Slurry Raw materials drying, Low temperature drying of difficult to dry liquid slurry raw materials / Test cases / Slurry drying, Slurry dryer

Summary

Unique Mechanism and Patents
KENKI DRYER has been granted 11 patents in 8 countries and uses a unique, internationally patented mechanism to dry highly adhesive and sticky materials without clogging, even if they are in liquid form or have high moisture content.

Heat Source and Drying Method
The dryer uses saturated steam as its heat source, which allows for low-temperature drying. This method combines conduction heat transfer and hot air, ensuring minimal changes to the material’s composition and preserving its quality.

Operational Benefits
KENKI DRYER operates continuously without manual labor, allowing for 24-hour unattended operation. It has low maintenance costs due to its slow blade rotation speed (≤5 RPM) and minimal wear and tear on parts.

Environmental and Economic Advantages
The dryer is environmentally friendly as it emits no carbon dioxide when using steam or alternative clean heat sources like electric or hydrogen boilers. It reduces waste volume and weight, lowering disposal costs and carbon emissions, and contributes to decarbonization and resource conservation.

Versatility
KENKI DRYER is versatile and can be used for various applications, including drying sludge, organic waste, beverage lees, and other high-moisture content materials.

Safety and Hygiene
The dryer is superior in terms of safety and hygiene due to its indirect steam heating method, which prevents burning of the materials and ensures a stable and uniform final product.

Efficiency and Cost-Effectiveness
KENKI DRYER is efficient and cost-effective, using minimal steam and no fuel costs when utilizing surplus steam. It also reduces labor requirements and improves productivity.

Even when drying raw material slurry, KENKI DRYER, which has already been granted an international patent, can demonstrate its full potential. Even if the material is highly adhesive or sticky, it will not clog the dryer and can be dried without problems even if it is in liquid form, allowing stable operation. Since saturated steam is used as the heat source and drying is performed at low temperatures, the components of the material being dried do not change and the material can be dried evenly, so there are no problems at all in drying the material. The heat source for drying in KENKI DRYER is only saturated steam. It uses a revolutionary drying method that combines conduction heat transfer and hot air, and is superior in terms of safety and hygiene. It is also able to dry the inside of the drying object to a sufficient degree thanks to its internationally patented technology, and after drying, it is discharged in a very stable and uniform state. It can operate unattended for 24 hours without the need for manual labor. If you replace your conventional box-type shelf drying system with KENKI DRYER, you will find that drying becomes much easier and you will be freed from the tedious task of drying.

KENKI DRYER dries at low temperatures, so there is little change in the components of the material being dried, making it completely safe to use for drying raw materials. After drying, there is little change in the components of the material being dried, so it can be shipped as a finished product. In addition, after drying, the material to be dried is evenly dried, so a stable product can be produced.

Even if the material to be dried has strong adhesion or stickiness and is difficult to dry, KENKI DRYER can dry it easily and evenly. Depending on the type of dryer, slurry materials with strong adhesion or stickiness may become clogged during drying and may not be able to be dried. KENKI DRYER uses a unique mechanism, which is patented worldwide, to enable the smooth drying of any slurry with high adhesion or stickiness, even if it has a high moisture content, without clogging inside the dryer.

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-fired dryers, which use burners, etc., emit carbon dioxide, which is bad for the environment and goes against the trend of decarbonization. KENKI DRYER uses steam as its 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, there is no fuel cost, and when drying, no carbon dioxide is emitted from the dryer, so you can dry without carbon dioxide. Alternatively, by installing electric boilers or hydrogen fuel boilers, there is no generation of global warming gases or carbon dioxide CO2 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 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. As a result, it is easy to manage and can operate unattended 24 hours a day. No human labor is required to install KENKI DRYER.

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, beverage lees dryer 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).

