Claims:WE CLAIM:
1. A system (100) for pre hydration of paddy, wherein the system (100) comprises:
a control module;
a surge bin (102), wherein the surge bin (102) is configured to receive a raw paddy from a pre cleaning unit;
a pre hydration tank (114), wherein the pre hydration tank (114) is configured to receive the raw paddy from the surge bin (102), wherein the pre hydration tank (114) consist of a cylindrical geometrical shape at top end and truncated cone with a shell at lower end; wherein a branched sparger system (400) is placed at centre of the pre hydration tank (114) in order to provide uniform steaming to the raw paddy;
a set of thermocouples (112a, 112b), wherein the set of thermocouples (112a, 112b) are mounted on the pre hydration tank (114); and
a rotary discharge system (108), wherein the control module is configured to control a discharge of the rotary discharge system (108) based on a signal received from the set of thermocouples (112a, 112b).

2. The system (100) as claimed in claim 1, wherein a high level sensor and a low level sensor mounted on the surge bin (102) are configured to monitor and control the level of the raw paddy in the surge bin (102) using the control module.

3. The system (100) as claimed in claim 1, wherein the surge bin (102) comprising a slide gate (116) configured for immediate discharge or as an emergency shut off gates to stop the raw paddy surges.

4. The system (100) as claimed in claim 4, wherein the slide gate (104) comprising a manual slide and a pneumatic operated slide gate, wherein the pneumatic operated slide gate is controlled by the control module.
5. The system (100) as claimed in claim 1, wherein the branch sparger system (400) comprising a series of horizontal slits arranged zigzag in tetrad pipes (500) emerging from a central vertical steaming line in order to introduce steam.

6. The system (100) as claimed in claim 1, wherein the control module comprises a Programmable Logic Controller (PLC).

7. The system (100) as claimed in claim 1, wherein a steam control valve (108) configured to control a steam inlet (106) in the pre hydration tank (114), wherein the Programmable Logic Controller (PLC) is configured to receive the signal from the set of thermocouples (112a, 112b) to control a steam inlet (106) through the steam control valve (104).

8. A method (800) for pre steaming of paddy, wherein the method (800) comprising a step of:
Receiving (801) a raw paddy at a surge bin (102), wherein the surge bin (102) is configured to receive the raw paddy from a pre cleaning unit;
Receiving (802) the raw paddy at a pre hydration tank (114), wherein the pre hydration tank (114) is configured to receive the raw paddy from the surge bin (102), wherein the pre hydration tank (114) consist of a cylindrical geometrical shape at top end and truncated cone with a shell at lower end, wherein a branched sparger system (400) is placed at centre of the pre hydration tank (114) in order to provide uniform steaming to the raw paddy;
Discharging (803) a pre hydrated paddy from a rotary discharge system (108), wherein the control module is configured to control a discharge of the rotary discharge system (108) based on a signal received from a set of thermocouples (112a, 112b) mounted on the pre hydration tank (114).

Dated this 22nd Day of September 2021
 
Priyank Gupta
Agent for the Applicant
IN/PA-1454
, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION

(See Section 10 and Rule 13)

Title of invention:
A SYSTEM AND A METHOD FOR PRE HYDRATION OF PADDY

APPLICANT:
AGRI PROCESS INNOVATIONS TECHNOLOGIES LLP
An Indian Entity having address as:
No.164 & 165,
KIADB, Obedenahalli Industrial Area,
3rd Phase, Doddaballapur,
Bangalore – 560125 Karnataka. India.

The following specification describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application does not claim priority from any other patent application.

TECHNICAL FIELD
The present subject matter described herein, in general, relates to a field of an agriculture processing. More particularly, the present subject matter relates to a system and a method for pre hydration of paddy.

BACKGROUND
The concept of conversion of a paddy to a rice is known as the paddy processing. The paddy processing comprising a parboiling system. Further, the parboiling comprises three stages namely a pre hydration (pre steaming), a hydration (soaking) and a post hydration (post steaming / gel cook). The first stage of the pre hydration of a paddy is configured to receive a raw paddy from a pre cleaning unit. In a conventional system, a batch wise pre hydration of the raw paddy decreases the productivity of the paddy processing system. The batch wise pre hydration also results in non-uniform quality between the batches. Further, the conventional system of the pre hydration is dependent on operator’s skill which will turn into the human errors and non-uniformity. Further, the conventional system of the pre hydration did not ensure the uniform thermal treatment to each grain of the paddy. Further, non-optimum use of a steam increases the operational cost in the conventional system of the pre hydration.

