Continuous flow dryer for treating bulk material

Abstract

A continuous flow dryer system according to various embodiments can include a source for supplying a material to be treated having a high moisture content, such as a distiller wet grain, a profile screw compression dryer, a profile screw, and a drive coupled to the profile screw for axially rotating the profile screw. The profile screw compression dryer includes an inlet for receiving the material for drying, which is fed therein in a controlled manner. The profile screw is provided within the housing of the dryer. The profile screw has a diameter that increases in dimension in a direction away from the inlet for increasing the compressive force applied to the material to assist with drying as the profile screw rotates and moves the material longitudinally along the profile screw to produce a final product, for example, a distiller dried grain for use as an animal feed.

What is claimed is: 
     
         1 . A dried grain produced by extruding (a) a material to be treated (1) having a high nutritional value and (2) having an initial moisture content greater than approximately 60% by weight through an extruder to extract the moisture content without lowering the high nutritional value to make (b) a dried grain (1) having the nutritional value substantially the same on a weight basis before extracting the moisture content and (2) having a final total moisture content of less than approximately 15% by weight. 
     
     
         2 . The dried grain of  claim 1 , wherein the dried grain has a high protein content, without adding any binders. 
     
     
         3 . The dried grain of  claim 1 , wherein the initial moisture content of the treated material includes two or more different liquids having a respective different boiling point. 
     
     
         4 . The dried grain of  claim 3 , wherein each of the different liquids are successively extracted from the treated material at each respective different boiling point from the treated material by creating a temperature and pressure sufficient to target extraction of a selected liquid, without substantially extracting other liquids contained in the treated material as the treated material travels successively through a plurality of treatment zones provided within the extruder. 
     
     
         5 . The dried grain of  claim 4 , wherein at least one of the other liquids comprises corn oil. 
     
     
         6 . The dried grain of  claim 1 , wherein the treated material is selected from the group consisting of a distiller wet grain, slurry, sludge and mixtures thereof. 
     
     
         7 . The dried grain of  claim 1 , wherein the dried grain comprises a dried distiller grain. 
     
     
         8 . The dried grain of  claim 1 , wherein the dried grain comprises an animal feed. 
     
     
         9 . An animal feed produced by extruding (a) distiller wet grain (1) having a high nutritional value and (2) having an initial moisture content greater than approximately 60% by weight through an extruder to extract the moisture content without lowering the high nutritional value to make (b) a dried distiller grain (1) having the nutritional value substantially the same on a weight basis before extracting the moisture content and (2) having a reduced moisture content of less than approximately 15% by weight then extruding the dried distiller grain with the reduced moisture content through a die to produce (c) pelletized dried distiller grain (1) having a final nutritional value that is higher on a per unit volume than the dried distiller grain and (2) having a high protein content, without adding any binders. 
     
     
         10 . The animal feed of  claim 9 , further comprising an outer surface lubricant provided on at least a portion of an outer surface of the pelletized dried distiller grain and is formed by extruding the dried distiller grain through the die causing a portion of the moisture content to migrate towards the outer surface as the dried distiller grain transforms to the pelletized dried distiller grain. 
     
     
         11 . The animal feed of  claim 10 , wherein the moisture content comprises at least one of corn oil or water. 
     
     
         12 . The animal feed of  claim 11 , wherein the corn oil serving not only as at least a portion of the protein content and providing lubrication on the outer surface during the extrusion as the dried distiller grain transforms to the pelletized dried distiller grain. 
     
     
         13 . An animal feed produced by extruding (a) distiller wet grain (1) having a high nutritional value and (2) having an initial moisture content greater than approximately 60% by weight through an extruder to extract the moisture content without lowering the high nutritional value to make (b) a dried distiller grain (1) having the nutritional value substantially the same on a weight basis before extracting the moisture content and (2) having a reduced moisture content of less than approximately 15% by weight then compressing the dried distiller grain with the reduced moisture content within a tub to produce (c) a final product shaped as a livestock feed tub having a high protein content, without adding any binders. 
     
     
         14 . The animal feed of  claim 13 , wherein the livestock feed tub is formulated having an intake limiting composition to control a rate of consumption of the dried distiller grain compressed within the tub by livestock. 
     
     
         15 . The animal feed of  claim 13 , wherein the livestock feed tub is formulated having a density that limits a daily intake of the dried distiller grain compressed within the tub by livestock to a rate of consumption of approximately 2 pounds or less. 
     
     
         16 . The animal feed of  claim 13 , wherein the livestock feed tub weighs approximately 200 pounds.