SLUDGE DRYING

TECHNOLOGIES
LOW TEMPERATURE BELT DRYING SYSTEM:
REDCO RBD SERIES

1. Introduction:

REDCO RBD series drying system is a highly

efficient method to dry sludge. Low emissions
as well as a high-quality final product in the
form of dust free granulates, together with low
operation costs are the striking advantages
of the REDCO belt drier technique.

2. Process Description: the conveyor belt. The belt is designed as

perforated plate belt. The hot air flows through
Dewatered sludge is conveyed into a the perforation. This hot air ventilates the
granulating unit by means of an eccentric screw pile and dries the wet product. This method
pump and extruded. Thanks to this extruding of convective drying treats the product very
operation, “noodles“ with a diameter of 7-11 carefully as the product heats up only slightly
mm are produced and evenly distributed over especially during the first drying passage.
the total width of the belt and fall onto the The heat for evaporation is extracted from
drying belt lying the hot air flow, which
underneath. Thus cools down this way.
a very regular pile After the product on
is formed on the the belt has passed
drying belt, which the drier tunnel, it
can be ventilated is discharged out
well. from the hot air area
This pile is fed and falls from the
into the drier upper onto the lower
tunnel through belt. The product is
turned for a homogeneous
drying all over the pile.
The lower belt conveys
the product already dried
to a great extent back into
the drier tunnel where the
drying is carried on to a
final DS content of approx.
90 %. Additional lump-
breaker units mix and
loosen the product layer
in order to achieve a very
homogeneous dry product.
in a direct hot air generator. The air stream
The discharging screw is water cooled which
is a combination of fresh air what is needed
is thus cooling the sludge. Then the product
for burning the gas and recycled air after the
leaves the drier and can be conveyed for
condensation process.
further use. The final product has the form
of pellets, largely dust free, cooled and thus
optimally suitable for all further ways of
disposal.

Heating / Heat Recovery:

The heating for the dryer is very flexible. The

RBD dryer can work with different sources
of heat, natural gas or digester gas. REDCO
is capable to design the dryer according to
the available heat source on site. Any sort of
waste heat, coal, fuel-oil, electricity, steam,
biogas, sync gas, natural gas, etc. can be
used to operate a RBD belt drying unit.
In case of availability of any sort of gas as
fuel, the hot air is generated by a gas burner
Circulation Air:

Once the drying air is heated up and fed

into the dryer, this air flow is circulated for a
pre-calculated no of turns inside the drying
tunnel. The cooled air flow is re-heated again
and again in order to have continuous and
efficient drying process. This circulation
method provides an optimal saturation of
circulation air resulting in a low temperature,
risk free and cost efficient drying process
Condensation Unit:
A part of the internal circulation air will be
sucked off and transferred to the condensation
unit. In the first step of the condensation the
air stream will cool down in a water air heat
exchanger to bring it near to the dew point.
The generated energy in the water heat
exchanger will be used for pre-heating of the
recycled air.
The condensation unit is an air scrubber with
water spray nozzles and integrated moisture
eliminator. Via cooling the exhaust air, the
exhaust air will cool down and condensate.
Recycled Air:
The recycled air has a temperature of approx.
40°C and will be divided into two air streams:
*Exhaust air what is to dispose and to be
treated by an additional odour control unit
*The rest of air flow, called as “Recycled
air”, will be pre-heated by a water/air heat
exchanger and transferred back to the direct
fired air heater, where this air is heated up to
a high temperature.
The heat recovery by exhaust air recovery
improves the thermal efficiency and reduces
the exhaust volume flow.
3. Emissions: Vapours / Odour

Dust The temperature of the drying air is within the

low-temperature range at approx. 130-140°C,
Before drying, the wet sludge is pressed into the product is dried very gradually thanks to
a pile of regular noodle shaped strings. This convective heat transfer. This means that
pre-conditioning avoids different grain sizes, the heat necessary for evaporation is evenly
especially the formation of fine particles. fed to the product by the hot air. Heavy
Thus dust is largely avoided.
The product is conveyed by the slowly
moving belt. There is no considerable friction,
shear or centrifugal stress causing extra dust
formation.
The air speed in the product zone is very low;
thus hardly any dust particles are carried
along into the air flow.
overheating of the product at hot surfaces, as condensation as well as a separation of ultra-
e. g. with contact driers, are avoided by the fine dust.
system. This careful drying method reduces
odours. Dry Product
Additionally, the homogeneous product The incoming sewage sludge is dried to a DS
structure as well as the constant heat supply content in the range between 60-95%. Thus a
avoid partial overheating. reduction in weight is achieved. The structure
in the form of pellets is very well suitable for
Exhaust Air Cooling / Vapours
Condensation

