Conti-Dry - - Low Temperature Dryer Brochure

Low-Temperature-Drying Klein Technical Solutions provides machines and plants for a large number of applications throughout the world. The main focus, in each case, is on volume reduction, recycling and separation of sludges and other suspensions. Our designs are made for consequent utilisation of energy resources, as for example waste heat. Drying of sludge and other suspensions with the Low-Temperature-Dryers of Klein Technical Solutions Low-Temperature-Drying The products of Klein Technical Solutions are designed for the treatment of suspen- sions and pre-dewatered products that are usually waste or difficult waste mate- rials. Therefore, the prior aim is to reduce the volume of these materials as much as possible in order to minimize the waste disposal costs. The different processes, as thickening, de- watering and drying, enable a concentra- tion of suspensions with a water content of more than 99 % to a residual product with a water content of < 10 %. Based on the high organic percentage of the suspensions the dried material forms an attractive combustible. The dried gran- ulate is hygienised, almost dust-free and easily storable. Drying of sludge and other suspensions also enables further utilisation possibili- ties, like combustion or gasification. In some cases the use as fertilizer may be possible as well. Low-Temperature-Dryer type Pro-Dry® One ton of dried material with a mois- ture content of 70 % is reduced to 330 kg dried granulate with a moisture content of 10 %. The drying process produces an abrasion-resistant, recyclable dry product which is suitable for all further disposal procedures. Reduction of disposal costs 2 ATEX - certified process The Low-Temperature-Dryers of Klein Technical Solutions are designed for a con- tinuous operation. In order to guarantee a trouble-free process, 24/7, every single operating condition is supervised with modern control programs. The monitoring devices, as dust and tem- perature measurement etc., avoid critical situations and enable a certification of our technology according to the ATEX regula- tions. Utilisation of low temperature waste heat An interesting aspect for the drying pro- cess is the utilisation of low-temperature waste heat generated by different pro- cesses as energy sources. The preheating of the drying air can be performed with waste heat, warm wa- ter, warm exhaust gases or low-pressure steam as well as with biogas, natural gas, oil or any other available energy source. A typical energy source is warm water with a temperature of approx. 80 °C which is transferred to the drying air by heat ex- changers. Combi-Dry Compact-Dry Conti-Dry Pro-Dry® Water evaporation in kg/h per line 100 - 150 150 -700 500 - 5,000 500 - 6,000 Utilisation possibilities of dried sewage sludge The product of the drying process is an al- most dust-fee and abrasion proof granu- late with min. 90 % DS that is easily stor- able. The net calorific value of dried sew- age sludge is comparable to brown coal. Therefore the granulate is very suitable for further utilisation processes, like incinera- tion or gasification. 3 Air fans of two Low-Temperature-Dryers type Pro-Dry® 4 Drying of sludges with the Drum-Dryer Combi-Dry 4 • Sewage sludge • Recycling products • Paper sludge • Fermentation residues • Wood and biomass waste • Lime sludge • Extruded and pelletized products Fields of application Drum-Dryer Combi-Dry (Outside installation) Odourless sewage sludge drying The drying process of the Low-Tempera- ture-Dryer Combi-Dry is a combination of a drying drum, a drying container and a container for technical equipment that does not need any exhaust-air-treatment because of the low temperatures and the constantly aerobic conditions. The drying drum is charged with the de- watered sludge (usually 20 - 35 % DS) with an appropriate conveyor technique (e.g. screw-conveyors). The constant rotation of the drum rearranges the dewatered sludge inside. Hot process air generated by a CHP-unit inside the container for technical equip- ment dries the dewatered and constantly rotating sludge. The pre-dried sludge is transferred to the drying container where it is dried up to 90 - 93 %DS by the hot process air inside. The container for technical equipment contains the electrical control system, the air-circulation-system (fans, heat exchang- ers etc.) as well as room for additional ra- diators, micro gas turbines or similar heat generators. To cover the thermal energy demand hot water, hot air, steam etc. can be used as waste heat from external sources. The final product of the drying process with the Drum-Dryer Combi-Dry is a dried sewage sludge with a DS-concentration of 90 %. The diameter of the grain is < 10 mm. The net heating value of the dried product ranges between 10,000 - 13,000 kJ/kg with 50 - 65 % ignition loss. The Drum-Dryer Combi-Dry of Klein Technical Solutions is designed for granulation and pre-drying of sludge inside a consistently rotating drum. The final drying process up to 93 %DS is effected in a drying container. • Water evaporation: 100 - 150 kg/h • Inlet-DS: 20 - 35 % • Outlet-DS: 90 - 93 % • Thermal energy consumption: approx. 1000 kW/t H2O • Electrical energy consumption: approx. 