Inorganic sludge drying, Low temperature drying of difficult to dry, lumpy inorganic sludges / KENKI DRYER / Sludge dryer, Waste reduction
KENKI DRYER: An Advanced Solution for Sludge Drying
Key Features and Benefits Summary
KENKI DRYER is an innovative indirect steam dryer that specializes in drying sticky and adhesive materials like dehydrated sludge. Here’s what makes it unique:
- Patented worldwide with 11 patents across 8 countries (Japan, Taiwan, USA, France, Germany, UK, Switzerland, Canada)
- Uses a unique mechanism to prevent material clogging inside the machine
- Capable of crushing lumpy materials during the drying process
- Operates at low temperatures with steam as a heat source
- Environmentally friendly with minimal CO2 emissions
- Runs continuously (not batch processing) at slow speeds (5 rpm or less)
- Requires minimal maintenance and enables 24-hour unmanned operation
KENKI DRYER Technical Advantages
KENKI DRYER overcomes critical challenges in sludge drying through several technical innovations:
- Anti-Clogging Technology: The patented mechanism prevents sticky materials from adhering to internal components.
- Crushing Capability: By breaking down lumps during the drying process, heat distribution is improved and drying is more thorough.
- Indirect Heating: Using steam as a heat source allows for:
・Low-temperature drying that preserves material composition
・Reduced energy consumption
・Minimal emissions - Slow-Speed Operation: The slow blade rotation (under 5 rpm) results in:
・Reduced mechanical wear
・Lower maintenance requirements
・Extended equipment lifespan
Comparison of KENKI DRYER vs. Conventional Dryers
| Benefit Category | Specific Advantages |
|---|---|
| Waste Reduction | • Reduces sludge weight and volume • Lowers industrial waste disposal costs • Decreases transportation requirements |
| Emissions Control | • No direct CO2 emissions during drying process • Compatible with electric/hydrogen boilers for zero-emission operation • Reduces truck transport emissions through waste volume reduction |
| Resource Recovery | • Preserves material composition for recycling • Enables phosphorus extraction from dried sludge • Supports mineral resource security in import-dependent countries |
| Material Upcycling | • Dried sludge can be used as compos • Can be repurposed as soil conditioner • Potential use as fuel source |
| Operational Efficiency | • 24-hour unmanned operation capability • Low maintenance requirements • Continuous rather than batch processing |
Q&A About KENKI DRYER
Q: What problem does KENKI DRYER solve?
A: It solves the challenge of drying lumpy and sticky materials (especially wastewater treatment sludge) that typically clog conventional dryers.
Q:How does KENKI DRYER work with lumpy materials?
A: It crushes lumpy materials inside the dryer, reducing their surface area to ensure thorough drying even inside the material.
Q: What environmental benefits does KENKI DRYER offer?
A: It reduces waste volume and weight, decreases transportation needs (lowering carbon emissions), and preserves material composition for upcycling and recycling purposes.
Q: Why is KENKI DRYER considered energy efficient?
A: It has high drying heat efficiency which reduces steam usage. It can also be paired with electric or hydrogen fuel boilers for zero CO2 emissions.
Q: What are the maintenance advantages?
A: Due to its slow rotational speed (under 5 rpm), there’s minimal wear on parts, making maintenance easy and inexpensive.
Summary of Environmental Impact and Resource Security
The KENKI DRYER technology addresses several critical environmental and resource challenges:
- Waste Reduction: By efficiently drying sludge, it reduces waste volume and transportation requirements, directly contributing to decarbonization efforts.
- Resource Recovery: In countries like Japan that are heavily dependent on mineral imports, the ability to extract valuable resources like phosphorus from dried sludge is increasingly important.
- Circular Economy: The low-temperature drying preserves material composition, enabling upcycling of the dried sludge into useful products like compost, soil conditioners, and fuel.
- Operational Efficiency: The continuous, unmanned operation capability reduces labor requirements while maintaining consistent output quality.