An additional stage of wet cleaning is

used for further exhaust air cleaning.
The exhaust air is cooled in a wet-
scrubber by spraying of water. A large
part of the vapour is condensed and
thus also volatile odour components.
Additionally, fine dusts are separated
from the air-flow during cleaning.
The scrubber-water is taken from the the most various kinds of disposal (landfill
outflow of the sewage-treatment plant. The area, incineration, agricultural spreading,
condensed share of vapours is discharged etc.).
from the scrubber together with the scrubber
water and supplied to the sewage-treatment-
plant and discharged to the plant inflow.
This exhaust air cleaning guarantees a
further deodorization of odours through
 Application Sewage Sludge

Width of Conveyor Belt 2500 or 4000 mm

Single or Double Conveyor Type Belt

Type
Dryer
Water Evaporation 300 – 1500 kg H O/saat (Single Conveyor)
2

Capacity 900 – 6000 kg H2O/saat (Double Conveyor)

Lenght of Conveyor 6 – 28 m (Single Conveyor)

Belt 8 – 40 m (DoubleConveyor)
Excess Heat
Natural Gas
Heat Source Biogas
Fuel oil
Diesel

1 – Granulation Unit
2 – Dryer Tunnel
3 – Belt Drive Unit
4 – Recovery Fan
5 – Hot Air Fan
6 – Hot Air Chamber
7 – Heat Exchanger
8 – Scrubber Unit
9 – Outlet Conveyor
SOLAR DRYING TECHNOLOGY
FOR SEWAGE SLUDGE
REDCO Solartiger Technology
The SOLARTIGER technology stands for
efficient solar drying of sewage sludge. The
strong point of the SOLARTIGER technology
is the mass reduction with dehydration of water
with as low as possible use of energy.
The SOLARTIGER technology combines
different important functions of the solar drying.
Turning the sewage sludge to have always
wet material on the surface. Aeration to hold
the sewage sludge aerobic and to avoid nasty
odours. To transport the sewage sludge in a
longitudinally of the drying hall during drying.
Distribution the sewage sludge after the input
to the drying hall.
With the SOLARTIGER technology you can
also use external sources of heat to increase
the dry matter content on the end of the drying
process.
Function principle of solar drying
Principle of solar drying
The natural solar radiation is used for the
evaporation of water in the solar drying plants.
To protect the sewage sludge from the rain the
area where the sewage sludge should be dried
is covered with a transparent roof cladding.
Lateral the building area is bounded by guide
tracks. These function as running surface for
the SOLARTIGER® and as foundation of the
cladding.
The natural solar radiation affects the sewage
sludge. The sludge warms up and the water
inside evaporates. (The reason is a natural
vapour pressure equalisation among the water
in the air and in the sewage sludge.)
On the surface of the sludge arises quickly a
high relative humidity. To transport this moist
air ventilators produce artificial wind on the
surface of the sludge.
In the case of equal temperature moist air is
lighter than dry air. The air exchange takes
place through the roof.
With the SOLARTIGER® technology the
sewage sludge is turned and aerated uniformly
over the enitre width of the hall. The sludge can
also be transported in the longitudinal direction
of the hall.
With the SOLARTIGER® technology we only
need 20 – 25 kWh electrical energy per 1,000 l
evaporated water.
With the technology of SOLARTIGER® a
rotation drum ensures for an evenly granulate
dry material and sufficient aeration of the dry
material.
The height adjustable and rotating drum is
mounted on a frame and aerates the sludge
during the drying process with paddles which
are fixed on the drum.
This crane-like frame runs longitudinally through
the hall. The immersion depth of the drum in
the sludge can be adjusted continuously.
The operation of the SOLARTIGER®
technology is very simple and works essentially
automatically. Personnel costs canbe kept very
low and ther are no technical skills required to
operate.
The operation occurs via touch panel on the
switchboard. Depending on the customer the
deliver is adapted to the application and the
drying material.
Benefits of the SOLARTIGER technology
Dry granulate in a sludge stock
Sewage sludge is not disposaled directly on
the WWTP. With 70-80% water in it the sewage
sludge is transported to the utilization.
1. Your benefits of the SOLARTIGER®
technology:
2. The SOLARTIGER® technology brings down
the costs for disposal.
3. The mass of sewage sludge is reduced
about 3/4.
4. During drying a granulate is produced which
can be stocked without nasty odour.
5. Solar drying with the SOLARTIGER®
technology is a clever step in the waste water
cleaning process.
 Technical Characteristics Of The Machine

Total Power İnput 6 - 14 kW

Rotation Speed Of The Drum 30 - 60 U / min.

