Technical Snapshot
| Material | Metal Sludge |
| Input Moisture | ~70% |
| Final Moisture | ~10% |
| Capacity | 70 kg/hr |
| Heating Source | Existing Plant Flue Gas |
| Dryer Type | Customized BELTOTHERM Belt Dryer |
Problem
- The wire processing plant generated around 70 kg/hr of abrasive metal sludge at approximately 70% moisture.
- Previous paddle dryer and other drying attempts failed due to severe wear, sludge sticking, and transfer/discharge problems.
- External disposal continued, creating recurring operating cost and maintenance burden.
Proposed Solution
- Gem Drytech engineered a customized BELTOTHERM belt dryer specifically for abrasive sludge.
- The design reduced internal mechanical contact to minimize wear and improved sludge layering for smooth transfer.
- The system directly utilized existing plant flue gas, avoiding additional fuel requirement while maintaining continuous operation.
Result
- Moisture was reduced from about 70% to around 10%.
- Abrasion-related failures were eliminated.
- Material handling became smoother and more consistent through drying and discharge.
- Sludge volume and disposal cost were reduced, with zero additional fuel cost due to flue-gas integration.
Conclusion
When abrasion and transfer problems make agitation-based dryers unsuitable, a properly engineered belt dryer with controlled airflow and reduced mechanical contact can provide a more reliable long-term solution.
Applicability
Well suited to abrasive sludge streams, high-density residues, and applications where mechanical wear has already caused dryer failures.
