System and method for applying an additive to a material stream

Abstract

The present disclosure is generally directed to systems and methods for applying liquid feed additives to a feed composition. In one embodiment, the system has a spray housing defining a spray chamber located adjacent a mix housing carrying a material composition. The mix housing defines a mix chamber, which contains an actuating device, such as an auger, that moves the material stream through the mix chamber. The mix chamber and spray chamber are in fluid communication. A spray nozzle is coupled to the spray housing and in fluid communication with an air source and liquid additive tank. The spray nozzle sprays a fog of air and liquid additive through the spray chamber and into the mix chamber, which gets deposited on the passing feed stream.

What is claimed:  
     
         1 . A system for applying a liquid additive to a material stream, the system comprising: 
 a pump operatively connected to an additive tank and in fluid communication with a spray nozzle to move the additive to the spray nozzle;    an air source in fluid communication with the spray nozzle, wherein the air source provides air to the spray nozzle;    a mix housing defining a mix chamber and a mix chamber opening, the mix chamber opening providing access to the interior of the mix chamber and to the material stream;    an actuating device disposed within the mix chamber, the actuating device arranged to move the material stream from a first end to a second end of the mix housing;    a spray housing defining a spray chamber and a spray chamber opening, the spray housing located adjacent to the mix housing providing fluid communication between the spray chamber and the mix chamber through the mix chamber opening and the spray chamber opening; and    the spray nozzle disposed to spray a fog of air and liquid additive into the spray chamber, which passes through the spray chamber opening and the mix chamber opening into the mix chamber and deposits onto the material stream as it passes through the mix chamber.    
     
     
         2 . The system in  claim 1 , further comprising a door positioned on the spray housing to allow access to the spray chamber.  
     
     
         3 . The spray housing opening in  claim 1 , wherein the spray chamber opening is about equal to the size of the mix chamber opening.  
     
     
         4 . The spray housing opening in  claim 1 , wherein the spray chamber opening is greater than the size of the mix housing opening.  
     
     
         5 . The spray housing opening in  claim 1 , wherein the spray chamber opening is less than the size of the mix housing opening.  
     
     
         6 . The system in  claim 1 , wherein the fog substantially fills a volume of the mix chamber defined by an area of the mix chamber opening and a depth of the mix chamber below the mix chamber opening.  
     
     
         7 . The system in  claim 1 , wherein the nozzle is arranged to produce a spray of a mixture of the liquid additive and air to substantially cover the material stream with the liquid additive.  
     
     
         8 . The system in  claim 1 , wherein the actuating device is an auger.  
     
     
         9 . The auger in  claim 8 , wherein the auger is a mixing auger.  
     
     
         10 . The system as in  claim 1 , wherein the liquid additive exiting the nozzle has a droplet diameter of about 1 to 100 microns.  
     
     
         11 . The system as in  claim 1 , wherein the spray housing is coupled to the mix housing between a midsection of the mix housing and a first end of the mix housing.  
     
     
         12 . The system as in  claim 1 , wherein the spray housing is located sufficiently close to a first end of the mix housing to allow the liquid additive and the material stream to be sufficiently mixed in the mix chamber.  
     
     
         13 . The system as in  claim 1 , wherein the system includes a control unit operatively connected to system parameter meters and controllers, a computer and modem, and a work station arranged to automate the system.  
     
     
         14 . The system as in  claim 1 , further comprising a valve operatively positioned between the air source and the spray nozzle.  
     
     
         15 . The valve as in  claim 14 , wherein the valve is a solenoid valve.  
     
     
         16 . The system as in  claim 1 , further comprising an air filter operatively positioned between the spray nozzle and the air source.  
     
     
         17 . The system as in  claim 1 , further comprising an air regulator operatively positioned between the spray nozzle and the air source.  
     
     
         18 . The system in  claim 1 , further comprising a steam chest in fluid communication with the mix chamber, wherein the liquid additive can withstand cooking temperatures within the steam chest ranging from 150 to 250 degrees Fahrenheit.  
     