KENKI DRYER represents a significant advancement in handling difficult-to-dry materials with its patented technology that solves longstanding problems in industrial drying applications, particularly for wastewater treatment facilities seeking more sustainable waste management solutions.
Videos / Low temperature drying of difficult to dry, lumpy Inorganic Sludges
Low temperature drying of inorganic sludge with KENKI DRYER
After dehydration, many of the dried sludge objects are found to be in a lumpy form, regardless of whether they are inorganic or organic. In KENKI DRYER, the dried objects, such as lumpy sludge, are crushed to a certain extent inside the dryer, and by reducing the surface area, the drying process is able to thoroughly dry even the inside of the dried objects. Even with lumpy objects to be dried, there are cases where the sticking adhesive quality is so strong that they get stuck inside the dryer and cannot be discharged, but KENKI DRYER has a unique mechanism that is patented worldwide, so it can dry objects smoothly without getting stuck inside the machine.
In addition, the sludge discharged from wastewater treatment plants tends to clump together during the drying process due to the effect of the flocculants used during wastewater treatment. When the material being dried forms lumps, the heat does not spread sufficiently throughout the material and the inside of the material does not heat up, so only the surface dries and the inside does not heat up and dry. Even if the material being dried forms lumps, KENKI DRYER can dry the inside of the material sufficiently by crushing and reducing the size of the material to a certain extent inside the dryer and reducing the surface area.
Even if the drying object has a strong sticking adhesive quality and is difficult to dry, KENKI DRYER can easily and smoothly dry it. For example, dehydrated sludge discharged from wastewater treatment plants with a strong sticking adhesive quality is difficult to dry. Depending on the type of dryer, sludge can become clogged inside the dryer during the drying process and may not be able to be discharged. With KENKI DRYER, however, even sticky or adhesive materials that would normally cause clogging can be dried easily without clogging inside the dryer. KENKI DRYER is an innovative drying device with unique technology that has been granted a total of 11 patents, including 2 in Japan and 9 in 7 countries overseas.
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 rising due to the recent trucking problem in 2024, and by reducing the number of trucks used to transport waste, thereby reducing carbon dioxide emissions.
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.
By drying sludge discharged from wastewater treatment plants at low temperatures, it is possible to utilize it as compost, soil conditioner, fuel, etc. as upcycling, with minimal changes in composition after drying. KENKI DRYER is an indirect drying system that uses steam as a heat source at low temperatures, so after drying, there are minimal changes in the composition of the dried material, making it fully recyclable and suitable for upcycling.
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. The KENKI DEYER uses steam as a heat source, but its high drying heat efficiency means that less steam is used. The use of excess steam is not costly in terms of fuel costs, and the dryer does not emit carbon dioxide during the drying process, allowing for decarbonized drying. Alternatively, by installing electric boilers or hydrogen fuel boilers , no greenhouse gases or CO2 emissions are produced during drying.
The dryer’s blades rotate at a very slow speed of 5 rpm or less, which means that wear on parts is minimal and maintenance is easy and inexpensive. KENKI DRYER is a continuous dryer, not a batch dryer that stores materials to be dried. Therefore, operation is simple and unmanned operation is possible 24 hours a day.
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 received 11 patents in 8 countries and is particularly effective at drying sticky materials that others cannot handle. It has no installation problems, is easy to maintain, and has low operating costs. The KENKI DRYER has been well received by companies that have installed it due to its uniform drying, improved productivity with less manpower, high performance and durability.
KENKI DRYER, which can dry sticky and adhesive materials that others cannot dry, is a breakthrough dryer with a total of 11 patents (2 in Japan and 9 in 7 foreign countries) and proprietary technology. Please consider KENKI DRYER for your high moisture organic waste dryer, sludge dryer, slurry dryer, methane fermentation digested liquid dryer, waste upcycling and recycling dryer.
KENKI DRYER has been granted 11 patents in 8 countries (Japan, Taiwan, USA, France, Germany, UK, Switzerland, Canada).
