Biosolids Dryers

Overview

Komline-Sanderson is the leading supplier of biosolids dryers in the United States.  Komline features stainless steel construction, experience, safety and robust construction in a proven, flow through design.  Komline has produced hundreds of paddle dryers including dozens of biosolids dryers.  Worldwide, the paddle dryer as manufactured by Komline-Sanderson has outsold all other types of biosolids dryers.
 

Who is Komline?

Komline-Sanderson Engineering Corporation is a family owned business that has been manufacturing wastewater and sludge handling equipment for more than half a century.  Corporate headquarters and the main fabrication shop are located in Peapack, NJ about 30 minutes east of Easton, PA.

How does the Komline paddle dryer work?

Sludge is pumped into the dryer with a positive displacement pump to ensure accurate metering.   The sludge passes through the dryer which consists of a stainless steel, sealed vessel containing twin, counter rotating shafts whose hollow paddles intermesh with one another.  Inside the hollow shafts and paddles, hot thermal fluid or steam provides the heat source to dry the sludge.  The paddles both mix and heat the sludge as it passes through the vessel whose walls are also heated.  Temperature is monitored throughout the dryer.  The dried product is discharged by displacement as it enters a collector conveyor.  Prior to delivering product to the customer, Komline cools the material to 50 degrees C (120 degrees F).  Water quenching systems and explosion panels are standard equipment.    

What is an indirect dryer?

An indirect dryer is a machine designed to evaporate water from a sludge or slurry where the product (e.g., biosolids) is separated from the heat source by a barrier (a metal surface).  An example of an indirect dryer is a frying pan with a cover.  An indirect dryer is contrasted with a direct dryer where the heat source (hot air) comes into direct contact with the product to be dried (think of a hair dryer: large volumes of very hot air are blown onto the product to be dried).

What are the advantages of an indirect dryer over a direct dryer?

• An indirect dryer produces significantly less off gas to be handled than does a direct dryer.
• With less air in contact with the flammable product (sludge), the Komline dryer minimizes the chance of a fire or an explosion when compared  to a direct dryer.  Less air means less oxygen is present with the highly volatile sludge particles.
• The Komline dryer uses a much lower operating temperature (<400 degrees F) than a direct dryer (800+ degrees F).  Biosolids are combustible...

Komline's paddle dryer is a flow through design meaning you dry sludge on a continuous basis as biosolids are constantly fed to the dryer.  The Komline flow through dryer operates under steady state conditions optimizing the time to process material.  A batch dryer processes sludge on an intermittent basis: the machine is filled with a discrete amount of sludge, closed, heated, opened, discharged, and then refilled.  These many steps take time away from processing material.  Each time a batch dryer is opened, fugitive emissions are released.

The Komline design is safer, faster, and more efficient:

Safer:

• Conditions for explosions are minimized in the Komline design.  Explosions are most likely to occur when you have low moisture levels concurrent with high oxygen levels, a condition that occurs at the end of every batch cycle!  During the operation of the Komline dryer,  oxygen levels are very low as the oxygen is displaced by water vapor on a continuous basis.  The Komline dryer is closed and sealed  throughout the operation resulting in very low oxygen levels in the dryer.
  
• In an unlikely event an explosion occurs within the dryer, the energy is dispersed through a blow out panel (a large rupture disk) that is vented to the outdoors thus protecting both personnel and the machine from harm.  The panel is replaced by the operator and operation is resumed.  Blow out panels are standard features at Komline.  There are no known provisions for safely accommodating explosions in typical batch system.
• The boiler is isolated from the drying area unlike some of the skid mounted systems.  If you use hot oil as the thermal fluid, your fire marshall may also prefer to keep the boiler contained and separated from the dryer.
• Discharge temperatures.  Komline's scope of supply includes a cooling conveyor to reduce product temperature to below 120 degrees F before discharge to the customer.

Odor control:  The Komline paddle dryer is closed and sealed during the drying and discharge functions.  The low off gas volume of the Komline dryer is treated using a biofilter or an aeration basin.

Bad batches.  Your biosolids are Class "A" long before they exit the Komline dryer as confirmed by the temperature probes (thermocouples).  The control systems continuously monitor temperature and make adjustments to maintain dryness levels.  The concept of a "bad batch" is meaningless.

Why should I use a paddle dryer from Komline?

Komline dryers are simple to operate (you do not need additional personnel), reliable, and efficient. No internal parts to adjust or maintain.  Low volumes of off gas.  A choice of steam or hot oil for the heat source.  As Komline dryers are engineered to meet your loading, the size is custom for your application in a range of 30 to 4000 square feet of drying surface area.  As hot sludge creates a harsh environment, Komline dryers are manufactured from stainless steel to provide corrosion resistance and have hard faced paddles to resist abrasion.   With high torque capacity and no metal to metal contact , the paddle dryer is a sturdy, ASME code stamped vessel.

If safety, longevity, and efficiency are your criteria for a biosolids dryer, then Komline is the solution to your sludge management problem.

Access hatches Paragould, AK

Insulated underside Paragould, AK

How do I get more information? Call:

In Eastern Pennsylvania, call E&W Equipment at 610-363-8372 or 610-983-4008
Elsewhere call Komline Sanderson at  800-225-5457 or 908-234-1000

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Komline Sanderson Corporate headquarters, Peapack, NJ
 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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