120 kW/t H2O Technical Data 5 » Water evaporation: 100 - 150 kg/h » Sturdy and compact construction , easy to maintain » Fully automatic operation » Utilisation of waste heat » Can be installed outside a building » In combination with a full service (after-sales service with online surveillance) » The appropriate drying system for sludge amounts up to 1,000 t/y Advantages » Re-utilisation of the dried sludge as combustible in incinerators and cement mills possible » Local heat source, for example heat utilisation from fan chambers (compression temperature and waste heat) » Optionally with integrated CHP-unit • flexible solution: natural gas, biogas and liquid gas » An exhaust-air-treatment is not necessary because of the low temperatures and the constant aerobic condi- tions M M CHP-unit Fresh air with/without waste heat Waste air Fuel gas Electrical energy Technology container with CHP unit, ventilation and control system Drying container with input and discharge system Drying drum M Process air M G Heat Dewatered sewage sludge Pre-dried sewage sludge Dried granulate Warm air Basic scheme of the drying process with the Drum-Dryer Combi-Dry 5 6 Drying of fermented substrates and biomass with the modular designed Belt-Dryer Compact-Dry 6 • Sewage sludge • Recycling products • Paper sludge • Fermentation residues • Wood and biomass waste • Lime sludge • Extruded and pelletized products • Granulates • Bulk materials Fields of application Belt-Dryer Compact-Dry 2/2 Low-temperature drying of bio- mass and fermented substrates The Low-Temperature-Dryer Compact- Dry is a modular designed drying system which is delivered “almost ready to run”. A working unit can be created by the combination of several fully equipped segments that can easily be activated by „plug-and-play“. The number of segments depends on the required throughput resp. the evaporation capacity of the Belt-Dryer Compact-Dry. As the inner design of the segments may vary according to individual requirements, the Compact-Dry technology can be used for the drying of wood chips, fermented substrates, biological waste, municipal or industrial sludge and more. The segments are equipped with heat ex- changers in order to heat the Low-Temper- ature-Dryer Compact-Dry with waste heat (between 60 and 90 °C) from CHP-units. The throughput depends on the tempera- ture. Higher temperatures can be reached with hot water, thermal oil, steam and flue gas. The modular design does not neglect safe- ty, safety is still first. The equipment is built in accordance to the state of the art and the known directives. The Low-Temperature-Dryer Compact-Dry is ATEX certified because of the prevention of dust deposits and ignition sources and the constant supervision of the conditions inside the Belt-Dryer. The Low-Temperature-Dryer Compact-Dry of Klein Technical Solutions is a Belt-Dryer with two belts, arranged one above the other. The modular design of the dryer enables a flexible adaption of the belt length to different quantities of sludge. • Water evaporation: 150 - 700 kg/h • Inlet-DS: 20 - 30 % • Outlet-DS: 80 - 90 % • Thermal energy consumption: approx. 850 kW/t H2O • Electrical energy consumption: approx. 70 kW/t H2O Technical Data » Water evaporation: 150 - 700 kg/h » Careful drying at low temperatures » No danger of explosion or fire » Safe process with low maintenance requirements » Utilisation of „low-quality“ or low-temperature energy sources (waste heat) » The dried material is an easily storable, abrasion- proof and almost dust-free granulate » Considerable reduction of disposal costs by weight reduction Advantages » Pollution by waste air and odour emission far below required limit values (with appropriate odour treat- ment) » Low investment costs » 24-h operation » Installation and operation of the drying system acc. to ATEX regulations » Easily extendable by modular design Waste air Belt-Dryer Granulate loading Dried product for disposal or thermal recycling M M M M M M Container Dewatered biomass Fresh air Process waste heat, ?ow f1 f2 f1 f2 f1 f2 Process waste heat, return ?ow Basic scheme of the drying process with the Belt-Dryer Compact-Dry 7 8 Drying of sludges with the semi-modular designed Belt-Dryer Conti-Dry 8 • Sewage sludge • Recycling products • Paper sludge • Fermentation residues • Wood and biomass waste • Lime sludge • Extruded and pelletized products • Granulates • Bulk materials Fields of application Low-Temperature-Dryer Conti-Dry The Low-Temperature-Dryer Conti-Dry of Klein Technical Solutions is a Belt-Dryer with two belts installed in a container. The container enables an uncomplicated transport and the choice between fixed installation or mobile plant. Low-temperature drying of bio- mass, fermented substrates and sludge The Low-Temperature-Dryer Conti-Dry is a modular designed drying system which is delivered “almost ready to run” and which complements the Compact-Dry line with higher capacities and water evaporation rates. A working unit can be created by the combination of several fully equipped segments that can be easily activated by „plug-and-play“. The Low-Temperature-Dryer Conti-Dry can be provided with further equipment, as for example belt and tray cleaning. The number of segments depends on the required throughput resp. the evaporation capacity of the Belt-Dryer Conti-Dry. As the inner design of the segments may vary according to individual requirements, the Conti-Dry technology can be used for the drying of wood chips, fermented