Driving Speed 0.4 - 8 m / min.

Total Weight Ca. 3,500 kg

Weight Of The Drum Ca. F1,000 kg

Capacities:

Suitable solution for each capacities.

Standard Area Dimensions: Each drying bed with 130 x12 meters(could be projected as per
available area dimensions )

System Units: Mechanical Rotating Drum, Circulation and Air Exchange Fans, Sensors

Heat Source: Solar Energy

Advantages: No need for any other outsource energy requirement(natural gas, fuel oil,etc..) in-
stead of solar energy

Disadvantages: Land requirement

QUICK DRYING SYSTEMS
REDCO RQD Serisi
1. General Description:
REDCO RQD series quick-drying units are
highly efficient sludge drying system. The most
obvious advantage of RQD series quick dryer
systems is to reach high dryness in limited
area. And this process is operated by lower
costs.
Quick Dryer is a feasible system for small
capacity water treatment plant in terms of
their low operating and investment costs.
Additionally, sludge drying process is an easily
operated system due to the practical properties
such as short process duration. Drying process
is progressed by the passage of the product
through the high temperature in a short period
of time, product dehumidification is provided
without reaching high temperatures.
2 . Quick Dryer Process
Quick dryer provides reduction in the total amount of wet product by means of pressurize hot air.
The counter suction of dehydrator generate pressure decrease and provides dehumidification
without reaching high temperature. By this means fuel consumption is highly minimize.

1. Wet Sludge Collection Bunker: Wet Sludge flour into the collection bunker.

2. Wet Sludge Feeding Conveyor: The product is transported from bunker.

3. Feeder: The mechanism that

provides the inlet of the product through
dehydrator to ensure drying process.

4. Dehydrators: The special design

machinery that provides the drying
process of wet sludge.

5. Hot Air Generator: The section

that provides hot air into system with
burners

6. Cyclone: The section that provides

separation and fall of dry product.

7. Airlock: This section that prevents air leakage to the system and increase the drying efficiency
of dry product.

8. Economizer: Provides heat recovery from circulation

of the hot air air which is removed by the furnace in this
section.

9. Suction Fan:The section that provides hot air

recirculation.

10. Funnel: The section that removes of moist air from

11. Dry product Discharge Conveyor: The machinery

that transport the dry product system.
3 . Technical Details

No Equipment Properties Quantity

The proportional (modulating) gas

1 Burner 1
burner ( Max. 500 kW thermal power)

2 Control Panel PLC control system, 1

For regular feeding and drying in

3 Frequency 2
dehydrator and feed conveyor

Isolated for minimizing heat losses.

4 Isolation System According to the temperature; -
ceramic, stone or glass wool
To receive product regularly from the
5 Air Lock 1
bottom of cyclone.
6 Material AISI 304 Stainless Steel -

Quick Dryer with

1000 mm dehydrator
(max capacity: 500
Quick Dryer with 800
kg/h)
mm dehydrator
Quick Dryer with 600 (max capacity: 350
mm dehydrator kg/h)
(max capacity: 250
kg/h)
 Technical Data For Quick Drying System

Wastewater Treatment Sludge

Capacity 1-15 ton / h

Evaporation Capacity 50 - 500 kg / h

Heat Source Burner

Waste Heat Natural Gas

Energy Source Biogas Fuel Oil
Diesel

Energy Consumption 0,90 kWh / kg H2O

1. Wet SludgeCollection Bunker

2. Wet Sludge Feeding conveyor
3. Feeder
4. Dehydrators
5. Hot Air Generator
6. Cyclone
7. Airlock
8. Economizer
9. Suction fan
10. Funnel
11. Dry product Discharge Conveyor
REFERENCES

İZSU ÇİĞLİ WASTE WATER

TREATMENT PLANT,
TURKEY

Low Temperature
Belt Drying
System Capacity:
800T / Day

AKHİSAR MUNICIPALITY
WASTE WATER
TREATMENT PLANT,
TURKEY

Solar Drying
Application Capacity:
24T / Day
ÇERKEZKÖY ORGANIZED
INDUSTRIAL ZONE WWTP,
TURKEY

Pilot Solar Drying

Plant Capacity:
10T / Day

EROĞLU HOLDİNG DNM

TEXTILE WWTP,
EGYPT

Quick Dryer
Capacity:
12T / Day

ÇORLU ORGANIZED
LEATHER INDUSTRIAL
ZONE

Low Tempereture Belt

Drying System
Capacity:
100T / Day
info@redco.com.tr www.redco.com.tr

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