Low-temperature drying of dehydrated organic sludge with high moisture content, which is difficult to process/ Test cases / Sludge dryer

Summary

1. Gentle drying of all types of sludge with high adhesion and water content.
Our world-patented original mechanism dries even sludge that tends to clump to the inside of the sludge.
Continuous low temperature drying with minimal change in composition, making it suitable for a wide range of applications
Unattended operation possible 24 hours a day

2.Low temperature drying minimizes compositional changes and is ideal for recycling and upcycling
Indirect steam drying suppresses compositional changes caused by high temperature drying
Can be used for recycling and upcycling as fertilizer, feed, soil conditioner, etc.

3.Reduced environmental impact and operating costs
No carbon dioxide emissions, unlike direct-fired dryers such as burners
High drying heat efficiency reduces steam consumption
Fuel costs can be reduced by using excess steam.
Decarbonized drying is possible by using an electric boiler.

4. Less trouble after start-up, easy maintenance
Low wear of parts due to slow rotation speed of dryer blades
Continuous drying system allows easy operation control and unmanned operation 24 hours a day.

5. Contributes to waste reduction, CO2 emission reduction and resource conservation
Drying sludge reduces its weight and waste disposal costs.
Reduces CO2 emissions by reducing the number of trucks used
Recover minerals and phosphorus contained in sludge and contribute to resource conservation

6. Patented original technology
We have a total of 11 patents (2 in Japan and 9 in 7 foreign countries) for our proprietary technology.

7. Diverse applications
Suitable for a wide range of applications, including organic waste with high water content, sludge, manure, digested methane fermentation liquid, and waste.

8. Energy saving design
Low-temperature drying and indirect steam method reduce fuel consumption and CO2 emissions.

9. economic efficiency
Low operating costs and energy-efficient design reduce power costs

10. Versatile applications
Capable of drying various types of high moisture content organic waste, such as sludge, slurry, and food waste

KENKI DRYER can easily and smoothly dry even highly sticky and difficult-to-dry materials. For example, highly sticky sludge is difficult to dry. Depending on the type of dryer, sludge may not be discharged due to clogging inside the dryer during drying. KENKI DRYER’s unique, world-patented mechanism allows sludge to be dried smoothly without clogging the dryer, no matter how sticky or adhesive the sludge is.
In addition, because the KENKI DRYER is a continuous low-temperature drying system, there is little change in the composition of the dried material after drying, so it can be used for a variety of purposes and can operate unattended 24 hours a day.

Sludge discharged from wastewater treatment plants tends to become lumpy during the drying process due to the coagulant used in wastewater treatment. When the dried sludge becomes lumpy, the heat is not sufficiently distributed to the inside of the dried sludge and the sludge is not heated inside, so only the surface is dried and the inside is not heated and dried. In the drying process of the KENKI DRYER, even if the dried material becomes lumpy, it is crushed to a certain extent in the dryer to reduce its surface area so that the inside of the dried material can be dried more than adequately.

By drying sludge discharged from wastewater treatment plants at low temperatures, the composition of the sludge after drying remains unchanged and can be used for recycling and upcycling. KENKI DRYER is an indirect dryer that uses steam as a heat source at low temperatures, so the composition of the dried materials after drying is little changed, and they can be fully utilized as recycled and upcycled products.

KENKI DRYER, with 11 patents in 8 countries, is an indirect steam dryer, but it is a completely unique product, different in structure from other similar indirect steam dryers. Direct-fired dryers, such as burners, emit carbon dioxide from the dryer, which is against the times in terms of environmental protection and decarbonization, and drying at high temperatures means high fuel costs, rapid wear of parts, and high maintenance costs.

Although KENKI DEYER uses steam as a heat source, it does not produce more global warming gases and CO2 than KENKI DRYER during drying. In addition, the KENKI DRYER uses less steam due to its high drying heat efficiency, so you can use the steam you currently use, and if you use the excess steam, the fuel cost will not increase and the CO2 emissions will not increase compared to boilers that generate steam during the drying process. Alternatively, by installing an electric boiler, drying can be done in a decarbonized manner, without producing any greenhouse gases or CO2 emissions during the drying process.

There are no problems after start-up, and the blades of the dryer’s main body rotate at a very slow speed of 5 RPM or less, so parts wear is minimal and maintenance is easy and inexpensive. KENKI DRYER is a continuous dryer, not a batch dryer that stores and dries materials to be dried. Therefore, operation is simple and unmanned operation is possible 24 hours a day.

Drying sludge to reduce the weight and volume of waste products can contribute to environmental protection and decarbonization by reducing the cost of industrial waste, which is increasing due to the recent trucking problem in 2024, and by reducing the number of trucks transporting waste, thereby reducing carbon dioxide emissions.

Japan is almost 100% dependent on imports for its mineral resources. In the future, precious metals and rare metals in particular will continue to be important resources, and securing these resources is essential to maintaining and strengthening international competitiveness. One of the measures to secure mineral resources is the reuse and recycling of minerals contained in sludge, which will contribute to environmental protection and reduce greenhouse gas emissions. Phosphorus, which is currently imported from China, is also an indispensable mineral. Therefore, the extraction of phosphorus from sewage sludge is being promoted as a national project.
The recycling of sludge from wastewater treatment plants is becoming increasingly important for environmental protection, decarbonization, and securing imported resources.

