Raw materials drying, Low-temperature drying of lumpy dehydrated raw materials residue / Test cases / Raw materials dryer

Summary of KENKI DRYER features and benefits:

1. Unique drying capability:
   • KENKI DRYER can dry any kind of sticky and adhesive materials, including bulky objects, by crushing and reducing the size of lumpy materials inside the dryer. Its patented mechanism prevents clogging and ensures smooth drying.
2. Continuous operation:
   • It operates as a continuous low-temperature dryer, allowing unattended 24-hour operation. This is in contrast to batch dryers, which store and dry items in batches.
3. Environmental benefits:
   • Uses steam as a heat source, which is more efficient and reduces fuel costs. It can utilize excess steam from facilities, reducing carbon dioxide emissions. Alternatively, an electric boiler can be used to completely eliminate greenhouse gas emissions.
4. Low maintenance:
   • The dryer has a simple structure with few spare parts, making maintenance easy and inexpensive. The slow rotation speed of the main body blades (5 rpm or less) minimizes wear and tear.
5. Industrial waste reduction:
   • By drying raw materials residue, the dryer reduces industrial waste, thereby reducing waste disposal costs and carbon dioxide emissions from reduced truck usage.
6. Resource Recycling:
   • Promotes the reuse and recycling of minerals in sewage sludge, contributing to environmental protection and decarbonization. This is particularly important for securing resources such as phosphorus and rare metals.
7. Patents and recognition:
   • KENKI DRYER holds 11 patents in 8 countries (Japan, Taiwan, USA, France, Germany, UK, Switzerland, Canada). It is recognized for its ability to dry materials that other dryers cannot, with high satisfaction from companies due to its uniform drying, improved productivity, and durability.
8. Applications:
   • Suitable for drying high moisture content sludge, raw material slurry, organic waste, and other sticky materials. It is also used for waste upcycling and recycling, and for drying methane fermentation digested liquids.

KENKI DRYER can dry any kind of sticky material, and it can easily dry even bulky objects. By crushing and reducing the size of the lumpy material to be dried inside the dryer and reducing the surface area, it is possible to dry even the inside of the material. Even with lumpy drying material, the adhesion and stickiness during drying can be so strong that it can clog the inside of the dryer and prevent the material from being discharged, but the KENKI DRYER has a unique mechanism that is patented worldwide, so it is possible to dry the material smoothly without clogging the inside of the machine.
In addition, because the KENKI DRYER is a continuous low-temperature dryer, unlike batch dryers that store and dry items, it can operate unattended 24 hours a day, and after drying, there is little change in the components of the dried items, so they can be used for a variety of purposes.

KENKI DRYER, which has 11 patents in 8 countries, is an indirect steam dryer, but it is a completely unique product with a different structure from other indirect steam dryers. Direct-fire dryers, such as those using burners, emit carbon dioxide, which is bad for the environment and goes against the trend of decarbonization. KENKI DRYER uses steam as a heat source, but because the drying heat efficiency is good, the amount of steam used is small, so you can use the steam you currently use, and if you use excess or surplus steam, you don’t have to pay any fuel cost, and when drying, no carbon dioxide is emitted from the dryer, so you can dry without carbon dioxide emission. Alternatively, by installing an electric boiler, there will be no global warming gases or carbon dioxide CO2 emissions at all during drying.
In addition, there are no problems after start-up, and the rotation speed of the dryer’s main body blades is very slow at 5 rpm or less, so there is little wear and tear on the parts, making maintenance easy and inexpensive. The KENKI DRYER is a continuous drying system that stores the product to be dried and is not a batch system. Therefore, operation is simple and it is possible to operate unattended 24 hours a day.

By reducing the weight of raw materials residue through drying, it is possible to reduce the amount of industrial waste generated, which in turn helps to reduce the cost of industrial waste, which has been increasing due to the 2024 truck problem and other factors, and also helps to reduce carbon dioxide emissions by reducing the number of trucks used, thereby contributing to environmental protection and decarbonization.

Japan is almost 100% dependent on imports for its mineral resources. In particular, precious and rare metals are important resources that must be secured in order to maintain and strengthen international competitiveness. One measure for securing mineral resources is to reuse and recycle the minerals contained in sewage sludge, which is important for environmental protection and leads to a reduction in greenhouse gases. Phosphorus, which is currently imported and is also essential, is another mineral that we cannot do without. For this reason, the extraction of phosphorus from sewage sludge is being promoted as a national project.
The upcycling and recycling of sludge, which is always discharged from wastewater treatment plants, is emphasized for environmental protection, decarbonization and securing resources that are dependent on imports and the demand for which is only increasing.

If you have any questions or concerns, please let us know. We will be happy to suggest the best dryer for your company’s needs.
Our dryer “KENKI DRYER” has obtained 11 patents in 8 countries and is good at drying sticky materials that others cannot dry, has no problems after installation, is easy to maintain and has low operating cost. Companies that have adopted this system have been very satisfied with its uniform drying, improved productivity without manual labor, high performance, and durability.

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).

The KENKI DRYER is chosen for drying lumpy raw material residue because it has a unique mechanism that crushes and reduces the size of the lumps during the drying process, preventing clogging and ensuring smooth operation. Its ability to handle sticky, adhesive materials makes it ideal for drying challenging raw materials, while its continuous operation, low energy consumption, and low maintenance needs make it cost-effective and efficient.

The residue of raw materials refers to the leftover by-products or waste materials that remain after the primary extraction or processing of raw materials. These residues can include organic waste, sludge, or other unwanted components that are not used in the final product. In various industries, these residues are often dried or treated to reduce waste, recycle materials, or minimize environmental impact.

Source：ChatGPT

The reason for drying raw material residue is to reduce its volume and weight, making it easier and cheaper to handle, transport, and dispose of. Drying also helps in recycling and reusing the residue for other purposes, minimizes environmental impact by reducing waste and emissions, and prevents potential hazards like odors or microbial growth from wet materials. In industries, dried residues are often upcycled or processed further, contributing to resource efficiency and sustainability.

Source：ChatGPT

Advantages of drying raw material residue include reducing the volume and weight of the material, which lowers storage and transportation costs. It also helps in recycling or repurposing the material, minimizes environmental impact by reducing waste, and prevents the growth of bacteria and mold. Additionally, drying can make the residue easier to handle and extend its shelf life.
Disadvantages include the energy consumption and costs associated with the drying process, especially if not optimized for efficiency. There is also the potential for changes in the chemical or physical properties of the residue, which may limit its reuse in certain applications.

Source：ChatGPT

• Material to be dry: Raw materials residue
• Purpose of drying: Reducing industrial waste cost and amount
• Moisture content: 46.7％W.B. before drying, 1.4％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

Slurry 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