Minor metal sludge drying, Low temperature drying for recycling of Urban mining・Minor metal sludge / KENKI DRYER / Sludge dryer, Recycling dryer
Why KENKI DRYER is the Optimal Choice for Rare Metal Sludge Drying
Introduction: Securing Valuable Resources Through Advanced Drying Technology
Japan imports nearly 100% of its mineral resources, making the recovery and recycling of rare and precious metals from industrial sludge a national priority. As global competition for these critical materials intensifies, technologies that can efficiently process and recover minerals from waste streams become strategically important. The KENKI DRYER has emerged as a breakthrough solution for this challenge, offering unique capabilities specifically suited for processing mineral-rich sludge.
The Rare Metal Recovery Challenge
Industrial sludge often contains valuable rare metals and minerals that are essential for high-tech manufacturing and renewable energy technologies. Traditional drying methods struggle with several challenges:
- Clumping and uneven drying – Flocculants used in wastewater treatment cause sludge to form lumps
- High energy consumption – Many dryers require significant energy inputs
- Environmental impact – Direct-fire dryers emit considerable carbon dioxide
- Maintenance costs – High-temperature operation causes rapid wear on components
Key Advantages of KENKI DRYER for Rare Metal Sludge Processing
Superior Handling of Lumpy Materials
The KENKI DRYER features a patented mechanism that effectively processes lumpy sludge materials that typically cause problems in conventional dryers. During operation, the dryer:
- Crushes lumpy sludge inside the drying chamber
- Reduces surface area for more thorough drying
- Prevents clogging through its unique internal design
- Ensures consistent drying throughout the material, not just surface drying
Environmental and Resource Benefits
When processing mineral-rich sludge, the KENKI DRYER offers significant environmental advantages:
- Low-temperature operation preserves material properties, making downstream mineral extraction more efficient
- Steam-based indirect heating eliminates direct CO₂ emissions during operation
- Minimal steam requirements reduce overall energy consumption
- Compatible with excess/surplus steam utilization from existing plant operations
- Electric or hydrogen boiler options enable completely carbon-neutral operation
Operational Excellence
The KENKI DRYER delivers exceptional performance metrics that make it ideal for continuous industrial applications:
- Continuous operation capability (24/7) with minimal supervision
- Low maintenance requirements due to slow rotation speed (under 5 RPM)
- Reduced wear on components compared to high-temperature alternatives
- Simple operation with automated controls
- Consistent, uniform drying results
Comparative Analysis: KENKI DRYER vs. Conventional Dryers
| Feature | KENKI DRYER | Conventional Direct-Fire Dryers | Traditional Steam Dryers |
|---|---|---|---|
| Handling of Lumpy Materials | Excellent – Crushes and processes lumps | Poor – Surface drying only | Moderate – Uneven drying |
| Temperature Operation | Low – Preserves material properties | High – May alter chemical composition | Medium to High |
| Energy Efficiency | High – Uses minimal steam | Low – High fuel consumption | Moderate |
| Carbon Emissions | Zero (with electric/hydrogen boiler) | High | Moderate |
| Maintenance Costs | Low – Slow rotation (< 5 RPM) | High – Frequent part replacement | Medium |
| Operation Mode | Continuous | Batch or Continuous | Typically Batch |
| Supervision Required | Minimal – Unmanned operation possible | Significant | Moderate |
| Patent Protection | 11 patents across 8 countries | Varies | Varies |
Technical Innovation for Resource Security
The KENKI DRYER’s patented technology represents a significant advancement in Japan’s resource security strategy. By enabling efficient processing of sludge containing valuable minerals, the system contributes to:
- Reduced dependence on imports for critical minerals including phosphorus
- Lower environmental impact through recycling and waste reduction
- Enhanced resource efficiency in industrial processes
- Support for national decarbonization goals through low-emission operation
Common Questions About the KENKI DRYER
Q: How does the KENKI DRYER handle sticky materials that cause clogging in other dryers?
A: The KENKI DRYER features a unique patented mechanism that prevents clogging by crushing lumpy materials and maintaining movement within the drying chamber, ensuring smooth discharge of dried materials even when processing highly adhesive sludge.
Q: What maintenance requirements should be expected with the KENKI DRYER?
A: Maintenance requirements are minimal due to the slow rotation speed (under 5 RPM) which significantly reduces wear on components. This results in lower maintenance costs and longer service life compared to high-temperature alternatives.
Q: How does the KENKI DRYER contribute to decarbonization efforts?
