1. PARAMETERS AFFECTING THE FINE GRINDING OF AQUAFEEDS USING A HAMMERMILL VICTAM – Utrecht – May 2007 Olivier Rousseaux STOLZ ASIA SALES MANAGER

2. INTRODUCTION A] Raw Materials B] Main Mechanical parameters we can change for better result C] Global solution CONCLUSION VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING CONTENT

3. VICTAM – Utrecht – May 2007 INTRODUCTION: GRINDING COST: HAMERMILL VS. PULVERIZER Pulverizer :  Needs a lot of aspiration  High aspiration means high moisture losses  High power consumption Hammermill :  Need aspiration  Reasonable power consumption  Reasonable Moisture losses Cost :  Electrical cost: easy to evaluate  Wearing parts cost: easy to evaluate  Moisture losses: difficult to evaluate

4. No.ParameterHM StolzPulverizer 1Actual Cap (T/H) 10 4 2Electric Consumption - in kWH/Ton 24 28 - Electric Cost (US$/Ton) 1,4 1,7 3Spare Parts - Hammer / Beater (US$/Pcs) 2,6 50 Number of Hammers 152 72 Total Hammer Cost/mch 401 3 564 Hammer Lifetime (Tons) 5 000 3 600 Hammer Cost (US$/Tons) (assump. 5000 T/month) 0,1 1,0 - Screener / Liner (US$/Pcs) 133 285 Number of Screen/liners 2 2 Total Screener / Liner Cost / mch 266 570 Screener/Liner Lifetime (Tons) 2 500 3 600 Screener Cost (US$/Tons) (assump. 5000 T/month) 0,1 - - Counterbeater & Liner: in H26/Tons 0,06 - - Turbo sifter Screener: in US$/Tons 0,09 - 4TOTAL COST (IN US$/TON) 1.752.70 DIFFERENCE US$ 0.95 SAVING / MONTH (IN US$/MONTH) US$ 4 750 VICTAM – Utrecht – May 2007 GRINDING COST: HAMERMILL VS. PULVERIZER HUGE SAVING

5. In terms of fineness Still pulverizer is better than Hammermill But this has a cost Compromise: Hammermill + Pneumatic System + TurboSifter VICTAM – Utrecht – May 2007 INTRODUCTION: GRINDING COST: HAMERMILL VS. PULVERIZER

6. Which raw materials: Corn, Soya, cassava… Wheat bran, rice bran… Fish meal, feather meal… Grinding design Either pre-grinding or post grinding system Either 1 or 2 step(s) grinding VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING A1] RAW MATERIALS

7. VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING A2] RAW MATERIALS a)Physical aspects Initial size of the particles  initial size,  capacity b) Biological aspects a)Moisture content  Moisture content,  capacity b)Fat content  fat content,  capacity c)Hardness  hardness,  capacity  BASICALLY, RAW MATERIALS have to be used as what they are

8. VICTAM – Utrecht – May 2007 Generally :  1500 rpm hammermills rotors are of about 1 400 mm diameter  3000 rpm hammermills rotors are of 650 to 700 mm diameter Disadvantages of a 1500 rpm hammer mill vs. a 3000 rpm :  The size  Screen changing more difficult  Needs more important screen surface Disadvantages of a 3000 rpm hammer mill vs. a 1500 rpm :  Noise Fan makes more noise than hammermills, what ever its size B1] Rotor Speed: 1500 or 3000 RPM PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result

9. VICTAM – Utrecht – May 2007 B2] Rotor Speed How can the rotor speed affect the granulometry? Speed variation of the rotor, using an inverter Speed Screen Table giving medium size of particles in function of Screen size and rotor speed. The mathematical model was made by TECALIMAN French Technical Centre. PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result   ROTOR SPEED,  PARTICLES SIZE

10. VICTAM – Utrecht – May 2007 How can you control the best quality? A: no steel heat treatment or bad treatment B: correct steel heat treatment + C Addition 1: new beater 2: one side worn 3: both sides worn A: no steel heat treatment or bad treatment concave wearing B: correct steel heat treatment : convex wearing A: no steel heat treatment or bad treatment Round shape wear B: correct steel heat treatment : Spoon shape wear PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result B3] Beaters : Steel treatment and Wearing

11. VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result B4] Counters Beaters  C ounters beaters increase Flow rate and fineness C ounters beaters

