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Drying Technologies for Sewage Sludge

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Drying Technologies for Sewage Sludge Drying technologies for sewage sludge www.andritz.com Sewage sludge treatment Reuse - Reduce - Recycle System solutions from a single sorce From waste to valuable substance by drying 1.000 kg 160 kg 44 kg 20 kg Wet sludge Dewatered sludge Dried sludge Ash 4% DS 25% DS > 90% DS 0–3% organic 40–80% organic in DS 40–80% organic in DS 40–80% organic in DS > 99% DS Agricultural utilizaton MATERIAL ENERGETIC Alternative fuel - fertilizer - coal-fired power plant - landscaping - waste incineration plant Mechanical waste water Dewatering Drying Thermal utilization treatment Belt presses, Belt-, Drum- and - direct with EcoDry Sieves, Decanter centrifuges, Fluidbed drying systems - external (industry, agri- UTILIZATION Screens, Filter presses culture) Sand filters Energy self-sufficient mono-incineration Nutrient utilizatoin Utilizsation in the - phosphor recycling cement industry The road from being a waste product to thermal and one that can produce both useful material substantial utilization and energy (dry granulate) with ANDRITZ SEPARATION’s thermal process provides Co-incineration in coal-fired Cement industry, the following special features: power plants and waste fertilizer, phosphor incineration plants, cement recycling industry • considerable reduction in the sewage sludge volume to be disposed of Significant reduction in ence, numerous references, and a world- This Class A granulate features the follow- • alternative fuel generated with a calo- weight and volume by wide service network make ANDRITZ ing properties: rific value comparable to that of lignite SEPARATION a leading global supplier of • substitute fuel with carbon neutral • Thickening mechanical and thermal sludge treatment ▪ Dry substance content > 90% DS properties • Dewatering systems. Sewage sludge as a final prod- ▪ Low dust content • natural nutrient reserves • Drying uct of wastewater treatment is upgraded ▪ Good handling properties • Incineration to a valuable substance (dried granulate) ▪ Biologically stable (hygienized) by drying. A broad product range, extensive pro- As a result, both the material and the ener- cess know-how, many years of experi- gy contained in the granulate can be used in different ways. 2 3 The right thermal process for each application Three technologies to offer custom-tailored solutions Three possibilities for the optimum path from waste to product Condensation Belt dryer (BDS) (heat recovery possible) ▪ for small to medium evapo- ration capacity Dewatered sewage sludge Exhaust air treatment ▪ to make use of waste heat with temperatures > 90°C evaporated Drum drying system water for and heating steam < 6 bar Preferred (DDS) cleaning heating systems Direct with exhaust gas 350–600°C Fluidized bed dryer (FDS) Dried granulate ▪ for medium to large evapo- >90%DS ration capacities Coal-fired power plant ▪ if heating media >180°C and Belt drying system (BDS) heating steam > 6 bar are available Waste heat (steam, exhaust gas, hot water) < 90°C Cement factory Drum dryer (DDS) ▪ for medium to large evapo- Fluidbed drying ration capacities system (FDS) Cyclone ▪ to make use of natural gas, Waste heat (steam, exhaust gas) ANDRITZ EcoDry biogas, or heating oil >150°C ▪ if granulate has to meet strin- Indirect with thermooil or steam gent demands (for fertilizer) Fertilizer With belt, drum and fluidized bed drying, ANDRITZ SEPARATION has Your advantage three technologies that offer custom-tailored solutions to the various cus- tomer requirements. 4 5 Belt drying system Ideal for making use of waste heat Recovery of material and energy content taking waste gas heat from cement production as an example By creating a thermal and material link be- ash is used as an additive in cement pro- tween a sewage sludge drying plant and duction and thus reduces the amount of a cement kiln, an innovative concept is minerals used. obtained for conserving resources (energy and minerals). The advantages ▪ 100% of the sewage sludge heating Here, the thermal energy for drying the value and ash are used in cement pro- sewage sludges comes entirely from the duction waste gases from the clinker cooler in the ▪ Considerable reduction in operating cement works. The dry granulate is pro- costs by substituting primary energy duced from the dewatered sewage sludge, and minerals which serves as carbon neutral auxiliary ▪ Substitute fuel that is carbon neutral fuel in the cement kiln to generate heat for cement production. The sewage sludge Belt drying plant, Hereke, Turkey Pre-heater Dried sewage sludge granulate as alternative fuel Belt drying plant, Clos de Hilde, France Electric filter The Process perature of the drying gases (< 150°C) and ▪ Combination of tried-and-tested com- Exhaust air/thermooil heat exchanger The ANDRITZ SEPARATION belt drying the low dust content in the system facilitate ponents from ANDRITZ SEPARATION system granulates the dewatered sludge in safe operation. sludge drying technologies. Rotary kiln a mixer with product that has already been ▪ More than 30 reference