47,12 28272 169632 21675200
9 Bt tr lc Kg 0,073 43,80 262,80 33580
10 B malt + b go Kg 13,4 8040 48240 6164000
11 Cn lng m Kg 0,27 162 972 124200
12 Maturec g 2,14 1284 7704 984400
13 Termamyl 120l g 4,67 2802 16812 2148200
14 CO2 thu hi m3 1,12 672 4032 515200
15 CO2 cn b sung m3 0,082 49,20 295,20 37720
16 Sa men thu hi Lt 2 1200 7200 920000
17 Men ging Lt 10,68 6408 38880 4876000
18 Men sa ti s dng Lt 1,068 640,80 3844,80 491280
19 Dch ng vo lng xoy Lt 110,12 66072 396432 50665200
20 Dch trc ln men Lt 106,82 64092 384552 49137200
21 Bia trc lc Lt 102,55 61530 369180 4717300
22 Bia sau lc Lt 101,52 60912 365472 46699200
23 Bia bo ha CO2 Lt 101,01 60606 363636 46464600
TT Cc thnh phn VT
100
Lt
60.000 l
(1 m)
360.000 l
(1 ngy)
54 tri
(1 n1 Malt Kg 13.54 8,124 48,744 7,311,2 Go Kg 5.80 3,480 20,880 3,132,3 Hoa vin 5% g 48.00 28,800 172,800 25,920,4 Hoa vin 8% g 28.00 16,800 100,800 15,120,5 Cao hoa g 3.10 1,860 11,160 1,674,6 Nc cho ni h ha Lt 31.90 19,140 114,840 17,226,7 Nc cho ni ng ha Lt 51.84 31,104 186,624 27,993,8 Nc ra b Lt 45.52 27,312 163,872 24,580,
9 Bt tr lc Kg 0.07 44 263 39,10 B malt + b go m Kg 16.62 9,972 59,832 8,974,11 Cn lng m Kg 0.34 204 1,224 183,12 Maturec g 2.20 1,322 7,931 1,189,13 Termamyl 120 l g 5.80 3,480 20,880 3,132,14 CO2 thu hi m3 1.42 852 5,112 766,15 Co2 cn b sung m3 0.17 102 612 91,16 Sa men thu hi lt 2.00 1,200 7,200 1,080,17 Men ging lt 11.01 6,606 39,636 5,945,
18 Men sa ti s dng lt 1.10 660 3,960 594,19 Dch ng vo lng xoy lt 113.56 68,136 408,816 61,322,20 Dch trc ln men lt 110.16 66,096 396,576 59,486,21 Bia trc lc lt 105.75 63,450 380,700 57,105,22 Bia sau lc lt 104.69 62,814 376,884 56,532,
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PHN IV
TNH TON THIT K CC THIT B C BN TRONG
DY CHUYN
IV.4.1 Tnh chn thit b cho phn xng nuTheo k hoch sn xut mt m nu ca bia hi v bia chai cng cho sn
lng bia thnh phm nh nhau, ch khc l nu bia chai s dng nhiu nguyn liu
hn bia hi (tr lng nc ra b). Do ta tnh ton thit b ch yu theo bia chai.
Lng nguyn liu dng sn xut bia 1 m l:
Lng malt: 8124 kg
Lng go: 3480 kg
Lng hoa houblon: 47,46 kg
+ Lng cao hoa: 1,86 kg
+ Lng hoa vin thm: 28,80 kg
+ Lng hoa vin ng: 16,80 kg
Lng nc ra b: 27312 lt
Lng nc dng cho h ha: 19140 lt
Lng nc cho van ni ng ha: 31104 lt
Lng men ging: 6606 lt
IV.1.1. Cn nguyn liuLng malt sn xut trong ngy cao nht l: 8124 x 6 = 48774 (kg)
Lng go tng ng l: 3480 x 6 = 20880 (kg)
Tng lng nguyn liu l: 48774 + 20880 = 69654 (kg)
Nguyn liu c cn theo tng m, tng loi ring bit nn ta chn cn cho
ton b dy chuyn.
Trong thc t, malt v go c ng sn trong cc bao ti 50 kg. Do , khi
s dng nguyn liu ta c th tnh theo u bao v chn cn m ln nht l 1000 kg
v sai s 0,5 kg.i vi hoa houblon ta s dng loi cn ng h c m cn l 10 kg v 1 kg.
Trong thc t th cao hoa c ng trong cc hp st ty vi trng lng 1kg, cn
hoa vin c ng trong cc ti nhm vi trng lng l 5 kg.
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IV.1.2. H thng nghin malt
ninumalt
8 1.5kw
5
6
4
3
2.2
kw
2
7
9
Cn
AIR
T
1
2.2
kw
h t h ng ng hin mal t
Hnh 4.1. S nguyn l h thng nghin malt
Lng malt ti a cho mt ngy l 48774 kg. Mi ngy nu 6 m th lng
malt dng cho 1 m l 8124 kg. Thi gian nghin mi m l 1 gi. H s s dng
my l 0,85. Nng sut yu cu ca h thng nghin matl:
8124 0,1.3480 9967( / )1.0,85Q kg h+= =
Ta i tnh ton thit k cc thit b c nng sut 10 (T/h)
1.2.1. Phu cha malt cha nghin s 1
- Dung tch: 0,2 m3. Kch thc D x R x C: 1 x 0,4 x 0,5(m). Chiu dy: 2 mm
- S lng: 1 chic
- Ch to bng thp CT3.