KENKI DRYER can dry sticky and adhesive materials that others cannot dry. KENKI DRYER is a breakthrough drying device with a total of 11 patents (2 in Japan and 9 in 7 overseas countries). Please consider KENKI DRYER for your high moisture organic waste dryer, sludge dryer, slurry dryer, methane fermentation digestate dryer, and waste upcycling or recycling dryer.

KENKI DRYER has been granted 11 patents in 8 countries (Japan, Taiwan, USA, France, Germany, UK, Switzerland, Canada).

Organic sludge refers to a semi-solid slurry that is primarily composed of organic matter. It can be generated from various sources, including:

1. Wastewater Treatment Plants: Organic sludge is a byproduct of the treatment process, primarily consisting of organic waste, bacteria, and other microorganisms that break down sewage.
2. Industrial Processes: Certain industries, such as food processing, paper manufacturing, and agriculture, produce organic sludge as a waste product.
3. Composting and Biogas Production: Organic waste material from these processes can also produce sludge.

Organic sludge typically contains a high level of nutrients, such as nitrogen and phosphorus, making it useful for agricultural applications as a soil amendment. However, it can also contain contaminants like heavy metals, pathogens, and chemical residues, necessitating proper treatment and handling before use or disposal.

Uses of Organic Sludge

1. Fertilizer: When treated and processed correctly, organic sludge can be used as a nutrient-rich fertilizer.
2. Soil Conditioner: It improves soil structure, enhances water retention, and provides essential nutrients to plants.
3. Energy Production: Through anaerobic digestion, organic sludge can be used to produce biogas, a renewable energy source.

Treatment Methods

1. Anaerobic Digestion: Breaks down organic matter in the absence of oxygen, producing biogas and reducing sludge volume.
2. Composting: Aerobic decomposition of organic matter, resulting in nutrient-rich compost.
3. Thermal Treatment: Processes like incineration or pyrolysis to reduce volume and potentially recover energy.

Environmental Considerations

Proper management of organic sludge is crucial to prevent environmental pollution. Untreated or improperly managed sludge can lead to issues such as water contamination, soil degradation, and the spread of pathogens. Therefore, regulations and guidelines are in place in many regions to ensure safe and sustainable handling and disposal of organic sludge.

Source：ChatGPT

Dehydrated sludge refers to sludge that has undergone a process to remove a significant portion of its water content. Sludge is a byproduct of wastewater treatment, consisting of a mixture of water, organic and inorganic materials, and microorganisms. Dehydrating sludge reduces its volume and weight, making it easier and more cost-effective to handle, transport, and dispose of.

The process of dehydrating sludge typically involves several stages:

1. Thickening: Concentrates the sludge by removing some of the water, usually through gravity or flotation thickening.
2. Conditioning: Adds chemicals to the sludge to improve its dewaterability.
3. Dewatering: Removes additional water through mechanical means, such as centrifuges, belt filter presses, or screw presses.
4. Drying: Further reduces moisture content using thermal methods, such as drying beds, ovens, or dryers.

Dehydrated sludge can be further processed or disposed of in several ways, including incineration, landfilling, or use as a soil conditioner or fertilizer after proper treatment.

Source：ChatGPT

Sludge is a semi-solid slurry that can be produced from a range of industrial processes, from water treatment, wastewater treatment or on-site sanitation systems. It can be produced as a settled suspension obtained from conventional drinking water treatment, as sewage sludge from wastewater treatment processes or as fecal sludge from pit latrines and septic tanks. The term is also sometimes used as a generic term for solids separated from suspension in a liquid; this soupy material usually contains significant quantities of interstitial water (between the solid particles). Sludge can consist of a variety of particles, such as animal manure.

Source：Wiki Sludge

There are several key reasons why sludge, often produced as a byproduct of wastewater treatment, needs to be dried:

• Volume Reduction: Sludge typically contains a high percentage of water. Drying significantly reduces this water content, leading to a much smaller volume. This makes transporting and storing the sludge far more manageable and cost-effective.

• Disposal and Further Treatment: Dried sludge can be easier and safer to dispose of compared to wet sludge. For instance, dried sludge can meet specific regulations for incineration or landfilling. In some cases, drying can also be a precursor to other treatment methods.

• Resource Recovery: When properly dried, sludge can be repurposed for beneficial uses. This could involve using it as a soil conditioner or even converting it into a fuel source.

• Pathogen Reduction: Drying can help reduce the number of harmful pathogens present in the sludge. This makes it a safer material to handle and potentially reuse.

• Odor Control: Wet sludge can be quite odorous. Drying helps to stabilize the sludge and significantly reduces unpleasant smells.

