精品柠檬酸发酵车间工厂设计.docx

精品柠檬酸发酵车间工厂设计.docx

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精品柠檬酸发酵车间工厂设计

1前言·····························································3

1.1柠檬酸的性质和用途···········································3

1.2柠檬酸的来源和发展情况·······································3

2生产工艺·························································4

2.1生产方法·····················································4

2.2工艺流程·····················································4

2.3操作工艺·····················································5

2.3.1原料的处理·············································5

2.3.2发酵工序···············································5

2.3.3醪液处理工序···········································6

2.3.4提取工序···············································6

2.3.5精制工序···············································6

3工艺计算·······

··················································7

3.1物料衡算·····················································7

3.1.1工艺技术指标及基础数据·································7

3.1.2原料消耗计算···········································7

3.1.3发酵醪量的计算·········································7

3.1.4接种量的计算···········································8

3.1.5液化醪量的计算·········································8

3.1.6成品柠檬酸·············································8

3.1.7年产5万吨一水柠檬酸总物料衡算·························8

3.2热量衡算·····················································9

3.2.1液化热平衡计算·········································9

3.2.2发酵过程中蒸汽耗量的计算·······························9

3.2.3发酵过程中冷却水耗量的计算····························11

3.2.4发酵过程中无菌空气耗量的计算··························11

4设备选型························································12

4.1主要设备的选型···············································12

4.1.1

发酵罐的选型··········································12

4.1.1.1发酵罐容积和台数的确定························12

4.1.1.2发酵罐主要尺寸计算····························12

4.1.1.3发酵罐冷却面积计算····························13

4.1.1.4发酵罐搅拌器的计算····························13

4.1.2种子罐的选型··········································14

4.1.2.1种子罐容积和台数的确定························14

4.1.2.2种子罐主要尺寸计算····························14

4.1.2.3种子罐型号的确定······························15

4.2辅助设备选型················································15

4.2.1调浆桶的选型··········································15

4.2.2喷射加热器的选型······································15

4.2.3其它辅助设备···········································16

5全厂车间布置概况················································17

5.1厂址选择····················································17