1.2.2. Gu ti malt cha nghin s 1 nng sut 5 tn/h
1.2.2.1Gii thiuGu ti l loi my nng chuyn c s dng rng ri trong cc nh my
ho cht v thc phm, vn chuyn theo phng thng ng hoc vi gc
nghing ln > 500 dng xp di hoc xp kin n cc my gia cng hay n cc
kho bo qun
1.2.2.2Phn loi
* Phn loi theo cu to b phn ko
+ Gu ti dng bng:
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c dng ch bin nng chuyn cc vt liu ri trong cc kho lng
thc, cc nh my xay bt, cc nh my xay xt go, cc nh my ch bin thc n gia
sc, cc ng my p du , cc nh my sn xut tinh bt v cc nh my bnh ko ...
+ Gu ti dng xch
Ch yu vn chuyn nhng vt liu nng dng cc v nhng vt liu gy
hi cho tm bng, nh vt liu lng
+ Gu ti cp
t c s dng rng ri v hay b trt
* Phn loi theo phng php tho liu: Theo phng php tho liu
ngi ta chia gu ti thnh 3 loi
+ Gu ti tho liu di tc dng ca trng lc
+ Gu ti tho liu di tc dng ca lc ly tm+ Gu ti tho liu di tc dng ca lc kt hp
Theo l thuyt ta c cng thc tnh l
.v k D=
Trong ;
v - Vn tc ca b phn ko
D - ng knh tang (a xch ) ca u my
k - H s vn tc (ch c tnh ca gu ti)
+ k < 2,2 Gu ti tho liu di tc dng ca trng lc. Loi gu ti ny chyu vn chuyn vt liu dng cc vn tc bng xch 1,5 - 2 ( m/s )
+ k = 2,2 Gu ti thuc loi tho liu di tc dng ca lc kt hp. Loi gu
ti ny dng vn chuyn cc vt liu dng ht v bt nghin
+ k > 2,2 Gu ti thuc loi ny tho liu di tc dng ca lc ly tm. Loi
ny dng cc kho cao hoc cc nh my ch bin lng thc vn chuyn ht
c m cao ( > 17% ) chng cng uc dng vn chuyn ht kh cc kho cao
, vi m l < 17% vn tc khng qu cao t 4 - 5 m/s
* Phn loi theo phng php t my
+ Gu ti thng ng
+ Gu ti nghing 60 - 700
+ Gu ti thng ng nghing , c b phn trn nghing do ti d
dng nhng c kt cu phc tp .
1.2.2.3. Chn gu ti
a . Nhng c s chn gu ti
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- ngha: Chn gu ti c ngha ln v kinh t v k thut, chn gu ti
cn c vo tnh cht c l v ln ca ht vt liu vn chuyn.
- Cc yu t chn
B phn ko, xch hay bng vn tc cao hay thp loi gu v cch gn gu
ln b phn ko (c nh hay quay ngc)
- Vi vt liu dng bt v ht thng dng loi gu ti bng vn tc cao, cn
vi vn liu m dnh th dng my vn tc thp
- B phn ko l bng dng tt hn xch khi vn chuyn vn liu c tnh mi
mn m nu dng xch ko th bt s xm nhp vo khe h gia cht xch v ng
ln lm cho xch chng mn.
b, Phng n chn ;
* Loi vt liuMalt l loi vt liu c dc trng bi cc tnh cht sau
+ Kch thc ht malt ; a = 2 mm
+ Khi lng ring ; y = 560 kg/m3 thuc loi vt liu va
+ Malt c t s kch thc ca ht ln nht v nh nht < 2 ln
+ Gc chy t nhin ca vt liu l 260
+ m trung bnh ca vt liu w = 24%
* Chn loi gu ti thch hp
- Da vo c tnh , tnh cht ca ht Malt ta chn+ Loi my c
Gu ti bng cao su
Vn tc trung bnh
Gu su
+ Chn loi gu ti thng ng
+ Tho liu bng lc kt hp
1.2.2.4. Cc thng s c bn ca gu ti.
a. Vn tc gu ti .
Nng sut ca gu ti c sc nh theo cng thc
3, 6. . . . 3, 6. . . . .i
Q v i Z va
= = (t/h ) ( CT 3-7 TL. I )
Trong ;
Z - S gu trn mt mt chiu di ca b phn ko
i - Dung tch gu, dm3
a - Khong cch gia hai gu lp gn nhau
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Theo u bi nng sut Q = 10 ( t/h ) nn chn loi gu I vn chuyn ht theo
bng (3-3 TL I) ta c a = 300 ( mm ), i = 1,8 dm3
Do tnh cht ca khi ht malt ta chn - H s cha y ca gu, tnh bng t s khi vt liu trong gu v th
tch hnh hc ca gu. i vi vt liu dng cc nh ta chn = 0,8 - Khi lng ring th tch ca vt liu vn chuyn = 560 ( kg/m3 )
v - Vn tc ca b phn ko
( )3. 0,3.10
1 /3,6. . . 3,6.1,8.0,8.560.10
a Qv m s
i = = =
b. Gu
Vi nguyn liu l malt, mt loi nguyn vt liu dng ht ri th ta
chn loi gu su. Vi nng sut gu ti l 5t/h ta chn c loi gu c cc thngs kch thc sau:
Chiu rng tm bng: B = 150 (mm)
Chiu rng gu: b = 135 (mm)
Tm vi gu: l = 125 (mm)
Chiu cao gu: h = 150 (mm)
Chiu cao ming gu: h2 = 75 (mm)
Gc ln y gu: r = 40 (mm)
Gc nghing thnh gu: = 40Gc xc: 041,30 =
Dung tch gu: i = 1,8 (l)
Khi lng gu: m = 0,55 (kg)
Bc gu a = 300mm
Dung tch trn 1m di l: i/a , i/m = 6,5
h
h2
l
r
6
b
c. u gu ti:
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xx
yy
Cv
III
v1
R
G
C
G
u gu ti c cc chi tit sau:
- B u my, trc dn ng cng bng tang
- V ngoi ca u gu ti c, ca tho liu, ca quan st, b phn hm
*. Tnh kch thc ca tang
Kho st qu trnh chuyn ng ca vt liu. Khi vt liu trong gu
chuyn ng theo mt ng trn quanh tang dn th vt liu s chu tc dng ca 2
lc l trng lc v lc ly tm .
