Huber worldwide

Select your Region and Language
Worldwide
Worldwide
Europe
Germany
France
Great Britain
Spain
Switzerland
Sweden
Finland
Norway
Czech
Russia
Poland
Hungary
North America
USA
Australia
Australia
South and Central America
Mexico
Chile
Peru
Brazil
Asia and Middle East
Turkey

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 t/h
  • Dewatered sludge throughput per dryer: 6 to 12 t/h *
  • DR throughput capacity per dryer: 1.5 to 6.0 t/h *
  • Heating medium: Saturated steam up to 10 bar(a)

      * dependent on inlet and outlet DR

Thermal drying of sewage sludge is an indispensable process component to ensure the sewage sludge has the right dry residue. The subsequent mono-incineration of the sewage sludge achieves an enormous reduction in volume and mass and provides for 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
1/6
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 dry exactly to the required DR content and thus enable a selfsustaining combustion in the fluidized bed incinerator.

The HUBER RotaDry® is available in different sizes, so that a water evaporation of about two to six tons per hour and dryer can be achieved. By using different disc diameters and numbers of discs, the heating surface can be optimally adapted to the amount of generated sludge and the dryer can be operated in the ideal capacity range.

The heat requires for drying is provided and, depending on the size of the plant, electricity is also generated by means of steam turbine.

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 monoincineration plant.

All dryers are optionally available with jacket heating.

Vapour condensation

The overall dryer system always includes the condensation of the vapours produced by the disc dryer. Depending on the project-specific conditions, there are various possibilities here.

  • Tube bundle condenser (indirect condenser)
    Compact design to maximise 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 vapour condensate is sprayed in the head of the condenser to knock down the condensable vapours. Robust and universal design.
  • Multi-stage condensation system
    Consisting, for example, of a sludge preheater (for energy optimization and polymer consumption reduction in the dewatering process) and an injection condenser as residual condenser.

Steam and condensate system

In order to operate the dryer as efficiently as possible, the use of saturated steam is essential. Depending on the concept in the water-steam cycle, steam cooling is therefore necessary in addition to  steam pressure control. Due to the ideal configuration of the controlled system. Both pressure-loss-minimized operation at nominal load and reliable regulation to the required  steam pressure can be achieved. Even after it has passed the dryer, the liquid  steam condensate does not remain energetically unused and is returned to the water-steam system. It is advisable to utilise the flash steam.

Vapour condensate treatment

Due to the high contact temperatures of the disc surface and sewage sludge, a high load of ammonium as well as particulate and dissolved COD (Chemical Oxygen Demand) is produced in the vapour condensate, which does not allow for immediate indirect discharge into the municipal sewage network and requires separate treatment on request, HUBER SE can develop a project-speficic solution for the treatment of the vapour 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-optimised 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® convinces by its compact design, which allows the dryer to be installed even on a small footprint or to be integrated into existing plants.
  • Proven and durable 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, a high volume-specific water evaporation can be achieved.
  • 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.
     

Media

Videos and Animations

Downloads

Customer Information and Documents

More information needed?

Feel free to contacts us
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
2023-08-02 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....

Continue reading
HUBER Disc Dryer RotaDry® after completed installation.
2023-02-16 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...

Continue reading
img-casestudy-23-02-versuchsscheibentrockner
2023-02-08

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...

Continue reading
img-casestudy-23-02-rotadry-hamburg-01-fav
2023-02-07 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...

Continue reading
img-casestudy-23-02-rotadry-benefits-01
2023-01-31

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...

Continue reading
img-casestudy-23-02-rotadry-berlin-01-baufeld
2022-11-23 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...

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

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...

Continue reading
HUBER Disc Dryer RotaDry® for partial contact drying of sewage sludge
2020-05-07

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...

Continue reading
  Search   Contact   Request