OneMaterial data and parameters
（1） Material parameters and customer resources
1. Dry material name: Sludge
2. Initial moisture content of wet sludge: ≤ 80%
3. Final moisture content of dried sludge: ≤ 20%
4. Material: Material in contact with 304 stainless steel
5. Raw material temperature: 20 ℃
6. Dry production capacity: 2 tons/hour.
Heat source: 0.3MPa thermal oil furnace;
Heat source temperature: 180-200 ℃
（2） Preliminary calculation
1. Hourly dry sludge production:
G dry=2.0T/h=2000 kg/h
2. Water evaporation rate per hour:
W water=2000 × (80-20) ÷ (100-20)=1500kg/h
3. 40% dry product output per hour:
G dry=G wet W water=2000-1500=500kg/h
4. Total heat consumption for water evaporation:
Q1= 1500×600kcal= 900000 kcal/h
5. The necessary heat for material heating:
Q2=500×0.4×(100-20)=16000kcal/h
6. The heat required to raise the temperature of moisture in wet materials:
Q3=2000×0.8×(100-20)=128000kcal/h
7. Total consumption of Q=Q1+Q2+Q3=1044000 kcal/h
8. Calculation of evaporation area of dryer at 200 ℃: m2=13kg water/h (empirical value of m2/13kg water/h when 80% drying to 20%);
The average evaporation rate is m2/13kg water/h: then W water=1500 ÷ 13=115m2
9. High temperature gas thermal oil furnace: 200 ℃;
Natural gas consumption: 1044000kcal/h ÷ 9300kcal=113m3/h (natural gas calorific value 9300kcal/m3).

（3） Equipment selection
Based on material characteristics, sludge treatment capacity, production requirements, and our past experience, we believe that using a disc hollow blade dryer is a form of drying equipment with low energy consumption, low processing costs, large processing capacity, high automation, continuous production, long equipment life, low maintenance rate, and high cost-effectiveness.
According to the requirements of processing capacity and evaporation capacity, the hollow disc propeller shaft and cylinder jacket are heated with 200 ℃ superheated steam to dry the sludge from 10% to a moisture content of about 10%. The average evaporation capacity of the disc mixing dryer is 10kg (water)/h²So the drying area of the disc mixing dryer should be 100m2,
If 10% margin is used in actual production, then: 100 × 1.1=110m2;
Therefore, the model of disc mixing dryer selected should be: KJG-110 continuous disc mixing dryer 1 unit.

Number of disc dryers on the production line: 1 set of processing system
IIsludgeProject Introduction
This project ishandlesludgeDryingprojectThe requirement is to design a dry product output of 2.0 tons/hour (processed with one set of drying equipment).
To dry the sludge with a moisture content of 40% (after drying) to a dried sludge with a moisture content of about 10%; The drying equipment system should include: gas thermal oil furnace, feeding device, dryer, discharge conveying device, dust collection equipment, high humidity steam condensation recovery device, exhaust gas treatment device, induced draft and dehumidification system, control system, etc.
IIIsludgedrydeviceBasic parameters, process conditions and requirements

