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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-SCRUTM 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-SCRUTM 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-SCRUTM 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.

Tri‐Lakes Biosolids Regional Drying FacilityBranson, MO
Location: Branson, MO
End User: Tri‐Lakes/ Taney County Process Capacity: 4,000 Wet lbs./hr. Fuel Source: Natural Gas Cake Dryness: 20% DS Bio‐Scru® Model: HSD‐30D‐28‐6 Heating Fluid: Thermal Oil Sludge Feed: Seepex Progressive Cavity Pump Start‐up April, 2015 Beneficial Reuse: End Product is to be given away or sold in bulk for agricultural use.
Project Overview: The Tri‐Lakes Biosolids Regional Drying Facility brings in material from three WWTP’s in the Branson area. Three Centrifuges and the Bio‐Scru® were the main components of the facility. Each of the three feeder plants installed a centrifuge with one of the plants also installing the dryer. Millions of dollars in construction cost were saved by placing all equipment in existing buildings that previously held gravity‐belt thickeners as well as the Truck Load‐Out Building. Biosolids from the outside two treatment plants are trucked to the central facility after dewatering and are then processed further using the dryer to achieve Class A Biosolids status. Project Benefit: Tri‐Lakes will take the biosolids at 19‐21% DS and process them at a rate of 4,000 wet lbs./hr. using the Bio‐Scru® Model HSD‐30D‐28‐6 to process the material to ≥90% DS. The Company will then have the ability to give away or sell the end material for local agriculture use rather than pay for transportation and landfill tipping fees.
Albertville WWTP, Albertville, AL
BCR Installation (Albertville)
  • TPO Story
  • Owner: Albertville Municipal Utility Board
  • Dryer Size: IC 5400 Bio Scru®
  • Completion Date: 2013
Wilsonville WWTP, Wilsonville, OR
  • Owner: City of Wilsonville, OR
  • Dryer Size: IC 3600 Bio Scru®
  • Completion Date: 2013
Wilmington WWTP, Wilmington, DE
  • Owner: Jacobs Engineering
  • Dryer Size: IC 12,000 Bio Scru®
  • Completion Date: 2015
Magnolia WWTP, Magnolia, AR
  • Owner: City of Magnolia, AR
  • Dryer Size: IC 3600 Bio Scru®
  • Completion Date: 2013
Foley WWTP, Foley, AL
  • Owner: Riviera Utilities
  • Dryer Size: IC 2500 Bio Scru®
  • Completion Date: 2015
Ft. Meade WWTP, Ft. Meade, MD
  • Owner: American Water
  • Dryer Size: IC 3600 Bio Scru®
  • Completion Date: 2013
Clear-Flow Tech Recycling Center, Lyndhurst, NY
  • Owner: Clear Flo Technologies
  • Dryer Size: IC 10,000XL (Total of 3)
  • Completion Date: 2013
Rio Dell WWTP, Rio Dell, CA
  • Owner: City of Rio Dell, CA
  • Dryer Size: IC 800 Bio Scru®
  • Completion Date: 2012
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