sub- strates, biological waste, municipal or in- dustrial sludge and more. The components are equipped with heat exchangers so that the Low-Temperature- Dryer Conti-Dry can be heated with waste heat (between 60 and 90 °C) from cogen- eration units. The throughput depends on the tempera- ture. Higher temperatures can be reached with hot water, thermal oil, steam and flue gas. The Low-Temperature-Dryer Conti-Dry is ATEX certified because of the constant supervision of the conditions inside the Belt-Dryer. • Water evaporation: 500 - 5,000 kg/h • Inlet-DS: 15 - 60 % • Outlet-DS: 60 - 95 % • Thermal energy consumption: 750 - 900 kW/t H2O • Electrical energy consumption: 70 - 100 kW/t H2O Technical Data » Water evaporation: 500 - 5,000 kg/h » Uncomplicated transport because of container » Optionally as fixed installation or mobile plant available » Careful drying at low temperatures » Safe process with low maintenance requirements » No danger of explosion or fire » Utilisation of „low-quality“ or low-temperature energy source (waste heat) » Dried material is an easily storable, abrasion-proof and almost dust-free granulate Advantages » Easily extendable by modular design » Considerable reduction of disposal costs by weight reduction » Pollution by waste air and odour emission far below required limit values (with appropriate odour treat- ment) » Low investment costs » 24-h operation » Installation and operation of the drying system acc. to ATEX regulations Waste air Waste water (only for cleaning process) M M Belt-Dryer Granulate loading Dried granulate for thermal recycling Process wast heat, return flow Wash water (only for cleaning process) M M M M M M M Container Dewatered sludge Fresh air Process waste heat, flow Heat exchangerM f1 f2 f1 f2 f1 f2 f1 f2 Basic scheme of the drying process with the Belt-Dryer Conti-Dry 9 10 Drying of sludges and other suspensions with the Belt-Dryer Pro-Dry® 10 • Sewage sludge • Recycling products • Paper sludge • Fermentation residues • Wood and biomass waste • Lime sludge • Extruded and pelletized products • Granulates and bulk materials Fields of application Low-Temperature-Dryer Pro-Dry® 2/3 Low-Temperature-Drying of sew- age sludge The Belt-Dryer Pro-Dry® is designed for the drying of sewage sludge and other suspensions from municipal and indus- trial wastewater treatment plants up to 92 %DS. The Low-Temperature-Dryer and the ven- tilation technology are made from stain- less steel for corrosion prevention and for a long lifetime. In order to use waste heat from cogenera- tion units the Belt-Dryer is designed for a 24-h-operation. The low temperatures guarantee a careful and safe drying. An interesting aspect from the economi- cal point of view is the utilisation of waste heat from different processes. Waste heat can be for example warm wa- ter, warm waste air, steam, biogas, natural gas, oil or other available resources that are used for the preheating of the air. A typical application is the utilisation of warm water at a temperature of about 80 °C that is transferred to the air by heat exchangers. The product of the drying process with the Low-Temperature-Dryer Pro-Dry® is an al- most dust-free and abrasion-proof granu- late that is easily storable. The net calorific value of the granulate is comparable to brown coal. Therefore this dried product is suitable for further treat- ments, as for example gasification or in- cineration. The Low-Temperature-Dryer Pro-Dry® is designed for high-efficient drying. Its design enables trans- portation of a high amount of sludge and other suspensions with an appropriate long retention time through the drying-zone with 80 - 90 °C. • Water evaporation: 500 - 6,000 kg/h • Inlet-DS: 15 - 60 % • Outlet-DS: 60 - 95 % • Thermal energy consumption: 750 - 900 kW/t H2O • Electrical energy consumption: 70 - 100 kW/t H2O Technical Data » Water evaporation: 500 - 6,000 kg/h » High efficiency by lowest thermal energy consumption » Careful drying at low temperatures » Safe process with low maintenance requirements » No danger of explosion or fire » Utilisation of „low-quality“ or low-temperature energy source (waste heat) » Dried material is an easily storable, abrasion-proof and almost dust-free granulate » Easily extendable by modular design Advantages » Considerable reduction of disposal costs by weight reduction » Pollution by waste air and odour emission far below required limit values (with appropriate odour treat- ment) » Low investment costs » 24-h operation » Installation and operation of the drying system acc. to ATEX regulations Waste air Waste water (only for cleaning process) M M Belt-Dryer Granulate loading Dried granulate for thermal recycling Process wast heat, return flow Wash water (only for cleaning process) M M M M M M M Container Dewatered sludge Fresh air Process waste heat, flow Heat exchangerM f1 f2 f1 f2 f1 f2 f1 f2 Basic scheme of the drying process with the Belt-Dryer Pro-Dry® 11 Klein Technical Solutions GmbH Konrad-Adenauer-Str. 194 D-57572 Niederfischbach Tel. +49 2734 43480-0 Fax +49 2734 43480-35 info@klein-ts.com www.klein-ts.com Klein Technical Solutions GmbH | Member of the SH+E GROUP SH+E GROUP ranks among the world‘s leading sup- pliers in the fields of water, energy and process en- gineering. Based on its global presence, the SH+E GROUP has executed projects in more than 160 countries.