KENKI DRYER is chosen for drying slurry raw materials due to its unique and innovative features. One of the primary reasons is its ability to handle highly adhesive and sticky slurries without clogging the equipment, thanks to its patented mechanism. This design ensures smooth and continuous operation even with materials that are typically difficult to dry.
The dryer uses saturated steam as a heat source, allowing for low-temperature drying that preserves the composition and integrity of the material being dried. This method prevents significant changes to the material’s components, making it completely safe for drying raw materials and ensuring the final product retains its quality.
KENKI DRYER operates continuously without manual labor, enabling 24-hour unattended operation. This continuous drying system is easy to manage and maintain, with a slow blade rotation speed of 5 RPM or less, which minimizes wear and tear on parts and reduces maintenance costs.
The dryer is also environmentally friendly, as it uses steam as its heat source and does not emit carbon dioxide, aligning with decarbonization efforts. When using excess or surplus steam, there are no fuel costs, and the dryer can be integrated with electric or hydrogen boilers to eliminate any generation of global warming gases.
Additionally, KENKI DRYER ensures uniform drying throughout the material, resulting in a stable and uniform final product. This consistency is crucial for maintaining the quality of the dried material and producing a finished product that can be shipped immediately after drying.
Overall, the combination of its non-clogging design, low-temperature drying, continuous operation, environmental benefits, and ease of maintenance makes the KENKI DRYER an ideal choice for drying slurry raw materials.

The KENKI DRYER is chosen for slurry raw materials drying due to several key advantages and unique features:
Non-Clogging Design
The KENKI DRYER is designed to handle highly adhesive and sticky slurries without clogging the equipment. Its patented mechanism, which includes self-cleaning twin screws, ensures smooth and continuous operation even with materials that are difficult to dry.

Low-Temperature Drying
The dryer uses saturated steam as a heat source, allowing for low-temperature drying. This method preserves the composition and integrity of the material being dried, ensuring that the components do not change significantly during the drying process.

Uniform Drying
KENKI DRYER ensures uniform drying throughout the material, resulting in a stable and uniform final product. This consistent drying is crucial for maintaining the quality of the dried material.

Energy Efficiency and Environmental Benefits
The dryer operates with high efficiency, using less steam and reducing fuel costs. It also supports decarbonization by using excess steam or alternative clean heat sources like electric or hydrogen boilers, minimizing CO2 emissions and contributing to environmental protection.

Continuous Operation
KENKI DRYER is a continuous drying system that can operate unattended for 24 hours a day, eliminating the need for manual labor and simplifying the drying process compared to traditional methods.

Easy Maintenance and Low Operating Costs
The dryer has a simple design with minimal wear and tear on parts, reducing maintenance costs and downtime. This makes it easy to maintain and operate with low operating costs.

Versatility
KENKI DRYER is versatile and can be used for various applications, including drying sludge, manure, methane digestate, and other high-moisture content organic waste. It can handle materials with different compositions and moisture levels effectively.

Patented Technology
The KENKI DRYER holds 11 patents in 8 countries, highlighting its unique and innovative technology. This patented mechanism ensures that the dryer can handle materials that other dryers cannot, making it a breakthrough in drying technology.

Overall, the combination of its non-clogging design, low-temperature drying, uniform drying, energy efficiency, continuous operation, ease of maintenance, and versatility makes the KENKI DRYER an ideal choice for drying slurry raw materials.

• Material to be dry: Liquid slurry raw materials 
• Purpose of drying: Product Manufacturing
• Moisture content: 82.1％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

A slurry is a mixture of denser solids suspended in a liquid, typically water, and it can be found in a wide range of applications. Slurries are characterized by their high concentration of solids, which can make them highly abrasive, thick, and sometimes corrosive, posing significant challenges for handling and transportation.
These mixtures can be categorized into two main types: non-settling and settling slurries. Non-settling slurries consist of very fine particles that remain in suspension for a long time, behaving in a homogeneous, viscous manner but with non-Newtonian fluid characteristics. These slurries usually have low wearing properties but require careful consideration when selecting the right pump due to their unique behavior.
Settling slurries, on the other hand, are formed by coarse particles that tend to settle quickly and can be kept in suspension only through turbulence. These slurries can be pseudo-homogeneous or heterogeneous, with the solids concentration often greater towards the bottom of the container or pipe.
Slurries are used in various industries, including mining, steel processing, foundries, power generation, and agriculture. For example, coal slurry is used in mining, manure slurry is used as fertilizer in agriculture, and paper slurry is used in paper manufacturing. Slurries are also used in chemical processing, wastewater treatment, and even in the production of ceramics and pottery.
The transportation of slurries often requires specialized pumps, known as slurry pumps, which are designed to handle the abrasive and corrosive nature of these mixtures. These pumps are engineered to withstand the mechanical wear and tear caused by the solid particles and are crucial in maintaining operational efficiency in industries that rely on slurry transportation.
In terms of their physical properties, slurries can exhibit both Newtonian and non-Newtonian fluid behavior, and their density and viscosity can vary widely depending on the composition and particle size of the solids involved.