A: The KENKI DRYER uses steam as an indirect heat source rather than direct combustion, eliminating CO₂ emissions from the drying process itself. When paired with electric or hydrogen boilers, the entire system can operate with zero carbon emissions.
Q: Can the KENKI DRYER operate continuously without supervision?
A: Yes, the KENKI DRYER is designed as a continuous drying system rather than a batch process. Its reliable operation and automated controls allow for 24-hour unmanned operation, reducing labor costs while maintaining consistent performance.
Q: How does the KENKI DRYER preserve valuable minerals in the sludge?
A: By operating at lower temperatures than conventional dryers, the KENKI DRYER minimizes chemical changes to the material being processed. This preservation of material properties is crucial for downstream extraction and recovery of valuable minerals.
Q: What international recognition has the KENKI DRYER technology received?
A: The technology has been granted 11 patents across 8 countries, including Japan, Taiwan, USA, France, Germany, UK, Switzerland, and Canada, demonstrating its unique and innovative approach to industrial drying challenges.
Conclusion: Advancing Resource Security Through Innovation
As Japan continues to address its dependency on imported minerals, technologies like the KENKI DRYER play a crucial role in resource recovery strategies. By enabling efficient processing of mineral-rich sludge, this innovative drying system contributes to environmental protection, decarbonization efforts, and resource security.
The KENKI DRYER’s ability to handle difficult materials that other dryers cannot process makes it an ideal solution for companies looking to recover valuable resources from waste streams while reducing operational costs and environmental impact.
Videos / Low temperature drying for recycling of Urban mining・Minor metal sludge
Low temperature drying of Minor Metal Sludge with KENKI DRYER
Japan is almost 100% dependent on imports for its mineral resources. In the future, minor metals and precious 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 reuse and recycling of sludge from wastewater treatment plants is becoming increasingly important for environmental protection, decarbonization and securing resources that are currently dependent on imports.
After dehydration, many of the dried sludge objects, whether organic or inorganic, are found in a lumpy form. With KENKI DRYER, the dried objects such as lumpy sludge are crushed to some extent inside the dryer, and by reducing the surface area, drying can be carried out thoroughly even inside the dried objects. Even with clumpy dried objects, there are cases where the adhesive quality is strong during drying and clogging occurs inside the dryer, and the dried objects cannot be discharged, but with KENKI DRYER, the unique mechanism of the world patent prevents clogging inside the dryer, and the dried objects can be dried smoothly.
In addition, sludge discharged from wastewater treatment plants tends to form lumps during the drying process due to the effect of flocculants used in wastewater treatment. When the material to be 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 to be dried forms lumps, the KENKI DRYER can dry the inside of the material sufficiently by crushing and reducing the size of the material to some extent inside the dryer and reducing the surface area.
By drying the sludge discharged from wastewater treatment plants at low temperatures, the components of the sludge change little after drying, making it possible to use it as a compost, soil conditioner, fuel, etc. as an upcycled product.
KENKI DRYER, which has 11 patents in 8 countries, is a steam indirect dryer, but it is a completely unique product with a different structure from other steam indirect dryers. Direct-fire dryers, such as those that use burners, emit carbon dioxide, which is bad for the environment and goes against the trend of decarbonization. Because they dry at high temperatures, they use a lot of fuel and their parts wear out quickly, making them expensive to maintain.
KENKI DRYER uses steam as a heat source, but because of its high drying heat efficiency, it only needs a small amount of steam, so you can use the steam you’re currently using, and if you use excess or surplus steam, you don’t have to pay for fuel. The dryer doesn’t emit carbon dioxide when it dries, so you can dry without carbon dioxide. Alternatively, by installing an electric or hydrogen fuel boiler, there is no emission of global warming gases or carbon dioxide CO2 during the drying process.
In addition, there are no problems after start-up, and the rotation speed of the dryer’s main body blades is very slow at less than 5 rpm, so there is little wear and tear on parts, and maintenance is easy and inexpensive. KENKI DRYER is a continuous drying system, in which the drying material to be dried is stored, rather than a batch system. 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, 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).
Test case / Low temperature drying for recycling of Urban mining・Minor metal sludge
Test Results / Low temperature drying for recycling of Urban mining・Minor metal sludge
- Material to be dry: Urban mining, Minor metal sludge
- Purpose of drying: Recycling, Reducing industrial waste cost and amount
- Moisture content: 79.3％W.B. before drying, 18.6％W.B. after drying
- Requirements for dryer: Drying is carried out inwards as the dried material is lumpy and heat does not penetrate easily into the interior. 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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