Trng lc: 3. . . 560.1, 8.10 .9, 81 9, 89(G m g i g N = = = =
Lc ly tm:2.m v
CR
=
Do tho liu bng lc kt hp do vy ta c
2
...
2 Dgv
R
vmgmCG ===
Trong : i - Dung tch gu (m3)
- Khi lng ring ht (kg/m3)
g - Gia tc = 9,81 (m/s)
v - Vn tc gu (m/s)
R - Khong cch t tm quay n tm gu (m)
m - Khi lng vt liu trong gu (kg)
i vi gu ti tho liu bng lc ly tm, ng knh tang phi tho mn:
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2
2.2.t
gD R
= > , - Vn tc gc ca tang
Tho liu bng lc kt hp nn ng knh tang c tnh theo:
2
2.2.
t
g D R l l
= + = + , l - l tm vi ca gu
Mun m bo nhng iu kin vn hnh ca bng ti cao su c bnh
thng cn phi chn ng knh tang ca gu ti dng bng theo cng thc
( )125 150 .tD Z (mm)
Z - S lp vi cao su ca tm bng, chn Z = 4
( ) ( )500 600t D mm
Chn s b ng knh tang dn l D t = 500 (mm)
Suy ra:
)/(6,12
5,0.81.9
2
.sm
Dgv ==
Ta chn c: chiu rng gu b = 135 (mm), chiu rng bng l B =
150 (mm). Chiu di tang thng ly ln hn chiu rng tm bng t 20 - 50 (mm)
nn chn chiu di tang L = 180 (mm).
* Cng sut gu ti:2
0.
. .367
qQ H v
N A B v C Q H
= + + (kW)
Trong : Q - Nng sut ca gu ti, Q = 10 (t/h)
H - Chiu cao vn chuyn ca gu ti, H = 10 (m)
v - Vn tc vn chuyn, v = 1,6 (m/s)
q0 - Khi lng mt mt chiu di b phn ko, (kg/m), c q0/Q = 1,36
A , B , C - Cc h s ph thuc vo dng gu
Tho liubng ly tm
A B C
1,14 1,6 0,25
Thay s ta c:
210000.10 1,6. 1,14 1,6.1,36.1,6 0,25. 1,28( )
367 10 N kW
= + +
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90
1
23
4
* Tnh ton cc hm :
S cc hm
1 - C hm ; 2 - Bnh hm c rng;
3 Thnh my; 4 - Trc ca tang dn.
Trong qu trnh lm vic ca cc s vo khp v ra khp vi rng trn bnh
xe trong trng hp nguy him nht cc hm t vo nh rng.
Lc vng ti v tr hm c xc nh theo cng thc:
974. .N
P n r=
Trong : N: cng sut gu ti (kW)
n: s vng quay ca tang trong mt pht, n = 61 (vng/pht)
r: bn knh bnh cc
S rng l 30, chn s b ng knh cc hm l:
1 1 1. .500 200( )
3 2 2,5c tg D D mm
= = =
31,28974. 205( )61.100.10P N= =
Chiu rng ca mp rng B = 30 (mm) bng chiu rng ca mp cc hm
2056,8( / )
30q N mm= =
Ta chn vt liu ch to cc hm l thp CT45
Thng s c bn ca cc hm l:
mb
m = : H s chiu di ca rng chn = 8
Mmen xon t trn trc bnh cc l
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. 205.20020500( )
2 2c
x
P DM Nmm= = =
T phng trnh trn v lc vng P ta rt ra c gi tr mun yu cu nh
nht l
2. 2.20500 3,75( ). . 8.6,8.200
x
m c
Mm mm
q D= = =
Chn m = 4 ( mm ) => D = Z.m
Vi z - S rng ca bnh cc
m - Mun rng
D - ng knh ngoi ca bnh cc
200
504
cD
zm
= = = ( rng )
Kim nghim sc bn un:6
2
19.10 . . .
. . . .u
N K Y
y m b z n =
Trong : Y: H s mn rng chn Y = 1,3
y: H s dng rng, z = 50(rng), y = 0,5
K: H s ti trng, chn K = 1,5
n: S vng quay n = 61 (v/ph)
b: Chiu di rng, . 8.4 32( )mb m mm= = =
[ ]6
2
19.10 .0,64.1,5.1,389,75 250( )
0,5.3 .32.30.61u u MPa = = < =
Bng thng s:
Dc (mm) Z (mm) m (mm) b (mm)
200 50 4 32
d. Cu to chn gu ti:
* Cu to
- Mt phu np liu c tm chn khng ch lng vt liu vn chuyn.
- Trc chn my mang tang lp trn hai gi .
- V chn my c ca quan st, v b phn cng bng.