Why KENKI DRYER is Chosen for Inorganic Sludges Dryers
Key Advantages of KENKI DRYER
KENKI DRYER stands out as an innovative solution for drying inorganic sludge with its patented technology and unique features that address common challenges in the sludge drying process.
Superior Handling of Lumpy and Sticky Sludge
The KENKI DRYER excels at processing difficult materials that cause problems for conventional dryers:
- Crushes lumpy sludge inside the dryer to reduce surface area
- Ensures thorough drying even for the interior of lumpy materials
- Prevents clogging with its patented mechanism that handles highly adhesive materials
- Overcomes the challenges of flocculant-affected sludge that tends to clump together
Environmental and Economic Benefits
| Benefit | Description |
|---|---|
| Weight & Volume Reduction | Reduces transportation costs and industrial waste management expenses |
| Decarbonization | Fewer trucks needed for waste transport, reducing CO₂ emissions |
| Resource Recovery | Enables extraction of valuable minerals like phosphorus from dried sludge |
| Upcycling Potential | Low-temperature drying preserves material composition for recycling opportunities |
Technical Advantages
- Indirect steam drying system with 11 patents across 8 countries
- High drying efficiency reduces steam consumption and operating costs
- Low-speed operation (5 RPM or less) minimizes wear on parts
- Simple maintenance requirements and low maintenance costs
- Continuous operation capability (24/7) without constant supervision
Environmental Sustainability
KENKI DRYER supports sustainability initiatives through:
- Zero CO₂ emissions during the drying process itself
- Compatible with green energy solutions (electric or hydrogen fuel boilers)
- Resource recovery from sludge supports circular economy principles
- Reduced transportation emissions from smaller waste volumes
Frequently Asked Questions
Q: What makes KENKI DRYER different from other industrial dryers?
A: KENKI DRYER features a unique, patented mechanism that crushes lumpy materials during the drying process, ensuring thorough drying even for sticky, adhesive sludge that would clog conventional dryers.
Q: How does KENKI DRYER contribute to environmental protection?
A: It reduces waste volume, minimizes transportation needs, enables resource recovery (including valuable minerals like phosphorus), and can operate with zero emissions when paired with electric or hydrogen boilers.
Q: Where has KENKI DRYER technology been recognized?
A: The technology has received 11 patents across 8 countries, including Japan, Taiwan, USA, France, Germany, UK, Switzerland, and Canada.
Q: What types of materials can KENKI DRYER process?
A: KENKI DRYER is particularly effective for high moisture organic waste, sludge, slurry, methane fermentation digested liquid, and materials for waste upcycling and recycling.
Q: What are the operational advantages of KENKI DRYER?
A: It offers uniform drying, improved productivity with reduced labor requirements, simple maintenance, continuous operation capability, and high durability with minimal wear on components.
Conclusion
KENKI DRYER represents an innovative solution for inorganic sludge drying challenges, offering superior performance for difficult materials while supporting environmental goals and resource recovery initiatives. Its patented technology enables efficient processing of materials that would typically cause problems in conventional dryers, making it an ideal choice for wastewater treatment facilities and industrial applications.
Test case / Low temperature drying of difficult to dry, lumpy Inorganic Sludges
Test Results / Low temperature drying of difficult to dry, lumpy Inorganic Sludges
- Material to be dry: Lumpy inorganic sludge
- Purpose of drying: Reducing industrial waste cost and amount
- Moisture content: 68.2％W.B. before drying, 13.8％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 / Brochure
KENKI DRYER which uses International Patented Technology can dry sticky, adhesive and viscous material containing high moisture contents and liquid material that no other company can deal with. It can dry without clogging inside of the dryer and with safe operation which meets no operational trouble. Organic wastes with high moisture contents such as coffee grounds,used tea leaves, soy pulps, livestock excretions, food residues, vegetables, fruits scraps, residues of processed marine product, etc. can be dried smoothly and each of these materials are discharged as valuable product with stable quality after drying.
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