تطوير وحدة متنقلة لتصنيع الأعلاف غير التقليدية

الملخص EN

Whereas the burning of the agricultural residues affects environmental pollution in Arab Republic of Egypt, so many researches in different trends proceeded to overcome such problem, in other hand the researches aimed to get benefit of residues as they have high economic value.

One of those trends is "recycling of these waste to produce fodders" .

Reason behind such thought in this direction is the great gap between the fodders needs for animal farms as cows and buffalos which reaches to 13 million tons / year and the production volume of fodders factories which reaches to 2.5 million tons/year .

The research confirmed that exploitation of 40 % of the agricultural residues to produce untraditional fodders may compensate part of this gap .

Whereas some of the present machinery do not compatible with the requested standards and the high cost of transporting of these residues to place of manufacturing, in addition of its seasonal production periods and its several varieties, so need of manufacturing multipurpose mobile fodder production units appeared in order to adapt varieties of agricultural residues.

The research aims to design and manufacture mobile integrated units to produce feeds from untraditional resources that meet the recommended technical standards, in addition an economical study has been carried out on such a unit to recognize its economical feasibility.

So the following design assumptions have been taking into consideration : 1-The unit was designed to be in movable status to suit the small villages with productivity of 500 kg/hour .

2-The unit driven by the agriculture tractor which is available in the farms as a power source with rating power fluctuated between 60 – 80 HP.

3-The unit consists of five essential units which are ( chopper unit – hammer mill & crushing unit – mixing unit – pressing unit – Trailer and Power train Unit) .

4-The transport means which carry the materials between units designed as follows : -Transfer the cutting residues from the cutting machine to the hammer mill & crushing machine by gravity .

-Transfer the crushed materials from hammer mill & crushing machine to mixing unit by left helical lever .

-Transfer the mixture from the mixing unit to the lower tank of the mixer using gravity -Transfer the mixture from the lower tank of the mixer to the pressing unit using by left helical lever 5-Transfer the power from the tractor to the unit using PTO power taken off the tractor and the motion transferred to the various parts of the unit through gear box, drive shafts, pulleys and belts to adapt the revolution speeds needed to each unit .

Design and manufacture Components of the Untraditional Fodder mobile unit : Agricultural Residues Chopper Unit ; The main purpose of such a unit is to cut various agricultural residues such as the rice stalks, maize firewood, cotton firewood and other residues to smaller pieces than its physical status in order to crush and grind them in a hammer mill & crushing unit .

After search it was found that the technical data of the machines to be as follows : -Best number of cutting knives are 8 knives on the moving drum of 2000 rpm (rev./minute ) against one fixed knife on the cover .

-Feeding pulleys linear speed : 0.7 – 0.9 m / sec -Cutting drum speed : 2000 rpm .

-The length of cutting rice stalks produced is 50mm -The length of rest of agricultural residues produced is 10 mm .

-Productivity : 240 kg/hour of rice stalks or 400 kg/hour for other agricultural residues -Power consumed : approximately 5 HP The chipping occurs due to the shear force between the fixed knife and the movable knife II .

Hammer Mill & crushing Unit : The main role of such a unit is to crush the residues which have been cut in the chopping machine, taking in consideration that the chop and mill of rice has one of the hard agricultural residues in cutting and crushing .

So, the milling machine has been designed with a free hammer system in order to carry out mill grains and crush the residues from the cutting machine .

It was found that the reasonable numbers of milling hammers and circular speed to produce 5 millimeter pierce of rice stalks and other agricultural residues and about 300 kg./hour productivity, 450 kg/ hour for other agricultural residues, and 750 kg/ hour for grain milling are : 24 hummer distributed in four rotating rows of 3000 rpm.

and the power needed to operate such unit is about 4.5 H III .

Fodder Mixing Unit : The main role of this unit is mixing fodder consequences to become homogeneous provender ready for the second operation .

The mixing unit consists of several successive units, the most main unit is the mixture .

The mixture designed with the following specifications : -Horizontal, with open double helicals .

-High mixing degree reached to 98.5 % -Flaw four mixtures per hour, equivalent to 150 kg each 15 minutes.

-Total productivity 100 kg/hour, to cover the pressure ratio increasing by 100 kg.

to ensure continued feeding of the piston .

-The reasonable speed of the helical mixture 16 rev./min.