Thus, there is a long-standing need of a system and a method for pre hydration of paddy which solves above mentioned problems.

SUMMARY

This summary is provided to introduce the concepts related to a system for pre-hydration of paddy and the concepts are further described in the detail description. This summary is not intended to identify essential features of the claimed subject matter, nor it is intended to use in determining or limiting the scope of claimed subject matter.

In one implementation a system for pre hydration of paddy. Further, the system comprises a control module, a surge bin, a pre hydration tank, a set of thermocouples and a rotary discharge system. Further, the surge bin is configured to receive a raw paddy from a pre cleaning unit. Further, the pre hydration tank is configured to receive the raw paddy from the surge bin. Further, the pre hydration tank consist of a cylindrical geometrical shape at top end and truncated cone with a shell at lower end. Further, a branched sparger system is placed at centre of the pre hydration tank in order to provide uniform steaming to the raw paddy. Further, the set of thermocouples are mounted on the pre hydration tank. Furthermore, the control module is configured to control a discharge of the rotary discharge system based on a signal received from the set of thermocouples.
In another implementation, a method for pre hydration of paddy is disclosed. The method may comprise a step of receiving a raw paddy at a surge bin, wherein the surge bin is configured to receive the raw paddy from a pre cleaning unit. The method may further comprise the step for receiving the raw paddy at a pre hydration tank, wherein the pre hydration tank is configured to receive the raw paddy from the surge bin. Further, the pre hydration tank consist of a cylindrical geometrical shape at top end and truncated cone with a shell at lower end, wherein a branched sparger system is placed at center of the pre hydration tank in order to provide uniform steaming to the raw paddy. The method may further comprise step for discharging a pre hydrated paddy from a rotary discharge system, wherein the control module is configured to control a discharge of the rotary discharge system based on a signal received from a set of thermocouples mounted on the pre hydration tank.
BRIEF DESCRIPTION OF DRAWINGS

The detailed description is described with reference to the accompanying figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.

Figure 1 illustrates a system (100) for pre hydration of paddy, in accordance with an embodiment of a present subject matter.
Figure 2a and 2b illustrates a manual operated slide gate (200a) and a pneumatic slide gate (200b) of the system, in accordance with an embodiment of a present subject matter.
Figure 3 illustrates a pre hydration tank (300), in accordance with an embodiment of a present subject matter.
Figure 4 illustrates a branched sparger system (400), in accordance with an embodiment of a present subject matter.
Figure 5 illustrates a transverse view of tetrad pipe (500), in accordance with an embodiment of a present subject matter.
Figure 6a and 6b illustrates a central pipe of sparger system (600a) and a tetrad pipe of sparger system (600b), in accordance with an embodiment of a present subject matter.
Figure 7 illustrates a rotary discharge system (700), in accordance with an embodiment of a present subject matter.
Figure 8 illustrates a method (800) for pre hydration for paddy processing, in accordance with an embodiment of a present subject matter.

DETAILED DESCRIPTION

Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

The present disclosure relates to a system (100) for pre hydration of paddy. Now referring to figure 1, the system (100) for pre hydration of paddy is illustrated, in accordance with an embodiment of the present subject matter. The system (100) for pre hydration of paddy may comprises a control module, a surge bin (102), a pre hydration tank (114), a set of thermocouples (112a, 112b), and a rotary discharge system (108). Further, the surge bin (102) is configured to receive a raw paddy from a pre cleaning unit. The surge bin (102) is fabricated for adequate storage of raw paddy with a 202 grade stainless steel make. The surge bin (102) receives the raw paddy from the pre cleaning unit through bucket elevators. Further, a high level sensor and a low level sensor mounted on the surge bin (102) are configured to monitor and control the level of the raw paddy in the surge bin (102) using the control module. The signals from these sensors are linked with Programmable logic controller (PLC) for maintaining the paddy for continuous pre-hydration process. Further, the surge bin (102) may comprise a slide gate (116) configured for immediate discharge or as an emergency shut off gates to stop the raw paddy surges. In one embodiment, the outlet of the surge bin (102) i.e. bottom hopper is mounted with a manual (Fig. 2a) and a pneumatic slide gate (Fig. 2b).

