In the feed mill, 80–90% of the steam is drawn by the pellet press conditioner. This steam mixes directly with the feed and does not return to the boiler as condensate; the boiler is therefore selected according to the winter condition (mash ≈ 5 °C) and almost entirely fresh feed water. 1 ton of poultry feed requires 67 kg of steam ≈ in winter and 50 kg ≈ summer. The Çiftel Kazan wizard calculates the condition temperature, hygienizer, expander, extruder and dryer separately according to the feed type; while 2 bar g is sufficient in the conditioner, the boiler pressure is at least 8.5 bar g since the boiler is operated at 7-9 bar g in the field.
Which machine draws how much steam?
| Machine | Typical capacity | Vapor / heat | Pressure |
|---|---|---|---|
| Pellet press conditioner, finned (85 °C) | 10 t/h, mash 5 °C (winter) | 668 kg/h (≈ 67 kg/t); average 585 kg/h per year | 2 bar g |
| Conditioner, cattle (70 °C) | 10 t/h | 533 kg/h (≈ 53 kg/t) | 1 bar g |
| Hygienizer + conditioner (85 °C) | 10 t/h, 5 kW jacket | 677 kg/h | 2 bar g |
| Double pass / long conditioner (92 °C) | 10 t/h | 750 kg/h | 2 bar g |
| Expander (with pre-conditioner, 92 °C) | 10 t/h | 736 kg/h | 2 bar g |
| Extruder preconditioner + barrel | 6 t/h | 557 kg/h (≈ 93 kg/t) | 2 bar g |
| Extruded feed dryer, steam | 6 t/h, humidity 23% → 9% | 1,715 kg/h (952 kW) | 10 bar g |
| Extruded feed dryer, thermal oil | 6 t/h | 952 kW ≈ 818,900 kcal/h | thermal oil 250°C |
| Molasses tank heating | 10 t/h feed × 3% molasses, 30 m³ tank | 28 kg/h (17 kW) | 2 bar g |
| Oil tank and coating | 10 t/h feed × 3% oil, 100 m line monitoring | 32 kg/h (19 kW) | 3 bar g |
| Steam flattening (flake) | 10 t/h corn, 10 → 98 °C | 886 kg/h (≈ 89 kg/t) | 1 bar g |
Example: 2 × 12t/h poultry feed mill
The template “Medium poultry feed” in the wizard: a two-line factory that works 20 hours a day, producing 480 t of pellet feed. The calculation is made based on the winter condition.
| Machine | Quantity | Condition | Steam |
|---|---|---|---|
| Pellet press conditioner, 12 t/h | 2 | 85 °C, mash 5 °C, vapor dryness 97%, loss 10% | 2 × 802 = 1.604 kg/h |
| Molasses tank | 1 | 720 kg/h molasses, 10 → 40 °C, 30 m³ tank | 38 kg/h |
| Oil tank and coating | 1 | 720 kg/h oil, 20 → 65 °C, 100 m line monitoring | 50 kg/h |
- Simultaneous requirement of the machines: 1,693 kg/h; 95% of this is direct steam mixed with the product.
- Line losses (5%) +85 kg/h, deaeration steam (condensate return 0%, make-up water 15 °C) +298 kg/h, growth share (10%) +208 kg/h → 2,283 kg/h.
- Recommended steam boiler: 2.5 t/h, working pressure 8.5 bar g (10 bar design class); reduced to 2 bar g to conditioners. Feed water 105 °C (with deaeration).
- Boiler thermal power 1,487 kW ≈ 1,278,000 kcal/h; natural gas ≈ 168 Sm³/h at full load.
- Sector supply: 65 kg steam/t feed (expected range 35–80). Although the growth margin is taken as zero, the recommendation remains 2.5 t/h.
- Other templates: single-line 8 t/h compound feed → 0.7 t/h; 2 × 15 t/h cattle feed (6% molasses) → 2.5 t/h; 4 × 15 t/h integrated plant (one line hygienic) → 6 t/h; 2 × 6 t/h extruded fish feed → with steam dryer 7 t/h (12 bar class).
Boiler type and pressure in feed mill
In the feed factory, the fluid is steam and the quality of the steam is as important as the capacity. If the dryness decreases from 97% to 80%, the same 1% steam heat the mash only 11.1 °C instead of 13.2 °C; a separator and steam trap should be placed in front of the conditioner. The boiler is operated at 8.5–9 bar g, selected in the 10 bar class and reduced to 1.5–2.5 bar g in front of the conditioner; when the steam carried at high pressure is reduced, it becomes hot and dry. Since almost all of the feed water is fresh water, deaeration and water treatment are essential.
Package type and hybrid type steam boilers of Çiftel Kazan up to 6 t/h, header type water tube steam boiler above 6 t/h are suitable; Economizer is recommended at 2 t/h and above. In large plants with low tolerance for interruption, a two-boiler (N+1) arrangement is established. If the extruded feed dryer is heated with thermal oil, the steam boiler goes down to 1.5 t/h, and 1,900,000 kcal/h thermal oil boiler is added for two dryers.
How to do the calculation?
In the formula, mash mass is m (kg/h), cp ≈ 1.75 kJ/kg· K; steam dryness lowers H”. Since the direct steam does not rotate as condensate, the deaerator steam is found in mass and energy balance and reaches 17% of the ≈ of the steam going to the machines. The condensate of molasses and oil tank coils is also not returned directly to the boiler due to the risk of leakage.
Use the wizard at the top of the page to calculate with your own list of machines; Boiler Capacity Calculator for all industries.
The results of the wizard are predictions to give a preliminary idea; boiler selection should be finalized by on-site exploration and engineering calculation. Contact us for free pre-engineering support.