-The power needed to operate the bender unit is about 2.5 HP .

-The second part of the mixing units is tank to receive the mixing material of dimensions 80×85×95 cm, it attached with evacuation helical, the power needed to operate such unit is about 1.5 HP IV .

Pressing Unit : The purpose of the manufacturing process is to press the grains of the feed materials in order to transfer them to small plaits by means of force them into dies with circular orifices to form the pressed fodder materials into requested volumes, lengths and shapes .

The pressing unit designed as follows : -Rotating horizontal forming mould, including pressing pulleys which rotate around its axes by friction force between the pulleys and the forming mould and the material to be pressed.

-The productivity of the pressing unit represent the total productivity of the whole unit, so it designed to produce discharge of 500 kg./ hour -The power requested to operate the pressing unit fluctuated between 29 -24.5- 26 HP when using forming moulds of diameters of 12–16– 18 mm respectively .

V.

Units Carrying Trailer : There are two main functions of the trailer, the first function is carrying the units of the feed production line and moving between fields, while the second function is to provide each unit of the line with the requested energy driven from the tractor ( about 60 – 80 HP) .

Distribution of the power among units done through power transmission unit, which consider the most important part of the trailer, it consists of : 1- Gear Box 2- Low Speed Transmission Group ( 250 rpm ) .

-Moving Transmission Group to Pressing Unit .

-Moving Transmission Group to Discharging helical of the mixer lower tank .

-Moving Transmission Group to pressing adapting Unit 3- High Speed Transmission Group ( 1000 rpm ) .

-Moving Transmission Group to Mixing Machine .

-Moving Transmission Group to the Feeder of the Press Helical.

-Moving Transmission Group to chopper Machine .

-Moving Transmission Group to Hammer Mill & Crushing Machine .

-Moving Transmission Group to the Feeder of the Mixer Helical The Most Points of Evaluation of the Units Formed the Mobile Unit Of Feeds Manufacturing 1.The chopper unit fulfills the design assumptions such as power consumption for operation, cutting speed, and its relation with cutting length and conductivity .

It was found that the operation total power fluctuated between 3.0 – 3.2 – 3.5 for maize firewood, bean trellis and rice hays respectively .

Also it was found the cutting lengths are : 45.76 mm for rice hays, 13.59 for maize firewood, and 14.01 for bean trellis , While the productivity about 235 kg/hour for rice hays, 412 kg/hour for maize firewood, and 393 kg/hour for bean trellis at rotation speed of 2000 rpm.

By using 8 knives and feed speed of 0.7 m/sec .

2.The hammer mill & crushing unit fulfilled active performance in milling seeds and crushing the agricultural residues which were already chopped in the chopper unit, beside, it fulfilled the design assumptions such as power consumption for operation, speed of hammering mills, number of hummers, crushing length and total unit conductivity .

It was found that the operation total power fluctuated between 2.8 – 3.1 – 2.3 hp for maize firewood, bean trellis and rice hays respectively .

Also it was found the crushing lengths are : 2.64 mm for rice hays, 2.24 for maize firewood, and 1.71 for bean trellis , While the productivity of 293 kg/hour for rice hays, 447 kg/hour for maize firewood, and 754 kg/hour for bean trellis at rotation speed of 3000 rpm for milling hummer.

By using 24 hummers.

3.Three different mixtures prepared to feed milk livestock and other three mixtures to feed first stage fattening livestock and three mixtures to feed second stage fattening livestock, using the recommended standards .

4.Chemical analysis of the above mentioned samples (provender) to check if they meat standards, it was found that the crude protein percentage fluctuated between 14.05 % - 14.86 % and between 11.75% - 12.78% and between 10.38% – 10.49% for the three samples respectively .While the percentage crude fibers in the three mixtures fluctuated between 15.73 % - 18.87 % and between 15.06% - 16.45% and between 12.88 – 13.92 % respectively .

5.Mechanical analysis of the above mentioned samples, it was found that the minimum diversity factor among the samples is at a mixing period of 10 minutes, declaring that it was the best mixing period, resulting in a homogeneity between mixture consequences.

When the mixing period decreases the diversity factor between samples increases, that is because the homogeneous process is not completed in the mixture, while increasing the mixing period also the diversity factor between samples increases, that is because separation happens between mixture consequent .