5.1.1厂址选择的一般性原则··································17

5.1.2本设计的厂址选择

······································18

5.2车间布置····················································18

5.2.1车间布置的基本原则和要求······························18

5.2.2本设计的车间布置······································19

5.3发酵厂卫生问题··············································19

6废物处理························································20

6.1发酵工厂污染概况············································20

6.2柠檬酸工厂的“三废”处理····································20

6.2.1柠檬酸发酵有机废水的处理······························20

6.2.2柠檬酸发酵废气的处理··································21

6.2.3柠檬酸发酵废渣的处理··································22

7设计评估及感想··················································22

参考文献··························································24

年产50000t柠檬酸发酵车间工厂设计

1前言

本设计采用薯干原料发酵，只需将薯干磨成粉，加水调浆，直接加入少量α－淀粉酶液化后灭菌、冷却即可接种发酵。

制备柠檬酸一般采用晒干的薯干作为原料。

其中薯干含水10%-15%、淀粉70%左右、蛋白质6%左右。

薯干原料中的蛋白质可作为氮源供菌体生长。

薯干原料中含有铁、镁、钾、钙等的无机盐，选用的黑曲霉C0527对这些成分不敏感,故不必对原料做这方面的预处理。

本设计采用液体深层好氧发酵、钙盐法提取技术生产柠檬酸。

这两种方法都是国内比较流行的生产方法，有着大量的实际经验，易于操作，风险小。

由于本设计为发酵车间的设计，着重于车间的工艺计算、设备选型。

通过全厂物料衡算、车间热量衡算，确定发酵车间主要设备发酵罐、种子罐的设计和选型以及全厂及车间布置。

本设计还包括发酵罐图，车间平面布置图，工艺流程图。

1.1柠檬酸的性质和用途

柠檬酸（citricacid），学名为2-羟基-丙烷三羧酸，结构为

分子量：

192.14，是一种重要的有机酸。

无色晶体，常含一分子结晶水，无臭，有很强的酸味，易溶于水。

其钙盐在冷水中比热水中易溶解，此性质常用来鉴定和分离柠檬酸。

结晶时控制适宜的温度可获得无水柠檬酸。

柠檬酸在自然界分布很广，主要存在于柠檬、柑橘、菠萝等。

柠檬酸具有宜人风味、高的水溶性和强的金属螯合力，长期以来占据食用酸味剂70%左右的市场份额，除可口可乐和纯果汁以外，几乎所有的饮料都使用柠檬酸作为酸味剂，通常的添加量为0.25%-0.4%（m/m）。

柠檬酸在化学技术上可作化学分析用试剂，用作实验试剂、色谱分析试剂及生化试剂；用作络合剂，掩蔽剂；用以配制缓冲溶液。

此外，食品加工和奶制品也添加柠檬酸和柠檬酸盐。

据不完全统计，使用柠檬酸的食品或药品约有上千种之多。

柠檬酸除用于食品和医药工业以外，最大的用途是代替三聚磷酸钠作为洗涤剂的助洗剂，20世纪90年代初，国外还有人发现柠檬酸加入混凝土中可作为一种“减水剂”，并能提高混凝土的凝固强度。

可以认为，柠檬酸早已成为现代食品、医药业、日化行业及其他行业的通用原料。

1.2柠檬酸的来源和发展情况

1784年C.W.舍勒首先从柑橘中提取柠檬酸。

1860年意大利开始用添加石灰乳的方法从果汁中得到柠檬酸，从而进行了工业化生产。

直到20世纪初，柠檬酸仍然主要是从柠檬中提取，产量还很低。

1893年C.韦默尔发现青霉（属）菌能积累柠檬酸，但未能实现工业化生产。

1917年，柯里发现了一株产柠檬酸的黑曲霉，并通过美国的辉瑞公司于1923年采用浅盘发酵实现了工业化生产，原料主要是糖蜜。

1952年美国迈尔斯公司首先成功采用液体深层发酵工业化规模生产柠檬酸。

这种新工艺具有很多优越性，因而推动世界柠檬酸工业的迅速发展，也成为了柠檬酸发酵生产的主要工艺。

我国的柠檬酸发酵工业：

1969年上海酵母厂成功利用薯干粉深层发酵柠檬酸。

20世纪80年代，由于出口的需要，我国的柠檬酸生产发展迅速，已成为世界上柠檬酸生产量最大的国家。

我国开发的以薯干为原料的产酸菌种具有其独到的特点，生产成本较低，在国际市场具有较强的竞争力。

中国不仅是柠檬酸生产大国，也是出口大国，目前出口量已占总产量的70%-80%。

近10年来，由于受出口刺激，中国柠檬酸生产能力和产量都增长很快。

1985年，中国柠檬酸产量只有3.7万吨，2002年已达到约40.0万吨。

目前全国有近90家柠檬酸生产企业，年生产能力近50万吨，占世界总量的40%多。

2生产工艺

2.1生产方法

本次生产工艺设计以薯干为原料，采用直接粉碎、调浆、液化，进行好气液体深层发酵，钙盐法提取，最后结晶、干燥得到柠檬酸。

2.2工艺流程

基本过程为：

在接收糖浆后，根据糖浆组成作适当的处理或配制，配成发酵原料，进行连续杀菌并冷却后，进入发酵罐，加入菌种和净化压缩空气后进行发酵；

发酵液经升温、过滤处理后，进入中和罐，用中和处理；

再经过过滤洗涤，得到柠檬酸钙固体，送入酸解罐，再添加酸解，并加入活性炭进行脱色；

然后，通过带式过滤机过滤、酸解过滤，除去及废炭；

酸解过滤液经离子交换处理后，进行蒸发、浓