     
         19 . A system for applying a liquid additive to a material stream, the system comprising: 
 a pump operatively connected to an additive tank and in fluid communication with a spray nozzle to move the additive to the spray nozzle;    an air source in fluid communication with the spray nozzle, the air source providing air to the spray nozzle;    a solenoid valve operatively positioned between the air source and the spray nozzle;    an air filter operatively positioned between the air source and the spray nozzle;    an air regulator operatively positioned between the air source and the spray nozzle;    a mix housing defining a mix chamber and a mix chamber opening, the mix chamber opening providing access to the interior of the mix chamber and to the material stream;    an auger disposed within the mix chamber, the auger arranged to move the material stream from a first end to a second end of the mix housing;    a spray housing defining a spray chamber and a spray chamber opening, the spray housing located adjacent to the mix housing between the midpoint of the mix housing and the first end of the mix housing, providing fluid communication between the spray chamber and the mix chamber through the mix chamber opening and the spray chamber opening;    the spray housing having a length of about 3 feet, a width about the width of the mix housing and a height about 1.5 feet, and the spray nozzle disposed to spray a fog of liquid additive having droplet sizes from about 1 micron to 100 microns into the spray chamber, which passes through the spray chamber opening and the mix chamber opening into the mix chamber and deposits onto the material stream as it passes through the mix chamber.    
     
     
         20 . The system as in  claim 19 , wherein the spray chamber is removable from the mix housing such that it can be added and removed as such a system is needed on a mix housing to combine an additive on a material stream.  
     
     
         21 . The spray chamber opening in  claim 19 , wherein the spray chamber opening is about equal to the size of the mix chamber opening.  
     
     
         22 . The spray chamber opening in  claim 19 , wherein the spray chamber opening is greater than the size of the mix housing opening.  
     
     
         23 . The spray chamber opening in  claim 19 , wherein the spray chamber opening is less than the size of the mix housing opening.  
     
     
         24 . The system in  claim 19 , wherein the fog substantially fills a volume of the mix chamber defined by an area of the mix chamber opening and a depth of the mix chamber below the mix chamber opening.  
     
     
         25 . The system in  claim 19 , wherein the nozzle is arranged to produce a spray of a mixture of the liquid additive and air to substantially cover the material stream with the liquid additive as it passes through the mix chamber.  
     
     
         26 . The system in  claim 19 , wherein a control unit, a computer and system meters are operatively arranged to automate the system such that a user can monitor and control the system from a workstation.  
     
     
         27 . A method for making an animal feed product, the method comprising the steps of: 
 passing a material stream through a mix chamber;    coupling the mix chamber to a spray chamber, wherein the mix chamber and spray chamber are in fluid communication;    forming a fog of liquid additive, the fog including a mixture of air and a liquid feed additive;    depositing the fog onto the material stream;    mixing the material stream and the liquid additive after the deposit of the fog; and    heating the feed stream.    
     
     
         28 . A system for applying a liquid additive to a material stream, the system comprising: 
 a pump operatively connected to an additive tank and in fluid communication with a spray nozzle to move the additive to the spray nozzle;    a mix housing defining a mix chamber and a mix chamber opening, the mix chamber opening providing access to the interior of the mix chamber and to the material stream;    an actuating device disposed within the mix chamber, the actuating device arranged to move the material stream from a first end to a second end of the mix housing;    a spray housing defining a spray chamber and a spray chamber opening, the spray housing located adjacent to the mix housing providing fluid communication between the spray chamber and the mix chamber through the mix chamber opening and the spray chamber opening; and    the spray nozzle disposed to spray a fog of liquid additive into the spray chamber, which passes through the spray chamber opening and the mix chamber opening into the mix chamber and deposits onto the material stream as it passes through the mix chamber.    
     
     
         29 . A system for applying a liquid additive to a material, the system comprising: 
 a pump operatively connected to an additive tank and in fluid communication with a spray nozzle to move the additive to the spray nozzle;    an air source in fluid communication with the spray nozzle, wherein the air source provides air to the spray nozzle;    a mix housing defining a mix chamber and a mix chamber opening, the mix chamber opening providing access to the interior of the mix chamber and to the material;    a mixing device disposed within the mix chamber, the mixing device arranged to mix the material in the mix chamber;    a spray housing defining a spray chamber and a spray chamber opening, the spray housing located adjacent to the mix housing providing fluid communication between the spray chamber and the mix chamber through the mix chamber opening and the spray chamber opening; and    the spray nozzle disposed to spray a fog of air and liquid additive into the spray chamber, which passes through the spray chamber opening and the mix chamber opening into the mix chamber and deposits onto the material as it is mixed in the mix chamber.    
     
     
         30 . The system in  claim 29 , wherein the fog substantially fills the mix chamber.  
     
     
         31 . The system in  claim 29 , wherein the nozzle is arranged to produce a spray of a mixture of the liquid additive and air to substantially cover the material with the liquid additive.  
     
     
         32 . The system as in  claim 29 , wherein the liquid additive exiting the nozzle has a droplet diameter of about 1 to 100 microns.  
     
     
         33 . The system as in  claim 29 , wherein the system includes a control unit operatively connected to a computer, process stream monitors and regulators and a work station such that a user can monitor and control the system from the workstation.