6.Through the descriptive analysis the fodder plaits were subjected to study to check their final quality regarding external shape, touch and odder, and it was found that the soft touch of the stick with no cracks resulted from good hammer mill and crush of the agricultural residues of the mixture before pressing process .

By proceeding nutrition analysis of the plaits for average protein percentage and average crude fibers in the samples it was found that it fluctuated between 14.27 % - 15.83 % for the third bend of milk livestock respectively and fluctuated between 12.50 % - 15.83 % for the fifth mixture, first stage of fattening livestock respectively and fluctuated between 10.33 % - 13.50 % for the seventh mixture of fattening livestock respectively, such results declared that the fodder plaits specifications meet the recommended standards .

7.

The third mixture of milk livestock and the seventh mixture of fattening livestock, 2nd stage , subjected to mechanical specifications test including axial pressure stress and perpendicular pressure stress to find the necessary power needed to break the stick through drawing the stress – strain diagram and determining the stick yield point.

The results show that the average axial pressure stress yield is 3.882 – 4.583 Mpa and the average axial strain is 0.0124 – 0.0126 mm.

regarding the third seventh mixture respectively .

While the average axial pressure stress yield is 3.858 – 4.818 Mpa and the average axial strain is 0.008 – 0.009 mm.

regarding third and seventh mixture respectively which indicate that the produced fodder plaits from the third mixture of milk livestock (which consist of 50% of agricultural residues) and the seventh mixture of fattening livestock (which consist of 30% of agricultural residues) have strong bond and homogenous, that is due to the efficiency of industrial procedures starting from chopping, hammer milling, mixing processes and ends with pressing process to produce plaits meets standards .

That shows the competence of the unit when performing its function, so we advise to spread and distribute such units in all agriculture sectors in Egypt to solve the shortage of fodder problem and participate in overcoming environmental pollution due to burning of agricultural residues, especially rice hays .

8.The unit has been subjected to feasibility study, in order to make financial & economical evaluation of the unit to acknowledge the feasibility study of fabricating and spreading such a unit .

In addition of its environmental effect, and to what extent it participate to improve farmer income, and we achieve the following results : a.Net value of the production modes which can be implemented fluctuated between L.E 520.000 as a minimum value and L.E 1.389.000 as a maximum value for five years .

b.The percentage of income against costs which can be implemented fluctuated between L.E Million1.11.000 as a minimum value and L.E 1.28 million pounds as a maximum value .

c.Capital can be retrieved in a period fluctuated between 0.36 year as a minimum period and 1.31 year as a maximum period of five years d.The internal income ratio of the production modes which can be implemented fluctuated between 92 % as a minimum value (i.e.

the minimum annual average of pound profit is 92 piaster during the five years) and maximum value of 278 % (i.e.

the maximum annual average of pound profit is 278 piaster during the five years) .

RECOMMENDATIONS: The thesis achieved an ideal solution of the environment pollution problem which resulted from burning the agricultural residues - through the trend dealing with untraditional fodder manufacturing using agricultural residues.

The study toke up design and execute mobile unit produced untraditional fodder using agricultural residues to fit small farms with productivity of 500 kg/hour, power fed through ordinary agriculture tractor of 60 – 80 HP, and it can move to waste sites to overcome the difficulty of transfer residues to manufacturing site, resulting economical revenue for both investor and farmer .

It reached an automatic way to shop the agricultural residues specially rice hays as it is the most difficult waste to chop .

The feasibility study of such a unit achieved a great annual revenue gain as the pound invested in this unit secured annual profit fluctuated between 0.92 – 2.78 pounds which exceeds most of the investments in the agriculture field .

So, we recommend the followings : -Spread and distribute the unit among various agricultural sectors through the ministry of agriculture, universities, and research centers & institutes, also encourage small investors to adopt the unit and activate operation in order to help youth and create work chances for them to solve unemployment problems .

-Start research to produce floating fodders for fish using floating plant residues as Nile flowers, to participate in the production of cheap floating fodders as the fish fodder prices increased recently.

-Study of providing electric motors to operate the unit instead of the agriculture tractor in the sites where electric sources are available to avoid side effects on the environment in addition to economy wise .

-Study of developing drive power to unit in order to decrease the use of drive axes, pulleys and belts, besides developing transmission motion and clutching power to unit .