plants drying dried. The moist granulate produced here is The dried material is not exposed to me- around 800,000 t of dewatered sludge distributed evenly over the belt in the dryer chanical stress during drying and is also per annum. Clinker cooler Thermo oil circuit by a specially designed feed module. The pre-cooled before the dryer discharge. even layer of material on the belt creates optimum conditions for even distribution of The technology - simple, convincing, the drying air. and successful ▪ The belt dryer is particularly attractive This, in turn, is necessary for even heating economically because it uses waste and drying of the sewage sludge. heat with a low temperature. ▪ Highly product quality of different The layer of material on the belt forms a sludges qualities due to variable back- Belt drying system BDS filter medium for the air flowing onto the feeding. granulate layer from above and thus pre- ▪ Modular structure and simple design vents entrainment of dust. The low tem- ▪ High availability. Flowsheet of a belt drying plant using waste heat 6 7 Fluidized bed drying system Drying in a closed inert gas loop Energy-optimized integration of sewage sludge drying in sewage treatment plant operations The heat for drying the dewatered sewage Advantages for the sewage treatment sludge is taken entirely from the sludge gas. plant operator The sludge gas is used to heat the fluid- ▪ Significant reduction in the residual ized bed dryer with an efficiency of >90% substances leaving the sewage treat- in modern incineration plants. ment plant At the same time, the fluidized bed dryer ▪ No additional costs for thermal energy provides the thermal energy to heat the di- needed in drying gester. In the drying process stage the sew- ▪ Environmentally friendly concept to age plant produces a valuable substance conserve resources by – reducing the (dried granulate), which is in demand as transport capacities for the sewage substitute fuel in cement production or in sludge and – producing a carbon neu- coal-fired power stations due to its calorific tral substitute fuel. value comparable to that of lignite and its carbon neutral combustion properties. Fluidized bed drying plant, Bailonggang, China Fluidized bed drying plant, Madrid, Spain Digestion tower The process The technology - simple, convincing, Sewage sludge drying at the highest Mechanical dewatering Fluidized bed dryers for drying dewatered and successful level of safety engineering sewage sludge operate in a closed inert ▪ Sludge feed without dry granulate – Sewage sludge with >90% dry substance gas loop. The entire heat required to evapo- backfeeding offers substantial flex- is an organic material that is combustible rate the water is fed to the dryer via heat ibility in adapting to different sludge and – under certain conditions – potentially exchangers, i.e. without any direct contact qualities. explosive. between the heat transfer medium and the ▪ High safety level due to drying opera- product. tion under inert gas conditions Operations under inert gas conditions as The dewatered sewage sludge is pumped ▪ Automatic operation (no personnel used in fluidized bed drying guarantee Hot water for digestion tower heating directly to the fluidized bed dryer without any present during the night and at week- safe plant operation in all operating modes pre-mixing, broken up using a mechanical ends) is possible and is also practiced (start-up, shutdown, stationary, upset). breaker, and then mixed into the dried granu- in many plants Thermo oil late which is held in motion by the fluidizing ▪ High thermal efficiency due to closed These inert gas conditions are maintained gas. Due to the excellent heat and material gas loops from the dryer, to product cooling, to stor- transfer conditions prevailing in the fluidized ▪ Low waste gas volume (<200 m3/h) age. Digestion gas bed, the sewage sludge fed to it is dried at due to closed design reduces expendi- 85°C to >90% dry substance in a very short ture for waste gas cleaning. time. The fluidized bed dryer uses waste ▪ More than 30 reference plants in op- heat from industrial processes, but also pri- eration all over the world. Fluidbed drying system mary energy. ▪ High plant availability and proven op- Thermooil boiler At the same time, waste heat at a tempera- erating times of >8000 h per annum ture level of 60°C is available for further use. Flowsheet of a fluidized bed drying plant 8 9 Drum drying system Drying and granulating in a single step Energy efficiency from combined heat and power generating (with a gas motor for example) The electric current for operating the sew- The advantages age sludge drying plant is supplied by a gas ▪ Having no direct contact between motor operated as a co-generation unit. CHP waste gas and the dryer system results in simple safety management The thermal energy required for drum dry- ▪ Fast and easy switch online from CHP ing is provided from the gas motor exhaust mode to burner mode without impair- air and also from their cooling water shell. ing product quality Efficient heat recovery is a very important ▪ Efficient heat recovery factor.
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