Project		name		Type		quantity	notes
Drying machine	Sludge drying equipment	disc dryer		KJG-120		1 set	Calculated based on actual operational data and calculations; 55kw/set; Frequency Control
	Processing raw materials	Sludge		Wet material moisture content initial moisture content 80% Final water rate of 20%			Sludge is a low acidity raw material; Containing corrosive and abrasive substances
	Number of processing devices			1		cover
	Heating source	High temperature thermal oil furnace		0.3		MPa	35kw/set, 1.2 million kcal gas oil furnace
	Heating medium	Thermal oil temperature		200		℃
	Feed moisture content	Initial water content		≤40%
	Discharge moisture content	Final moisture content		≤10%
	Wet sludge	Feed temperature		normal temperature		20℃	Process data
	Equipment material: Material in contact with 304 stainless steel	The disc cylinder and disc heating shaft are made of 304 carbon steel, while the feeding screw, discharge screw, cyclone carbon steel, condenser, and water film sprayer are made of 304 carbon steel. The rest are made of ordinary carbon steel		304/Q235B			Considering the strength, manufacturing economy, and usage requirements of the equipment, material contact with 304 stainless steel is selected
	Evaporation rate of sludge moisture	1500kg/h. set					Calculated at a temperature of 200 ℃;
	Sludge processing capacity	2000kg/h. set
	Production of finished sludge products	500kg/h. set
Supporting auxiliary equipment for production line	Loading device	Spiral feeding machine	DN300*7000		1 set		3kw； Variable frequency speed regulation; Hopper 1000 * 1300;
	Air intake	Compensated heating	100m2		1 set		The intake air adopts hot air compensation heating;
	Dust recycling	Efficient cyclone separator	XLP-850		1 set
	High humidity steam recovery	Efficient condenser	DN-1200-120m2		1 set		Moisture tends towards a U-shape
	Exhaust gas treatment system	Tail gas spray tower	DSP-1200		2 sets		1.5kw； Water tank 4.5m3
	exhaust system	Induced draft fan	4-72-5A		2 sets		15kw with air regulating valve
	Discharge	Spiral conveying discharge	DN200*3000		2 sets		1.5kw；
Equipment operating parameters and shared consumption	Feed temperature	At room temperature of 20 ℃
	inlet air temperature	100-150℃
	Induced draft exhaust gas temperature	60℃					Condenser exhaust temperature
	Exhaust temperature	Not exceeding 45 ℃					Exhaust temperature of washing tower
	maximum throughput	2000kg/h.
	Maximum output	500kg/h
	calorie consumption	1044000kcal/h
	water consumption	(Used for condenser and bearing seat cooling to increase service life)					Circulating cooling water
	Total power consumption	90kw					complete set of equipment

4sludgeDisc mixingIntroduction to Drying Machine
The disc mixing dryer uses thermal oil or steam as the heating medium, and the shaft end is equipped with a rotating joint for introducing and exporting the heat medium. The heating medium enters the inner cavity of the dryer rotor and heats the rotor to conduct heating and dry the sludge. At the same time, a heating medium is also introduced into the jacket of the dryer cylinder to heat and dry the sludge material, evaporating the moisture in the sludge.
The dried wet sludge is continuously fed into the disc dryer by the spiral feeder, and the sludge is flipped and stirred by the rotation of the rotor to fully heat the material, thereby evaporating the moisture contained in the sludge. At the same time, the material is pushed towards the discharge port by the pusher as the rotor rotates, and continues to stir during transportation, so that the water seeping out of the material continues to evaporate. After treatment, the uniformly dried qualified product is discharged from the discharge port.
The speed range of the rotor can be adjusted between 3-7rpm to control the dryness of the material and adapt to different process conditions on site.
Key technological innovation points and improved design
(1) Introducing foreign disc blade technology, improving design, and successfully applying it in large-scale production;
(2) Design and overall machining of bearing seat fittings, and installation of cooling devices;
(3) The cylinder, bearings, and shaft are all designed for thermal expansion and free sliding. The overall framework of the main engine is designed to prevent deformation of the equipment, making it easy to transport and operate;
(4) The overall reinforced design ensures better strength and service life;
(5) Replace the heating element with a disc welded as a whole, which has better strength and is less prone to wear and leakage; Scraper plates can be added according to the material status, with 4 to 8 plates per disc for better flipping performance. They automatically clean the sludge on the shaft disc to ensure heat transfer efficiency;
(6) The structural design is more compact, and a single unit can be designed with a large blade dryer with an area of ≤ 250m2;
(7) Samsung gear transmission structure design ensures more balanced operation and reduces swing and tension issues caused by chain transmission;
(8) The unique processing and assembly technology of the Navigation Drying Engineering Company ensures better concentricity of the equipment and superior sealing performance at both ends;
(9) According to different situations, semi-circular tube jacket heating and integral jacket heating types can be designed;
(10) The hot medium enters the rotary joint of the shaft in the form of steam entering one end and condensate exiting the other end. This process solves the problem of thermal short circuit of the blades at the transmission end.

