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BIO-SCRU® Biosolids Dryer System

As the challenges of disposing of Class B biosolids become more daunting, forward-thinking treatment plants are searching for cost effective solutions that will help their communities become EPA-compliant. For many reasons the disposal of Class B has become a problem. Transportation cost and tipping fees are soaring, in some instances landfills are, without notice, refusing to accept further deliveries of Class B biosolids.

 

Our Patented BIO-SCRU® Technology makes possible energy-efficient, automated, continuous drying of biosolids and production of a Class A Biosolid. Under 40 CFR, part 503 the United States Environmental Protection Agency has published regulations for technologies to further reduce pathogens in Municipal biosolids and to reach Class A biosolids that are safe for the environment. Municipalities now have new choices in the safe disposal of biosolids as opposed to the regulations addressing Class B biosolids.

 

BCR has designed the IC series biosolids dehydration system with design criteria to address the needs of the small to medium size municipality and to keep operator attention and maintenance cost to a minimum. The BCR IC Series BIO-SCRU® sludge dryer system is an automated continuous processor. All operating parameters are under the control of the PLC system and the automated process operates continuously, all with minimal operator attention.

 

The BIO-SCRU® can dry sludge’s other systems can’t. The BIO-SCRU® is effective in drying a wide variety of treated municipal biosolids. The unique design of the BIO-SCRU® includes features to continuously remove buildup from the heat transfer surfaces. The system also eliminates any large clumps from building and passing through the system via a series of cutters that break up the clumps and homogenize the particle size at each stage of the rotor.

 

The BIO-SCRU® continuously produces 90%+ dry product with a variety of sludge consistencies due to three primary control factors. With the ability to control the feed rate into the dryer, the residence time in the dryer and the temperature of the dryer, the IC-Series BIO-SCRU® continually produces a dry product of consistent solids content.

 

The heat energy for drying, is indirect, thermal fluid is circulated through the rotor, fliting and the outer jacket of the drying chamber, in a closed loop path. The drying process operates under a slight negative pressure in a sealed chamber. Feed is extruded into the dryer from the feed hopper. A lock box and cooling screw maintain the seal at the discharge. A integrated scrubber/condenser removes the vaporized water from the system and captures any particulate.

 

All this adds up to a better, cleaner, safer, and more efficient choice for your treatment plant. To find out more about the BIO-SCRU® please download our brochure and contact us for additional information.

Bio-Scru Design

At the heart of the BCR BIO-SCRU® sludge drying system is proven HOLO-SCRU® screw type heat exchanger technology. Screw type heat exchangers have been used in bulk processing for the agriculture, chemical, construction, and food industries for over 70 years. This versatile system is capable of processing everything from Apples to Zinc. Both reliable and customizable, HOLO-SCRU® equipment is the world standard in indirect screw type heat exchange equipment.

Technology that Works

Step 1 – Feed Hopper

The feed hopper includes twin, intermeshed paddle mixers to keep the biosolids homogenized and break up bridging. This feature insures a consistent feed rate and material uniformity. A screw auger located in the bottom of the feed hopper conveys the biosolids to the dryer.

 

Step 2 – Thermal Fluid Heater

The thermal oil heater uses PLC control for optimal heating efficiency. The heating can be accomplished with a variety of energy sources including; waste heat, solar thermal, bio-gas, natural gas, propane, #2 fuel oil, diesel, coal, or electricity.

 

Step 3 – BIO-SCRU Dryer

The dryer chamber includes twin, intermeshed HOLO-SCRU® rotors. In the drying chamber, biosolids are heated under slight negative pressure in a sealed, anaerobic environment. The dehydrating heat is indirect. Thermal fluid is circulated throughout the HOLO-SCRU® rotor and outer jacket of the drying chamber.

 

Step 4 – Scrubber/Condenser

The condenser system provides the continuous removal of moisture evaporating from the biosolids. The process captures particulate and condenses the evaporated water.

 

Step 5 – Cooling Screw

The water-cooled screw rotor and jacketed housing combine to cool the dried biosolids for safe handling.

Optimum Volumetric Reduction and Efficiency

Through proprietary design, the BIO-SCRU® dryer reduces biosolid volume by decreasing capacity, or pitch, at each stage of the rotor. This increases loading capacity and utilizes the maximum amount of heat transfer surface A through the length of the dryer. Biosolids are accumulated between each stage (A) of the rotor in no-pitch zones (B) allowing the mixing blades to homogenize particle size. The rotor flights use wipers to remove material adhering to the opposing screw. The self-clearing design of the rotors insures that heat transfer surfaces remain free of build-up.

Why IC Series BIO-SCRU Dryers are the Clear Choice

BIO-SCRU® dryers are built in accordance with ASME code

Available in a variety of sizes

Each unit is custom-built by Therma-Flite, a world leader in bulk processing and heat exchange equipment

Self-clearing, intermeshing dual rotors provide efficient agitation, breakage and heat transfer

An anaerobic drying chamber, with continuous evaporation and odor control, prevents combustion and ensures safety

The entire process is PLC-controlled to guarantee Class A compliance, maximizing process automation while minimizing maintenance and operational cost.