12. VICTAM – Utrecht – May 2007  Useful Screen Size,  capacity  Screen perforation,  Particles size  Screen Opening (%),  capacity  Screen Thickness,  Particles size Opening% = D² * 0.907 / EA² EA D PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result B5] Screen : Dimensions and design

13. VICTAM – Utrecht – May 2007 WORN: while rebounding, the grain is taken again by the hammers NEW: while rebounding, the grain is returned outside rebounding Product Worn screen New screen rebounding Screen wearing effect PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result B6] Screen: Wearing Lifetime of the screen depends also of the cleanliness of the raw materials

14. VICTAM – Utrecht – May 2007 For Coarse Grinding (Screens 2 mm and more): Air Flow of about 8500 m3/h for 1 m² Air Pressure is of about 300 to 500 mm water column on the screen For Fine Grinding (screen 1.5 mm and less): Air Flow of about 5500 m3/h for 1 m² Air Pressure of about 700 to 1000 mm water column on the screen Air flow is made 2 main parameters: Air flow : m 3 /h, … Pressure: WC, bar PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result B7] Air Flow

15. VICTAM – Utrecht – May 2007 AIR SPEED :  Air speeds:  22-23 m/s through the destoner  4-6 m/s through the grid  2.5 to 3 m/s through the filtering media AIR FLOW ACTIONS:  Generally little effect on the particle size  Depending of the hammermill feeder design: Better heavy materials removal.  Will help reducing the T° increase of the ground product, avoiding down stream condensation  Enables product passing through the screen AIR FLOW REGULATION :  Allows a constant flow rate, whatever may be the pressure loss  From where, a better de stoning  Avoids any overload of the filtering media  Allows a progressive air flow increase, avoiding inopportunely emptying of the stone box PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result B8] Air Flow through hammermill and air jet filter

16. VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING B] Main Mechanical parameters you can change for better result a) Mechanical handlingb) Pneumatical handling B9] GRINLING LINE DESIGN

17. FeederHammermill VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C1] HAMMERMILL

18. The Feeder Dimension same as the grinding room Pneumatic Magnet Heavy particle remover  Unique  Very advanced System The Grinder Liner Screen Beaters Counters beaters But also for safety reasons Temperature control Auto greasing Screen sliding VICTAM – Utrecht – May 2007 C2] HAMMERMILL: Feeder + Grinder PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION

19. Magnet Air Inlet with a djustable flaps Feeder with global regulation Pocket feeder with frequency inverter Automated Air flow adjustment Heavy particle remover Stainless steel Stone Sand Any high density particle VICTAM – Utrecht – May 2007 C3] Feeder : Very unique PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION

20. Material to be ground Raw materials Air flap Feeder Magnet Heavy particles separator Air Air inlet VICTAM – Utrecht – May 2007 C4] How works the feeder PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION

21. Thanks to the design of the feeder: Removal of any heavy particles ( Stone or not) Adjustment of the air flow through the feeder Not the least, the feeding of the hammermill is: Regular Continuous Done homogenously on all the length of the hammermill All the conditions are gathered for a good grinding: VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C5] Feeder : Its benefits

22. Crushing plate or liner Rotor made of 8 axes Beaters VICTAM – Utrecht – May 2007 Counters Beaters PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C6] Hammermill : Its design

23. Locking plate to release or tighten the screen Air cylinders to pull in or push out the screen No doors to open to replace a screen  safety VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C7] Screen fixations

24. Step 1: Stop of feeder Step 2: Unlocking Step 3: Pushing out Step 4: Change of screen Step 5: Pulling in Step 6: Locking Step 7: Start of feeder Time = Maximum 3 MINUTES VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C8] Screen replacement  SAVE POWER AND TIME

25. Rotor specially designed High speed Clock rotation Sieving drum rotates Low speed Clock rotation Sequenced rotation Compressed air @ 7bars When sieving drum rotates Sequenced air pulsing Cross contamination less Main features VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C9] Turbosifter

26. Screw inlet Design of the rotor Paddles arrangement Sieves Small gap between sieves and paddles VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C10] Turbosifter: Rotor

27. Adjustable Air Pressure Nozzles lines VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C11] Compressed air system

28. VICTAM – Utrecht – May 2007 PARAMETERS AFFECTING FINE GRINDING C] GLOBAL SOLUTION C12] Grinding line for shrimps feeds or fish feeds

29. VICTAM – Utrecht – May 2007