FivesludgeClass materialsdiscCharacteristics of blade dryer
1. The rotor and cylinder of the dryer are designed to be compact and reasonable, with low space occupancy. The dryer has a large heat transfer area per unit volume and fast drying speed; Having the largest heat exchange surface within the unit effective volume, the equipment size can be reduced, and the processing time can be shortened;
2. The shaft rotates uniformly, the material is stirred evenly, the drying force is uniform, and the product particle size is uniform;
3. By adjusting the speed, process (intermittent or continuous), and drying time, the adjustable sludge drying effect can achieve different final moisture contents, such as reducing the sludge moisture content from around 80% to 40%, 30%, 20%, 10%, and 5%, etc;
4. High thermal efficiency, good mixing and stir frying effect, with 4 to 8 plates per disc for better stir frying performance, and automatic cleaning function for dual axis rotating discs;
5. The movement regularity of dry particles is strong, and the wear on the components is small, making it suitable for sludge material drying equipment.
6. The heating disc is pressed as a whole with few welds, strong corrosion and wear resistance, low running resistance of the disc, and low equipment vibration;
7. The two axis embedding method can form a thin layer of material with animal material on the blade, achieving the effect of thin layer heat transfer;
8. The relative rotation of the two shafts and the action of the scraper can scrape off the maximum amount of adhesive material stuck to the rotor, keeping the heat exchange surface clean and automatically cleaning, ensuring stable heat exchange effect;
9. Wide range of material handling It can be widely used for particles, powders, and viscous materials. It can dry materials with high or low moisture content, and can be operated continuously or intermittently. It is a highly applicable and energy-saving drying equipment.
10. Low energy consumption:
The spindle speed is low, and the material conveying system requires low power and low electricity consumption.
Drying with conductive heat results in high thermal efficiency and low energy consumption. 1.1-1.2 Steam/kg/water.
VI KJG-110typediscInstructions for Drying Sludge System of Drying Machine
This project requires the processing of 3.0 tons of wet sludge with an initial moisture content of 40% per hour The wet sludge conveying equipment uses a spiral feeder to transport the sludge from the silo to the top feeding port of the dryer, and then enters the dryer. The dryer is slightly tilted, and under the stirring and pushing of the rotor, it continuously moves towards the discharge port while being indirectly dried by high-temperature heat transfer oil, becoming a dry product with a moisture content of 10%. It is discharged through the discharge port and transported out of the shaft screw conveyor for bagging and storage.
The rotor and jacket of the dryer are filled with 0.3 MPa, 200 ℃ high-temperature heat transfer oil, which indirectly comes into contact with the material for drying. The low-temperature heat transfer oil after heat transfer is circulated by the high-temperature oil pump to the heat transfer oil furnace for further heating and circulation.
The exhaust gas (steam) generated during the drying process of the dryer mostly comes from the moisture of the material itself, with a small amount being volatile gases. After being dedusted by a cyclone separator, the exhaust gas enters the high humidity steam condensation recovery and deodorization system. The exhaust gas is then drawn by a fan to the tail gas treatment equipment, which is a spray absorption washing tower that uses a circulating spray method for cooling and dehumidification. The circulating water is cooled by a circulating water pump through a cooler and sprayed to remove acidic volatile gases in the sprayed water and tail gas. At the same time, the water vapor in the tail gas is cooled and removed, and the condensed waste liquid is returned to the water tank. The excess circulating water in the pool flows out from the overflow port and is then pumped and pressurized by a water pump before being sent to the sewage treatment system for treatment.

73tonsludgePersonnel quota for the operation of the drying processing system
The production personnel required for the 3-ton sludge treatment plant workshop are as follows:
1-2 personnel for system operation and inspection
1 system control system operator (part-time)
Subtotal: 2 people

8Dry sludgeComplete process diagram of chemical machinery