* Hot ng ca chn gu ti
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Gi ca trc, tang chn my c g cng vo gi ca b phn cng. Vic
cng bng ti chn gu ti c thc hin nh bulng cng bng. Khi cng bng bng
bulng ta iu chnh bulng y cc gi mang trc v mang chn my.
iu chnh tm chn khng ch lng vt liu a vo vn chuyn c th
dng c cu bnh rng hoc thanh rng.
Vic np liu vo chn gu ti: Cho vt liu i ngc chiu chuyn ng ca
tm bng. Ngha l hng ht vo gu ang chuyn ng ln.
e. Thn gu ti:
* Nhim v: thn gu ti dng bo v b phn ko trn ng chuyn
ng t chn gu ti n u gu ti v ngc li.
* Cu to:
Thn gu ti gm nhiu ng tit din hnh ch nht hoc trn ni vi u vchn gu ti. Nhng ng ny lm bng thp l dy 2 (mm) c chia thnh nhiu
on ring bit v mi on di 2 (m). Cc mt u ca mi on u c bch bng
thp gc. Cc on c np ni tip nhau t u my ti chn my bng nhng
bulng M12
quan st s hot ng ca gu ti cng nh ni li nhng tm bng
hoc thay gu khi cn ngi ta lp mt s on ng ca thn gu ca quan st.
f. Cng sut ng c in dn ng c xc nh bng cng thc:
1 2. .dc
N K K N
=
Trong : K 1 - H s k n sc cn khi xc vt liu K1= 1,3
K2 - H s an ton cho my K2 = 1,15 - 1,2 - Hiu sut ca b chuyn ng = 0,8
1,28.1,3.1,22,5( )
0,8dc N kW = =
Cc thng s k thut ca ng c:
Kiu ng cCng sut
(kW)Vn tc quay
(vg/ph)Cos %
dnT
Tmax
dn
K
T
T
4A100S4Y3 3 1420 0,83 82 2,2 2,0
Trong qu trnh vn chuyn cho bng khng b un do trng lng ca
gu cn tr qu trnh chuyn ng th phi lm cng bng.
+ Xc nh lc S0 xc nh lc cng S0 ta cn ly mmen ti im O
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( )0
1
.
.sin
G aS
h h =
(kg)
Trng lng v i trng hoc lc y l xo l
02.P S= (kg)
Trong :
G: Trng lng ca gu c vt liu,
G = (m1 + m2).9,81 = (0,48 + i.).9.81
= (0,55 + 1,8.10-3.560).9,81 = 15,28 (kg)
h , h2 , a - Cc kch thc hnh hc, (m) - L gc thnh gu v phng vn chuyn, chn s b, = 600
0 0 01 1sin(90 ). .sin(90 60 ).110 27,5( )
2 2
a l mm= = =
h - h2 = 150 - 75 = 75 (mm)
abeta
Go.m.gSo
Sk
O
S xc nh lc cng
my lm vic bnh thng th gc lch cho php < 20 khi ta c lc
cng thc t l:
( )0
2
28,7. .G aS
h h=
028,7.15,28.27,5
161( )75
S N=
Nh vy lc cng ln nht ca tang dn:
0 03. 3.161 483(S S P S N = + = = =
Trng lng ca i trng hoc lc y l xo l:
02. 2.161 322( ) P S N = = =
+ Lc vng cn thit ko cc gu:
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' 974..
NP
n R= (kg)
Trong : N: Cng sut nng vt liu (kw)
n: S vng quay ca tang dn (vg/ph)
R: Bn knh tang dn (m)Vi ng knh tang l Dt = 500.10-3(m), s lp vi Z = 4, vn tc v =
1,6(m/s)
. 1, 28.3,14
' 974. 974. 81,56( )30. 30.1, 6
NP N
v
= = =
+ S gu ti:2. . 2.9000 .500
65300
L H Dm
a a
+ += = = = (gu)
g. Tnh ton b truyn ai
* Thng s c bn:
T cc thng s ca ng c ta chn s b loi ai chuyn ng l ai thang
thng k hiu A, v ta chn ng knh bnh ai nh t 100 - 200 (mm). Chn
ng kch bnh ai ln t 500 - 4000 (mm)
Chn hp gim tc bnh rng tr rng nghing 2 cp c t s truyn i = 10.
Nn t s truyn t hp gim tc ca ng c n trc tang quay:
14202,3
. 10.61dc
tg
ni
i n= = =
Chn d1 = 200 (mm) th ng knh bnh ai ln:
)1.(1
2
2
1
==
d
d
v
vi
- L h s trt chn = 0,02
2 1. .(1 ) 2,3.0,2.(1 0,02) 0,45( ) 450(d i d m mm= = = =
Chn khong cch s b gia trc ng c v trc puly tang
( ) ( )2
1 2 2 1.
2. 2 4.
d d d d
l a a
+ = + +
Chn s b khong cch 2 trc:
( ) ( )1 2a 1,5 2 . d +d =1,5.(200+450)= 975(mm)
Chiu di ai:
( ) ( )2
. 200+450 450-200l 2.975 + =2987(mm)
2 4.975
= +
Chn chiu di tiu chun l = 3000 mm
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( )( )
( )2
21 2 2 1
1 2
d +d d -d1a . . . d +d 8.
4 2 4t l
= +
( ) ( ) ( )2 2
. 200+450 . 200+450 450-2001a . 3000 + 8.
4 2 2 4
981( )
t
ta mm
=
=
Chn khong cch trc l at = 980 (mm)
* Tnh gc m:
( ) ( )0 02 10 0 0d -d .57 450-200 .57180 180 164980a
= =
0150 nn ta dng ai vi cao su.
