Wet Grain Drying System and Method

Abstract

A device according to various embodiments for drying wet grain can include a first screw configured to receive wet grain. A second screw receives the wet grain from the first screw. At least one mechanism is included within at least one of the first screw and the second screw to vaporize water content in the wet grain.

What is claimed is: 
     
         1 . An animal feed produced by the process comprising:
 supplying a raw material having a first moisture content to a drying unit to remove moisture from at least a portion of the raw material to produce a substantially dry final product having a second moisture content lower than the first moisture content;   heating the raw material during a startup period of time;   discontinuing heating of the raw material after the startup period when the raw material begins to flow through the drying unit;   generating mechanical heat directly applied to the raw material by a shearing force, without adding additional heating after the startup period; and   removing the moisture from the portion of the raw material using steps of shearing, compressing, and vaporizing, without adding additional heating after the startup period, to produce the dry final product having a nutritional content of a high fat content and a high protein content, without adding any additives, binders, or fillers.   
     
     
         2 . The animal feed produced by the process of  claim 1 , wherein the first moisture content of the raw material is within a range of about 13% to about 90% by weight. 
     
     
         3 . The animal feed produced by the process of  claim 1 , wherein the second moisture content of the substantially dry final product is within a range of about 0% to about 12% by weight. 
     
     
         4 . The animal feed produced by the process of  claim 1 , wherein the raw material comprises granular material or wet distiller grain. 
     
     
         5 . The animal feed produced by the process of  claim 1 , wherein the step of removing the moisture from the portion of the raw material, further comprises reducing the moisture in the raw material from about 13% to about 90% by weight to a substantially dry product having a moisture content within a range of about 0% to about 12% by weight. 
     
     
         6 . The animal feed produced by the process of  claim 1 , further comprising the step of:
 extruding the final dry product through a die to form the final product in a shape of a pellet or a cube.   
     
     
         7 . The animal feed produced by the process of  claim 1 , further comprising the step of:
 forming the final product in a shape of a pellet, a cube, or a tub.   
     
     
         8 . An animal feed produced by the process comprising:
 supplying a raw material having a first moisture content to a multiple stage drying unit to remove moisture from at least a portion of the raw material in sequential stages to produce a substantially dry final product having a second moisture content lower than the first moisture content, wherein the multiple stage drying unit includes a plurality of extruders connected in multiple stages and one of the extruders is operated at each of the sequential stages;   providing a plurality of screws within each extruder including at least a first screw and a second screw;   rotating the at least a first screw and the second screw to compress the raw material between and advance the raw material along the at least first screw and the second screw;   heating, during a startup period of time, at least one of the plurality of screws to approximately 220° F.;   discontinuing heating of the at least one of the plurality of screws after the startup period when the raw material begins to flow through the first screw and the second screw;   shearing the raw material between intermeshing flights of the at least first screw and the second screw;   generating mechanical heat directly applied to the raw material by the shearing, without adding additional heating after the startup period;   compressing the raw material between the at least first screw and the second screw to squeeze moisture from the raw material;   vaporizing the moisture from the raw material by substantially increasing an initial temperature of the raw material, without adding additional heating after the startup period; and   removing the moisture from the portion of the raw material at least some stages of the sequential stages using the steps of shearing, compressing, and vaporizing, without adding additional heating after the startup period, to produce the dry final product having a nutritional content of a high fat content and a high protein content, without adding any additives, binders, or fillers.   
     
     
         9 . The animal feed produced by the process of  claim 8 , wherein the first moisture content of the raw material is within a range of about 13% to about 90% by weight. 
     
     
         10 . The animal feed produced by the process of  claim 8 , wherein the second moisture content of the substantially dry final product is within a range of about 0% to about 12% by weight. 
     
     
         11 . The animal feed produced by the process of  claim 8 , wherein the raw material comprises granular material. 
     
     
         12 . The animal feed produced by the process of  claim 8 , wherein the raw material comprises wet distiller grain. 
     
     
         13 . The animal feed produced by the process of  claim 8 , wherein the step of removing the moisture from the portion of the raw material, further comprises reducing the moisture in the raw material from about 13% to about 90% by weight to a substantially dry product having a moisture content within a range of about 0% to about 12% by weight. 
     
     
         14 . The animal feed produced by the process of  claim 13 , wherein the raw material comprises wet distiller grain. 
     
     
         15 . The animal feed produced by the process of  claim 8 , further comprising the step of:
 extruding the final dry product through a die to form a shape of the final product.   
     
     
         16 . The animal feed produced by the process of  claim 15 , wherein the final product is in the shape of a pellet. 
     
     
         17 . The animal feed produced by the process of  claim 15 , wherein the final product is in the shape of a cube. 
     
     
         18 . The animal feed produced by the process of  claim 8 , further comprising the step of:
 forming the final product in a shape of a pellet.   
     
     
         19 . The animal feed produced by the process of  claim 8 , further comprising the step of:
 forming the final product in a shape of a cube.   
     
     
         20 . The animal feed produced by the process of  claim 8 , further comprising the step of:
 forming the final product in a shape of a tub.