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HUBER Disc Dryer RotaDry® Partial contact drying of sewage sludge for recycling in fluidized bed incineration plants

Contact Drying of Sewage Sludge

Partial drying of sewage sludge for recycling in fluidized bed incineration plants.

  • Water evaporation per dryer: 2 to 6 ton/h
  • Dewatered sludge throughput per dryer: 6 to 12 ton/h *
  • DR throughput capacity per dryer: 1.5 to 6.0 ton/h *
  • Heating medium: Saturated steam up to 150 PSI / 10 bar(a)

      * dependent on inlet and outlet DR

Thermal drying of sewage sludge is a crucial step to ensure the sludge has the proper residue. The subsequent mono-incineration of the sewage sludge results in a substantial reduction in both volume and mass, while facilitating the recovery of phosphorus.

HUBER Disc Dryer RotaDry® for partial contact drying of sewage sludge
HUBER Disc Dryer RotaDry®
HUBER Disc Dryer in the factory
HUBER Disc Dryer RotaDry®: Partial contact drying of sewage sludge for recycling in fluidized bed incineration plants
Installed Disc Dryers for a mono-incineration plant
Installed Disc Dryers for a mono-incineration plant
Preparations for lifting a disc dryer
Preparations for lifting a disc dryer
Lifting a Disc Dryer with a caterpillar crane
Lifting a Disc Dryer with a caterpillar crane
A disc dryer is lifted into place with the help of a heavy-duty crane
A disc dryer is lifted into place with the help of a heavy-duty crane
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Design sketch: HUBER Disc Dryer RotaDry® with upstream and downstream peripherals
Design sketch: HUBER Disc Dryer RotaDry® with upstream and downstream peripherals

Design and Function

Design sketch: HUBER Disc Dryer RotaDry® with upstream and downstream peripherals
Design sketch: HUBER Disc Dryer RotaDry® with upstream and downstream peripherals

The HUBER Disc Dryer RotaDry® is designed for homogeneous partial drying of dewatered sewage sludge. Due to its compact design and high specific water evaporation, it is not only ideally suited for use in new sewage sludge mono-incineration plants, but also for capacity expansions of existing plants. The dryer can precisely achieve the required dry residue (DR) content, ensuring self-sustaining combustion in the fluidized bed incinerator.

The HUBER RotaDry® is available in various sizes, allowing for a water evaporation capacity of approximately two to six tons per hour per dryer. By selecting different disc diameters and numbers of discs, the heating surface can be optimally tailored to the amount of sludge generated, ensuring the dryer operates within its ideal capacity range.

The heat required for drying is supplied, and depending on the size of the plant, electricity is also generated through steam turbines.

A reliable condensate removal system, an innovative concept for moisture control, an optimized feed and a steam control line with minimized pressure loss characterize the HUBER Disc Dryer RotaDry® as the perfect sewage sludge dryer in combination with a mono-incineration plant.

All dryers are optionally available with jacket heating.

Vapor condensation

The complete dryer system always includes the condensation of the vapors produced by the disc dryer. Depending on the the specific project requirements, there are various options available for this process.

  • Tube bundle condenser (indirect condenser)
    Compact design to maximize the extraction steam for district heating, as heating water is raised to the required temperature level directly in the condenser.
  • Injection condenser (direct condenser)
    Circulating and cooled vapor condensate is sprayed in the head of the condenser to knock down the condensable vapors. Robust and universal design.
  • Multi-stage condensation system
    Options may include components such as a sludge preheater, which optimizes energy use and reduces polymer consumption during the dewatering process, and an injection condenser, serving as a residual condenser for further energy recovery.

Steam and condensate system

In order to operate the dryer as efficiently as possible, the use of saturated steam is essential. Depending on the design of the water-steam cycle, steam cooling is required in addition to steam pressure control. Thanks to the optimal configuration of the controlled system, both pressure-loss-minimized operation at nominal load and reliable regulation to the required steam pressure are ensured. Even after passing through the dryer, the liquid steam condensate is not left energetically unused; it is returned to the water-steam system. Utilizing the flash steam is recommended to further enhance energy efficiency.

Vapor condensate treatment

Due to the high contact temperatures between the disc surface and sewage sludge, the vapor condensate contains elevated levels of ammonium, as well as particulate and dissolved COD (Chemical Oxygen Demand). This makes immediate indirect discharge into the municipal sewage network unfeasible. Separate treatment is required, and upon request, HUBER Technology, Inc. can develop a project-specific solution for treating the vapor condensate.

Ease of maintenance disc dryer

Maximum reduction of the activities during walkarounds

  • The main rotor bearings and the discharge screw bearings are supplied with automatic grease lubrication.
  • Highly efficient direct drive with peripheral speed adjustment capability. Wear-optimized driving style and startup under load possible.
  • Discharge screw is easily accessible and removable for replacing wear plates and screw spiral.