* Tnh chiu rng ca bnh ai B
Theo cng thc: B = (Z -1).t + 2.e
Vi tit din ai chn k hiu A c t = 15 , e = 10
=> B = ( 2 - 1 ) .15 + 2.10 = 35 ( mm )
Xc nh lc cng ca ai tc dng ln trc:
1
0
780. .
. .
d
v
P k
F Fv C Z= +
Trong : mq : Khi lng 1m ai thang thng tit din A, mq = 0,105
(kg/m)
v: Vn tc ai . 2,3.3 6,9( / )v
i v i l m sl
= = = =
M Fv = qm . v2 Fv = 0,105.6,92 = 5 (N)
kd: H s ti trng ng = 1,25
P1: Cng sut trn trc bnh ai ch ngC : H s k n gc m, C = 0,98
Chn s ai l Z = 2 (ai)
0
780.1,5.1, 255 113,14( )
6,9.0,98.2F N= + =
Cc c tnh loi ai l
tb ( mm ) b ( mm ) h ( mm ) Y0 ( mm )
11 13 8 2,8
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Din tch tit din ai A = 81 (mm2)
1.2.3. Cylo cha malt cha nghin s 2 (trong cn in t nh lng go)
- S lng: 1 chic.- Dung tch: 5 m3
- Kch thc DxRxC = 1,5x1,5x2,3m
- Ch to bng thp CT3, phn di ca phu hnh chp vung gn vi cn
in t.
1.2.4. Gu ti malt cha nghin s 2
Tnh ton, thit k ging gu ti malt s 1
1.2.5. Cylo cha malt cha nghin s 3
- Dung tch: 5 m3
- S lng: 1 chic.
- Kch thc DxRxC = 1,5x1,5x2,3m
- Ch to bng thp CT3, phn di ca phu hnh chp vung gn vi u
my nghin.
1.2.6. My nghin malt nng sut 10 tn/h
1.2.6.1 Gii thiu mt s loi my nghin
a. My p mVt liu trong my p m b chn p theo chu k bi 2 m. S tc ng qua
li ca m chuyn ng c th theo phng thc :
- M chuyn ng c trc treo bn trn.
- M chuyn ng c trc treo bn di.
- M chuyn ng ng u.
+) Cu to: Bao gm m khng chuyn ng c lp cc tm lm bng cc
vt liu chng mi mn, cn tm trn m chuyn ng c lp trn trc treo. M
dao ng qua li nh tay bin lp trn trc lch tm. Tay bin ni vi m chuynng bng thanh truyn. c h l xo gi cho m chuyn ng lun c xu
hng m & c c iu chnh nghin. nghin tng ng vi t l ca m
pha trn & pha di l 1 : 5 n 1 : 8.
+) My p m c u im: Cu to n gin chc chn, phm vi s dng
rng (thng dng p vt liu c cc ln, cng) thao tc nh nhng.
+) Nhc im: Tc dng theo chu k nn lm vic khng u, to rung
ng ln nn my phi lp trn b nng, ht khng u.
+)nh hng ca cu to my n kt qu p nghin:
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- nh hng ca dng m nghin: Thay m thng bng m cong tng nng
sut, nghin mn hn & tiu hao nng lng t hn.
- nh hng ca b mt m nghin: Thay m phng nhn bng m c kha
tng ng k nng sut nghin khong 50%, gim nng lng ring 25% (tnh cho 1
tn nguyn liu), khng nh hng n dng ht & s phn b ht.
- nh hng ca nghin: Khi s vng quay khng i, nu gim khong
cch khe s tng gi thnh. Dn n: tng phn ht mn, nng lng tiu hao cho 1
tn nguyn liu tng, nng sut gim, dng ht tt hn, kch thc ht t l vi
khong cch khe h th nh.
- nh hng gc nghing ca m c nh: gc nghing khng nh hng n
dng & s phn b ht, v tr thng ng nng sut tng khong 10%.
- nh hng ca iu kin lm vic & yu cu ln ca sn phm. S phnb ht nguyn liu khng nh hng n s phn b ca ht sn phm. Nu ht
nguyn liu ln s gim nng sut khong 25% & nhu cu nng lng tng ln.
Khi nghin vt liu c bn cao th dng hnh khi ca sn phm t hn,
nng lng tiu hao cho tng tn vt liu tng, phn ht mn gim & kch thc ht
trung bnh tng.
+) Hiu sut: Lm vic ca my nghin m hin i t khong 65%. Cng
sut tiu hao c phn b nh sau :
- Dng nghin nh vt liu 63,5%- Cho v tr trc 22,5%
- Cho v tr khuu 13,5%
- Cho v tr dao ng 1%
+)Kt lun: My p m ch t nng sut vi cc loi vt liu th c kch
thc ln, m khng ph hp vi nghin malt.
b. My nghin hnh nn ct
+) Cu t : Gm hnh nn c t lch tm trong thn hnh nn rng. Trc
treo trn mt trn gn cht vi thn hnh nn. Nng trc ln hay th trc xung
nh 1 cu iu chnh khe thi ca my. u di ca trc t t do trong cc
lch tm, cc quay nh b phn truyn ng bnh rng.
Vt liu nghin c a vo khng gian hnh phu. Vt liu c nghin
gia b mt ngoi ca hnh nn trong & b mt trong ca hnh nn ngoi. B mt
lm vic ca hai hnh nn ny l nhn hay nhm ty theo tnh cht ca vt liu.