Now referring to Figure 2a and 2b, a manual operated slide gate (200a) and a pneumatic slide gate (200b) of the system is illustrated, in accordance with an embodiment of the present subject matter. The pneumatic slide gate (200b) is operated by the signals from the control module. The pneumatic slide gates (200b) may comprise a compact and economical design involving opening and or as cut off valves or as emergency shut off gates to stop material surges. In another embodiment the system (100) for pre hydration of paddy may comprise a steam control valve (104) configured to control a steam inlet (106) in the pre hydration tank (114). Further, the control module comprises a Programmable Logic Controller (PLC). Further, the Programmable Logic Controller (PLC) may be configured to receive the signal from the set of thermocouples (112a, 112b) to control a steam inlet (106) through the steam control valve (104).

Now again referring to Fig. 1, the pre hydration tank (114) is configured to receive the raw paddy from the surge bin (102). Further, the pre hydration tank (114) consist of a cylindrical geometrical shape at top end and truncated cone with a shell at lower end. Further, a branched sparger system (400) is placed at centre of the pre hydration tank (114) in order to provide uniform steaming to the raw paddy. Further, the set of thermocouples (112a, 112b) are mounted on the pre hydration tank (114). Further, the control module is configured to control a discharge of the rotary discharge system (108) based on a signal received from the set of thermocouples (112a, 112b).
Now referring to figure 3, a pre hydration tank (300) is illustrated, in accordance with the embodiment of the present subject matter. Further, the pre hydration tank (300) is configured to receive the raw paddy from the surge bin (102). Further, the pre hydration tank (300) consist of a cylindrical geometrical shape at top end and truncated cone with a shell at lower end. Further, a branched sparger system (400) is placed at centre of the pre hydration tank (300) in order to provide uniform steaming to the raw paddy. Further, the pre hydration tank (300) constitute a dynamic steaming chamber which operates in a continuous or online mode. Further, pre hydration tank (300) is fabricated with a cylindrical geometrical shape made up
of 202 grade stainless steel with a top cover and an outlet neck assembly at the base. Further, the pre hydration tank (300) comprises a top cover assembly consists of shell and a circular flange for monitoring and maintenance of the tank. Further, the pre hydration tank (300) comprise the lower end of the chamber has a truncated cone with a shell. Further, the pre hydration tank (300) comprises total length of the units is 3402 mm and a diameter of the chamber at the centre is 1200 mm. The pre hydration tank (300) is anchored vertically by the mounting brackets consisting of four bracket opposites to each other. Further, a steam is introduced into the pre hydration tank (300) through a stainless-steel inlet pipe attached to the upper cylindrical area. The main component inside the pre hydration tank (300) is the branched sparger system.

Now referring to figure 4, the branch sparger system (400) is illustrated, in accordance with the embodiment of the present subject matter. In one embodiment, the branched sparger system (400) is placed at centre of the pre hydration tank (300) in order to provide uniform steaming to the raw paddy. The steam may be introduced into the pre hydration tank (300) through the sparger system unit comprising of a series of horizontal slits arranged throughout the central pipe and on the tetrad pipes emerging from a central vertical steaming line. Further, the slits are designed at varying degrees located at the three sides covering the lower and two sides. However, the end of the pipe there are perforations. Each sparger system consists of three level arrangement of horizontal pipes. Each level is distinctly arranged in cross to the other. The total length of the branched sparger system is 2589 mm from base to the tip.