Source：Gemini

Sludge drying is a challenging process due to several factors that complicate its efficient and effective execution. Here are the main reasons why sludge drying can be difficult:

1. High Moisture Content:

   • Initial Moisture Levels: Sludge typically has a very high initial moisture content (up to 98% water), which requires significant energy to reduce.
   • Bound Water: Some water in sludge is chemically bound to particles, making it harder to remove through conventional drying methods.

2. Energy Requirements:

   • High Energy Consumption: Drying sludge to a low moisture content requires substantial energy, especially for thermal drying processes.
   • Cost: The energy costs associated with sludge drying can be high, impacting the overall economics of the wastewater treatment process.

3. Complex Composition:

   • Variable Composition: Sludge composition can vary widely depending on the source and type of wastewater being treated. This variability can affect drying efficiency and the selection of appropriate drying technologies.
   • Presence of Inorganic and Organic Materials: The mixture of organic and inorganic materials in sludge can complicate the drying process.

4. Handling and Processing:

   • Sticky and Viscous Nature: Wet sludge can be sticky and viscous, making it difficult to handle, transport, and process in drying equipment.
   • Clogging and Fouling: Sludge can clog or foul drying equipment, requiring frequent maintenance and cleaning.

5. Environmental and Health Concerns:

   • Odor Emissions: Drying sludge can produce unpleasant odors, which need to be managed through odor control systems.
   • Air Pollution: Thermal drying processes can release volatile organic compounds (VOCs) and other air pollutants, necessitating air pollution control measures.

6. Equipment and Technology:

   • Specialized Equipment: Sludge drying often requires specialized equipment, such as belt dryers, drum dryers, or fluidized bed dryers, which can be expensive to purchase and maintain.
   • Operational Complexity: Managing the drying process requires skilled operators to ensure optimal performance and to address any issues that arise during operation.

7. Disposal of By-products:

   • Residual Waste: Even after drying, there is still a need to dispose of the dried sludge or its ash if incinerated, which can involve additional costs and regulatory compliance.

8. Regulatory Compliance:

   • Stringent Regulations: There are often strict regulations governing the drying and disposal of sludge, particularly concerning emissions and pathogen reduction, which can add complexity to the process.

In summary, sludge drying is difficult due to high moisture content, significant energy requirements, complex sludge composition, handling challenges, environmental and health concerns, specialized equipment needs, and stringent regulatory requirements. These factors make sludge drying a technically and economically challenging process in wastewater treatment.

Source：ChatGPT

• Material to be dry: Dehydrated organic sludge
• Purpose of drying: Reducing industrial waste cost and amount
• Moisture content: 86.2％W.B. before drying, 15.3％W.B. after drying
• Requirements for dryer: To prevent clogging inside the dryer caused by the stickiness and adhesiveness. Automated continuous operation with no operator attended.
  Machine cost can be recovered in short term.
• Test result: OK

Sludge drying

Competitive comparison

One of the International Patented Technology that KENKI DRYER has is a self-cleaning structure called Steam Heated Twin Screw technology (SHTS technology). No matter how materials are sticky, adhesive and viscous is, they can be dried without clogging inside of the dryer because of this unique structure that no other products has.
For example, even materials stuck to the blades of one screw, blades of the other screw in the dryer’s body forcibly peels the materials off as they rotate. Since the blades rotate by peeling the material off each other, any sticky, adhesive and viscous material does not adhere to the blade, and the blades continue rotating, peeling, agitating and heating material without stopping while they carries material further. Also, since surface of blades are always renewed and kept clean, heat near the blades is not blocked and it is conducted directly into the materials.

Self-cleaning screw

KENKI DRYER has three main characteristics. They are 1) Any materials can be dried as expected including sticky, adhesive and viscous materials and raw material slurry that no other company can deal with, 2) dried material can by recycled or utilized as raw materials because of its low-temperature drying method, and 3) there is no need to assign operator since its continuous operating system makes 24 hours unattended operation possible.

Products

The unique and original drying mechanism of KENKI DRYER is also International Patented Technology. Because 4 drying mechanisms which are crashing drying, agitation drying, circulation drying and indirect drying work simultaneously and add heat to material being dried repeatedly and continuously, inner part of the material is dried thoroughly and quality of discharged material after drying is stable. This series of drying mechanisms prevents agglomeration which causes insufficient drying from feeding process of the material into the dryer until discharging process after drying completed. Various ingenuities to conduct heat surely into inner part of the materials are exercised and stable heating and drying are proceeded continuously.

Methods

Even KENKI DRYER uses only saturated steam as its heat source, it is outstanding in safety and hygiene point of view with its unique drying mechanism based on combined use of conductive heat transfer method and heated air method. Since steam is a stable heat source, quality of discharged material after drying is also stable and equable. Maximum allowed steam pressure is 0.7Mpa and adjustment of steam pressure, adjustment of drying temperature in other words, can be easily done. Saturated steam is commonly used in many factories so that it can be said as a familiar and handy heat source. In comparison with drying methods using burner or hot blasts, saturated steam method is an indirect drying applying heat exchange via pipes that steam is passing through, therefore, it hardly burns the materials and is outstanding in safety and hygiene point of view.

Heat source, Steam