Nn trong quay nh con lc, nghin cc cc vt liu bng chn p & b
gy, nn gim c nng lng tiu hao. Mt khc, sn phm nghin t to ccht b & bi.
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+) u im: So vi my p m loi ny c: nng sut ln do lin tc nghin
vt liu bng cch va chn p va b gy, nng lng tiu hao nh, lm vic iu
ha nn my khng cn phi c bnh & b iu chnh, np liu d dng. Tuy
nhin, nhc im l cu to phc tp, iu chnh chiu rng khe h kh khn,
khng nghin c vt liu do, thao tc kh.
+)Kt lun: My nghin hnh nn ct khng thch hp ng dng nghin
malt v nng sut khng m bo, iu chnh khe h kh khn nn d b tc do kt
v tru.
c. My nghin a
Trong cng nghip thc phm, my nghin a c s dng trong cc
ngnh ch bin thc phm tinh, men, tinh bt mt, bnh ko & tht. Trong nhng
trng hp y, i vi mt mc nghin cn m bo nhiu ln tc dng canhng b phn lm vic ln sn phm.
Theo c cu chung th cc my nghin a c th chia lm 4 nhm :
- My c trc quay thng ng & a trn quay.
- My c trc quay thng ng & a di quay.
- My c trc quay nm ngang, mt a c nh, cn a khc quay.
- My c trc quay nm ngang, c hai a u quay nhng ngc chiu nhau.
a ca nhng my nghin c ch to bng kim loi, i lc bng bt
mi. B phn cng tc hay a nghin c lm bng nhn to (trong trng hpny nghin a thng c gi l ci xay mi) hay bng thp c, i khi bng
gang, ngi ta cng ch to a lin hp gm l kim loi trn gn khi mi.
a nghin sn phm c hiu qu, chng phi c rn m bo chu
mn, dai trnh b trc nhng mnh , kim loi nh a ra & ri vo sn
phm, nhm nng cao tc dng ma st ln sn phm, ng nht tc
dng ng u ln sn phm nghin trn c b mt lm vic, bn m bo
cho a khng b gy di tc dng lm vic ca lc ly tm.
a kim loi thng c ch to bng thp Mn chu mn hay bng gang
c trong khun kim loi. Trn b mt lm vic ca a c cc rnh profin tam gic,
cng dng ca chng l tng cng mc nghin, thng gi cho a & d
dng vn chuyn sn phm nghin.
a quay khng to nn ti trng ng trn trc & gi trc ca n th
trng tm ca a cn phi nm trn trc quay, m trc quay phi l trc qun
tnh chnh ca n. Khi tun theo nhng iu kin y th a quay s cn bng. a
lm bng nhn to lm vic vi tc quay n 10m/s khi trc thng ng &
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n 18m/s khi trc quay nm ngang. a bng gang c lm vic c vi tc
quay n 28m/s, cn a thp c th n 68m/s.
+)Kt lun: My nghin a hot ng theo nguyn l va p ch thch hp
vi vt liu kh, gin m khng thch hp nghin malt c hm m 14,5 15,5 %.
d. My nghin ba
Trong cng nghip thc phm ng dng cc dng my nghin va p & va
p ma st nh sau: my p ba, my nghin rng, my p hnh ni & my
nghin a nhiu bc. Ph bin nht l my p ba & my nghin rng.
My p ph v tt cc loi vt liu gin (ht kh, xng, mui, ng )
& t hiu qu khi nghin sn phm m hay sn phm c cha nhiu cht bo (khi
socola). Trong nhng my ny, vt liu c ph v nh va p ca cc ba thp
vi n, va p ca cc ht vo v my & do kt qu mi mn ca vt liu vi lisng thp. Ph bin nht l nhng my p ba c ba treo t do.
My nghin ba c dng nghin cc vt liu c m khng qu 15%.
Cu to gm: trc chnh nh c then a c lp cht vi cc khu trung gian.
Theo hng chiu trc a c ghp cht bng ai c, trc quay trong hai a,
thanh treo cc ba t do. phn di ca my c li sng thay th c lp cht
trong cc rnh vnh khn ca thn my. Ti mt u mt ca trc c lp gung qut
quay trong v qut. L ht ca qut ni ng dn khng kh vi phn di ca my
nghin, khng kh c y ra thng c ni vi thng thu hi sn phm gmxyclon & my lc ti vi. on ni ng kp c ca van tho sn phm nghin ra
nm bn di ca xyclon.
My nghin ba c th nghin mn. Trong trng hp ny vt liu sau khi
nghin c qut ht mang i m khng cn qua li sng. Khi nghin mn vt liu
va chu tc dng va p ca ba, va chu ma st gia cc ht & gia ht vi my.
My nghin ba thng lm vic vi s vng quay ca trc khong 500 800
vg/pht khi nghin th & khong 1000 1500 vg/pht khi nghin mn. nghin
t c 10 15 i vi nghin th & 30 40 i vi nghin mn.
+)Kt lun : My nghin ba c th ng dng nghin la m. Tuy nhin,
khng c kh nng iu chnh ht, sn phm khng ng u nn nng sut
khng cao.
e. My nghin trc
My nghin trc gm c hai trc hnh tr t song song, quay ngc chiu
nhau. Vt liu b nghin ch yu do lc chn p. Trc nghin phi bn, cng, chu
mn, dn nhit v c dng hnh tr. ng thi, i hi mt s ng trc cao giangng trc v ng lt ca n.