The raw materials for slurries can vary significantly depending on the intended application and industry.
In the context of ceramic slurries, the raw materials typically include a ceramic raw material powder, such as oxides like alumina, zirconia, titanium oxide, barium titanate, lead titanate zirconate, and manganese ferrite. These powders are mixed with a water-soluble acrylic binder and an aqueous solvent. The binder is crucial for providing an ideal dispersion system and ensuring the ceramic green sheets obtained are less hygroscopic and have excellent strength and elongation properties.
For Chemical Mechanical Planarization (CMP) slurries, the raw materials often consist of abrasive particles such as alumina, silica, and ceria, which are dispersed in an acidic or basic solution. These slurries may also include additional components like peroxygen compounds, such as hydrogen peroxide, and stabilizing agents to maintain the stability and effectiveness of the slurry over time. However, the presence of heavy metals like iron, copper, cobalt, manganese, nickel, and chromium can catalytically accelerate the decomposition of hydrogen peroxide, affecting the slurry’s performance.
In construction and drilling applications, raw materials can include naturally occurring minerals like bentonite and clay. Bentonite, when added to water, swells significantly, increasing the viscosity of the solution and helping to stabilize the cutting face in excavation processes. Clay, on the other hand, is used primarily as a filling material due to its inability to swell, adding weight and smaller particulate size to the slurry mix.
Thickeners, dispersants, and filling materials are also common raw materials in various slurry applications. Thickeners, such as water-soluble polymers, are used to manage muddy water by inhibiting sedimentation. Dispersants chemically prevent the agglomeration of clay particles, reducing viscosity and making the slurry thinner. Filling materials help gather and hold coarse particulates together, often used to reduce or remove loss circulation materials and perform core blocking functions.
The quality control of these raw materials is critical, involving steps such as dilution, blending, and multiple stages of filtration to ensure the slurry meets the required specifications. For example, in CMP slurry manufacturing, the raw materials and DI water are filtered through several stages to prevent contamination and ensure the desired particle size distribution.

Drying slurry raw materials is a complex and challenging process due to several inherent properties and operational factors of the slurries.
One of the primary difficulties is the high viscosity and stickiness of slurries, particularly those with high moisture content. This viscosity can cause the slurry to clog drying equipment, making it hard to handle and process without specialized machinery. The sticky nature of these materials can lead to issues such as sludge buildup on dryer surfaces, potentially causing equipment damage and requiring higher torque requirements in drying installations.
The high moisture content in slurries also poses a significant challenge. Removing a large amount of water from these slurries is energy-intensive and time-consuming, necessitating careful management to avoid overheating or under-drying, which can affect the quality of the final product. Incorrect drying conditions, including temperature, air flow, and drying time, can lead to poor quality or incomplete drying.
The feedstock characteristics of the slurry, such as its solids content, surface tension, and viscosity, further complicate the drying process. For instance, higher solids content can make the slurry more difficult to pump and atomize, while higher viscosity can increase droplet size during spray drying. These properties require precise control over the drying conditions to ensure the desired outcome.
Additionally, the drying process must be optimized to minimize energy consumption, as drying slurries often requires significant energy. This can make the process costly and necessitate careful optimization to reduce costs and maintain efficiency.
Specialized drying equipment, such as KENKI DRYER, is often necessary to handle these challenges. This equipment is designed to handle sticky and adhesive materials without clogging, using low-temperature drying with saturated steam to preserve the material’s composition and ensure uniform drying.
Despite these advancements, the overall process remains complex and requires careful management to achieve the desired results.