Now referring to figure 5, a transverse view of tetrad pipe (500) is illustrated, in accordance with the embodiment of the present disclosure. Further, the branch sparger system (400) comprising a series of horizontal slits arranged zigzag in tetrad pipes (500) emerging from a central vertical steaming line in order to introduce steam. Further, the branching pipes are sloped at an angle of 30 degree corresponding to the subsequent tetrad unit in such a way to cover the total area across the central axis. These tetrad pipes cover a diameter of 1151 mm inside the chamber. The zig zag arrangement of spargers facilitates equal distribution of the steam for the paddy fed within the chamber, thereby achieving the uniform steaming for all the paddy grains

Now referring to figure 6a and 6b, a central pipe of sparger system (600a) and a tetrad branched pipe of sparger system (600b) is illustrated, in accordance with the embodiment of the present disclosure. Further, a main inlet steam pipe is connected to the pre-hydration tank through an 88.9 mm outer diameter central pipe (600a). Further, the branched tetrad pipes have an outer diameter of 48.26 mm. Further, the central pipe (600a) has four sets of perforations opposite to each other covering the entire area of the pipe. The arrangement of slits varies between the two ends of the central pipe (600a). The distance between the perforation slits gradually decreases towards the base forming a dense cluster at the base to bring about higher steaming efficiency. The central pipes (600a) having four rows of perforations each measuring 1.5 x 25 mm slit width and length, respectively. Further, the tetrad branched pipes (600b) have three rows of perforations (two sides and one bottom) each measuring 1 x 15 mm slit width and length, respectively. Further, referring to the figure 6b, the perforation slit on the tetrad branched pipes (600b) are in a linear fashion. The slit at the bottom is linear without an inclination angle while the sides are at an inclination angle of 60 degree from the central axis. The distance between each adjacent sets of perforations gradually decrease towards the centre. The inclinations of pipes and the perforation arrangements was deduced after a series of trails which met the requirements with maximum efficiency. This design facilitates three-dimensional thermal treatment and equal distribution of low-pressure steam across the chamber for uniform quality of paddy. The steam consumption of this steaming chamber is about 1200- 1600 kg/hr and the pressure of 2 bar. The output capacity of system (100) for pre hydration is between 12-42 tph. The steamed paddy moves by the influence of gravity and the tetrad pipe arrangement of sparger brings about uniform steaming of paddy. Once the paddy reaches the required thermal treatment equilibrium, the rotary discharge gates (RDG) are activated for discharge of paddy which is controlled by the PLC. The speed of the emerging paddy is regulated by RDG which varies between 6 to 10 rpm depends on process and the paddy variety.

Now referring to figure 7, a rotary discharge system (700) is illustrated, in accordance with the embodiment of the present subject matter. Further, the rotary discharge system (700), wherein the control module is configured to control a discharge of the rotary discharge system (700) based on a signal received from the set of thermocouples (112a, 112b). This unit consists of eight plates arranged to the central coupled gear box. Further, the rotary discharge system (700) may comprise of a rotating type of monitor fixed with a discharge plate. Further, the discharge of paddy from the rotary discharge system (700) is directly influenced by the equilibrium thermal temperature and is achieved once the grain attains the linear temperature acquisition.

Now referring to figure 8, a method (800) for pre hydration of paddy is illustrated, in accordance with the embodiment of the present subject matter.

At step (801), the system is configured for receiving the raw paddy at the surge bin (102), wherein the surge bin (102) is configured to receive the raw paddy from a pre cleaning unit.
At step (802), the system is configured for receiving the raw paddy at the pre hydration tank (114). Further, the pre hydration tank (114) is configured to receive the raw paddy from the surge bin (102). Further, the pre hydration tank (114) consist of the cylindrical geometrical shape at top end and truncated cone with the shell at lower end, wherein the branched sparger system (400) is placed at centre of the pre hydration tank (114) in order to provide uniform steaming to the raw paddy.
At step (803), the system may be configured for discharging the pre hydrated paddy from the rotary discharge system (108). Further, the control module is configured to control the discharge of the rotary discharge system (108) based on the signal received from the set of thermocouples (112a, 112b) mounted on the pre hydration tank.
The embodiments illustrated above, especially related to the system for pre-hydration of paddy provide following advantages:
• The system for pre hydration of paddy is equipped with continuous steaming mechanism for soaked paddy which ensures uniformly distributed heat load to each grain.
• The pre-hydration process increases the porosity of the husk and brings about complete and homogeneous parboiling of the paddy rice.
• The system for pre hydration of paddy is online or continuous process involving fully automated controlled system, which is essential for reducing the process time, steam efficiency & to obtain uniform steaming of paddy.
• This reduces the human interference and brings about consistent and quality results of the output paddy.

Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.

The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure.

The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.