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iu c ngha c bit ti s cn bng ca cc trc nghin. Nu khng
t yu cu s dn ti dao ng v lm cho khe h gia cc trc khng n nh,
lm gim ng k hiu qu cng ngh nghin. B mt ca trc nghin phi c
nhm xc nh ph hp vi mc ch cng ngh ca my.
trc ca trc nghin phi c kh nng t iu chnh song song vi trc
hnh hc, c cu bi trn tin cy & c b mt rng thot nhit ra mi trng
xung quanh, khng c php bi ri vo cc trc.
Khe h gia cc trc nghin thng rt nh, gim khe h lm thay i ng
k mc ca nghin ca sn phm. V vy, c cu iu chnh khe h gia cc
trc nghin phi m bo :
- D dng thay i khe h gia cc trc nghin trong khi vn gi nguyn s
song song tng h ca chng c xc lp t trc.- Khng c kh nng cc trc nghin quay tip xc vi nhau.
C cu lm sch b mt trc nghin phi m bo s tip xc ng u &
khng i ca nhng chi tit lm vic ca n vi b mt trc nghin, m vn m
bo khng lm nhit trc nghin tng cao do ma st.
C cu cp liu phi m bo a sn phm ng u vo vng nghin trn
sut c chiu di trc vi tc bng hay gn bng tc ca trc nghin. C
nhy cao iu chnh lu lng nguyn liu a vo my nghin vi phm vi rng.
Trn b mt trc l nhn hay nhm. Nu nghin vt liu gin c cng trungbnh th ngi ta lm trc c rnh kha. My nghin trc c nghin i = 10 15.
+) u im: my nghin trc c cu to n gin nhng chc chn, lm vic
tin cy.
+)Nhc im: vt liu hay b dt nht l i vi trc nhn, khng thch hp
khi nghin vt liu c cng qu cao.
+)Kt lun: Cc ci tin k thut c thc hin trong cc giai on tin
ha, bt u t h thng nghin th cng bng tay u tin n vic s dng
phng cch nghin bng trc cn kh ng hc. ng nhin, mi quc gia c lch
s pht trin cng nghip nghin ca ring mnh.
Trong sn xut cng nghip, vic ng dng my mc vo qu trnh sn xut
l phng php tt yu. Nhng vn t ra l ng dng loi my mc no cho quy
trnh cng ngh nghin la m l thch hp. C rt nhiu loi my nghin nhng
my c bn c p dng vo quy trnh cng ngh nghin la m nc ta cng
nh cc nc khc trn th gii l my nghin trc.
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ng dng my nghin 2 trc trong dy chuyn nghin malt mt nh my
sn xut lin tc trn quy m cng nghip ln, c mc t ng ha cao: nng
sut 10 tn/h.
Vi cng ngh nghin malt ng dng my nghin trc, hai l nghin c cng
ng knh, c vn tc vng khc nhau c nhim v x lp v bao bc ht la
mch, ht la mch c ko vo khe nghin. Bng vic thay i khe h gia hai
trc nghin, ngi ta c th d dng gia cng cc loi mail c ht khc nhau v
ng knh. Vi cht lng sn phm ng u, nng sut cao hn hn vic ng
dng cc loi my nghin khc trn quy m cng nghip. Hiu qu kinh t k thut
cao, gim chi ph cho mt n v sn phm trn cc my nghin thng thng. Bt
c c thng qua quy trnh nghin bng phng php ny c cng nhn l sn
phm t tiu chun quc t nh phm vi s dng chng rt rng. Qua qu trnh tm hiu cu to cng nh u nhc im ca tng loi
my nghin em nhn thy my nghin trc l loi thit b ph hp nht cho vic
nghin malt quy m cng nghip, cu to cng nh tnh nng ca my nghin
trc hon ton c th p ng c cc yu cu t ra cho vic nghin malt.
1.2.6.2. Cu to
Trc nghin l c cu ch yu trong my nghin trc, ht mch di tc
dng ca mt cp trc c rng nghin vi c tnh quay ngc chiu nhau, 1 trc
nhanh 1 trc chm p, bc, x ht la mch tch v, phi my& phi nh ca lamch nghin ra.
Trc nghin trong a s trng hp c lm bng gang c bit (C 3,2
3,7%, Si 0,4 0,7% Mn 0,2 0,8%, P 0,5%, S 0,14%, Ni 0,25%) c c trong
khun kim loi. Nhng trc cn nh th lp b mt gang bin trng c chiu dy
20 25mm & rn b mt t 370 450HB.
Ngi ta cng s dng trc nghin 2 lp, li ca n c c bng gang xm
thng, cn phn ngoi l Crm Niken c hm lng (C 3,7%, Si 0,25%, Mn
0,3%, Cr 0,4%, Ni 2%). Trc cn lp c rn ng u lp b mt c chiu dy
15 20mm, cng b mt bng 500HB, chu mi mn cao hn & bn hn c
bng gang c bit.
1.2.6.3. Nguyn l lm vic
Nguyn l lm vic ca my nghin trc l cho sn phm cn nghin i qua
khe h gia 2 trc nghin. Hai trc nghin hnh tr, t nm ngang, c b mt rt
cng, trn b mt c th trn hoc c gia cng ty theo nguyn liu c nghin.
i vi sn phm nghin th, trn b mt trc c x rnh a nguyn liuvo d hn. Trng hp cn nghin tht mn, b mt trc thng trn.
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Nguyn liu khi i qua khe h gia 2 trc s b p, kch thc nh li. i
vi qu trnh nghin malt, yu cu nguyn liu nghin c m 5% . m bo
kch thc ht sau khi nghin.