The Benefits of the HUBER Disc Dryer RotaDry®

  • Compact design
    The HUBER Disc Dryer RotaDry® stands out for its compact design, enabling it to be installed on a small footprint or seamlessly integrated into existing plants, maximizing space efficiency.
  • Proven and reliable technology
    The many years of successful use of disc dryers in combination with sewage sludge incineration plants demonstrate the robust technology of the process.
  • High specific water evaporation capacity
    By heating the rotor discs and optionally the jacket, the HUBER Disc Dryer RotaDry® achieves a high volume-specific water evaporation rate, enhancing the efficiency of the drying process.
  • Competent partner
    Thanks to the cooperation between HUBER and OESTERGAARD, the customer is offered the best possible solution, both in terms of process and design.
  • Maintenance-friendly dryer
    Minimal effort for operating personnel thanks to automatic grease lubrication and low-maintenance direct drive.
  • Extended service life
    By using a special welded construction for the discs, the minimum permissible residual wall thickness can be reduced. The service life of the rotor is thus extended to a maximum.
  • Control concept adapted to mono-incineration plants
    In the event of fluctuating sludge quality, the DR measured online can be included in the control.
  • Secure condensate drainage
    Reliable condensate drainage from the discs due to the omission of a syphon pipe.
     

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Feel free to contact us

FAQ

Frequently Asked Questions

The RotaDry® disc dryer can be used in existing plants as well as for the new construction of a sewage sludge incineration plant. The sludge to be dried must comply with the HUBER sewage sludge specification for the disc dryer. Ideally, it should be well-stabilised municipal sewage sludge.

Due to its compact design, the dryer requires little space. Proven and durable technology ensures uniform and homogeneous drying to up to 45% DR (dry residue). The heat recovery and possible heat extraction of condensation power in the indirect condenser makes the process thermally very efficient. In addition, the RotaDry® disc dryer has an optimised control concept for the acceptance of external sludge.

The RotaDry® disc dryer dries dewatered sludge with a dry residue (DR) of 18% to 30% up to 45%. In the process, the sludge is conveyed in the rotating dryer to the discharge outlet by paddles attached to the disc periphery. Parameters such as sludge temperature and negative pressure in the plant are measured during the entire drying process. In addition, the DR content at the dryer inlet and dryer discharge is constantly monitored to exploit maximum water evaporation.

Incorporated into a sewage sludge mono-incineration system, the disc dryer shows its full strength. The sewage sludge is dried in the disc dryer to such an extent that it can be autothermally processed in the fluidised bed incinerator. The steam produced is used to heat the dryer.

The water vapour produced during drying is precipitated by the vapour condenser. There are various ways to process the vapour condensate so that it can be disposed of safely afterwards. Part of the heat used for drying can be recovered and fed into a district heating network, for example.

Case Studies

HUBER Solutions in Operation

img-casestudy-23-10-rotadry-hannover-02-building
08/02/2023 Hanover, Germany

Successful commissioning of the first HUBER RotaDry® disc dryer in Hanover-Lahe

The sewage sludge recycling plant in Hanover-Lahe will go into operation after successful hot start-up and optimisation....

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HUBER Disc Dryer RotaDry® after completed installation.
02/16/2023 Hannover-Lahe, Germany

Plant for mono-incineration of sewage sludge in Hannover-Lahe: HUBER Disc Dryer RotaDry® ready for hot commissioning

The Hannover-Lahe project of HUBER and sludge2energy GmbH is progressing further: The two HUBER Disc Dryer RotaDry® 2050...

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img-casestudy-23-02-versuchsscheibentrockner
02/08/2023

HUBER Disc Dryer RotaDry®: Trial disc dryer for small-scale tests

New RotaDry® trial disc dryer designed for homogeneous partial drying of sewage sludge on a pilot scale. The...

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img-casestudy-23-02-rotadry-hamburg-01-fav
02/07/2023 Hamburg, Germany

Success story continues: HUBER SE receives major order to deliver three disc dryers for Germany's largest sewage sludge incineration plant

On the way to Germany's largest sewage sludge incineration plant: HUBER supplies three HUBER Disc Dryer RotaDry® units...

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img-casestudy-23-02-rotadry-benefits-01
01/31/2023

Innovation for drying sewage sludge: The benefits of the HUBER Disc Dryer RotaDry®

Extensive know-how, decades of experience and intensive studies and discussions: building on this foundation in sewage...

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img-casestudy-23-02-rotadry-berlin-01-baufeld
11/23/2022 Berlin, Germany

Over 40 tons of sewage sludge per hour: Berlin-Waßmannsdorf STP receives four HUBER Disc Dryers RotaDry®

Reliable and innovative products from Berching for the German capital: HUBER will deliver four RotaDry® disc dryers to...

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img-casestudy-20-10-conditions-discdryers-03-cross-section
10/28/2020

General conditions for the use of disc dryers

Disc drying technology has proven itself over decades for the partial and full drying of sewage sludge. For an effective...

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HUBER Disc Dryer RotaDry® for partial contact drying of sewage sludge
05/07/2020

The new HUBER Disc Dryer RotaDry®

HUBER SE has expanded its range of sewage sludge dryers by adding a disc dryer to its future product portfolio. This...

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