B phn thot ti l h thng l xo p 2 trc nghin vi nhau. Khi vt cng
qua khe h my nghin hay khi vt liu qua qu nhiu,b phn thot ti lm vic,
khi h thng l xo b p li, khe h ln ra v vt cng i qua d dng m khng
lm h my.
1.2.7. iu chnh khong cch trc nghin
Chnh th :
Trc ht ng cht, iu chnh l xo n nn xung 8 10mm, lc nn 2
l xo phi bng nhau. Dng nhng tm cn bng thp c dy t 0,5 1mm o
khe h ca trc v m bo hai trc c khe h nh nhau.Tinh chnh :
t 1 t giy rng 300mm vo khe gia 2 trc nghin, quay bnh xe iu
chnh c ly cn, dng tay ko dy ai, quan st vt cn ca trc nghin ln t giy
xem c u nhau khng. Nu vt hn khng u, c th iu chnh ai c 9 trn
thanh vt u trn 5 lm cho 2 u trc chm 8 & u trc nhanh 6 song song, thng
bng nhau. Sau khi ng cht vng m 10 trn thanh vt u phi hi lng, khng
nn nn cht. Sau iu chnh 2 ai c 15 chiu di sau khi p li ca l xo
thanh vt bng nhau l c.iu chnh trong khi s dng :
Kim tra sn phm nghin ra c v u hay khng. Nu ht v khng u ch
cn iu chnh l xo nn l c.
iu chnh lu lng :
12 my nghin c kt cu tng t nhau ch khc nhau v iu chnh khong
cch trc. Lu lng ln hay nh quyt nh bi khe h gia tm iu chnh lu
lng & trc np liu. Do vt liu a vo mi m ht khng ging nhau, bi vy
m kch thc khe h cng phi iu chnh theo, ng thi dng chy nguyn liu
cng phi cho va phi & ri u ra. Nu mng qu nng sut s thp, c th cn c
c im tng my tng kt tr s theo kinh nghim, ng thi ghi s liu trn
ng h lu lng ca mi m nhng ln sau u xoay n n v tr tng ng.
Sp xp hnh rng trc & thay i bnh rng
Sp xp rng trc nghin : Trc nghin ca my mi hay mi tut li rng
khi sp xp th 2 mt sc ca trc u quay v pha ngi thao tc. Khi trc nghin
b mn sn lng gim i r rt. C th i ch trc nhanh vi trc chm hay tru trc chm rng xp theo ht i vi sc. Khi nh rng trc nghin tip tc
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mn thm, sn lng gim st thm, li i u trc nhanh rng sp xp theo sc
i vi sc. Khi nh rng b mn thnh mt mt phng tng i ln, sn lng
cng gim i, lng tiu hao in ln ln, phi em ra chut li rng
Trc nghin sau khi chut li rng nhiu ln, ng knh l p b nh li th cn
phi thay nhng cp bnh rng tng ng m bo khe ng yu cu cng ngh.
iu chnh tm thnh :
thnh trong ca hai u v my c lp tm thnh bng g hay bng nha
trnh nguyn liu lt ra hai u trc nghin. Khi ng knh trc nh i, trc
ht phi ni lng bulng dch tm thnh xung di, n mc hai u trc khng b
lt vt liu ra l tt nht. Sau xit cht bulng li l c.
1.2.8. Phn tch cc yu t cng ngh
La m sau khi sng phn loi tch sn, tru & la lp b ht loi b, lac phi trn a vo bin m, hm m trong ht la m t 1 gi tr thch hp
t 14,5 15,5 %, ngm t 18 n 24h.
Ht la m cng qu, hm lng nc thp v cm v vn hoc khe h trc
nghin cha hp l lm cho bt sau khi nghin ko c mn, t l ra bt thp, mu
sc bt km.
Hm lng m thp, thi gian ngn khi nghin la bt mng, hm lng v
cm ln, hiu sut nghin thp, cht lng bt gim cc gi tr dinh dng.
Ch yu l xem mc sch thong ca v cm : th hin mu vng nht,mit tay vo thy mn, ti & trn mt. Nu t l sng lc thp, hiu qu nghin
khu trc thp th s gy ln ph ti qu ln bc sau. Nguyn liu nghin
khng k xut hin hm lng bt trong v cm nhiu. Nu hm lng m trong
la mch iu tit khng tt hay 2 u trc b r nguyn liu khin s ln nghin b
gim i, lm cho v cm bc ra khng c sch, v cm b trng.
Cht lng bt : mu sc, dai, hm lng tro c ha nghim kim tra
theo bt mu.
1.2.9. Tnh ton my nghin trc
1.2.9.1. Gc m hay gc kp ht
Theo l thuyt tnh gc kp ht ca XOKOLOV. S tnh ton xc nh
gn ng ng knh nh nht cn thit ca cc trc nghin nhn quay vi tc
nh nhau, xut pht t iu kin m bo kp c sn phm nghin.
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Vt liu khi ri vo gia hai trc s b tc dng bi p lc P ca trc. Trc
khi bin dng ht tip xc vi b mt cc trc nghin ti cc im A v A'. ngthi, tc dng ln chng theo phng php tuyn v tip tuyn ti im A & A' mt
lc P no . Lc P c phn tch thnh 2 lc thnh phn l P.sin theo hng
thng ng c khuynh hng ko ht ra khi dc hnh cu do b mt hnh tr ca
trc to nn, thnh phn P.cos theo hng nm ngang c xu hng ko ht vo
khe h gia hai trc. Lc ma st F = f.P ko ht vo gia hai trc & cng c chia
thnh hai thnh