Heated Roller Mill for Sludge Drying and Granulation
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Solution Overview
Problem
Current methods for drying high-moisture materials like sludge and viscous substances are energy-intensive and inefficient, requiring significant kinetic and heat energy consumption, and struggle with separating hard foreign matters from soft materials.
Innovation Solution
A composite granulator system utilizing heated roller mills with multiple layers of vertically arranged roller shafts, featuring swivel joints for various heating sources, a flexible stripping frame for foreign matter separation, and an automatic control system for optimized energy use, which efficiently dries and granulates materials into hollow, irregular shapes with minimal energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If traditional drying methods are used for high-moisture materials, then drying capacity is achieved, but energy consumption is excessive
Solution Approach 1:
The drying system is divided into multiple independent heating zones with separate roller shafts, each capable of operating autonomously. This segmentation allows optimized energy distribution to different zones based on moisture content requirements, reducing overall energy consumption while maintaining drying capacity.
Solution Approach 2:
The invention transitions from conventional surface drying to three-dimensional internal drying by introducing heated roller shafts that penetrate into the material bulk. This dimensional change enables direct heat transfer to the core of high-moisture materials, dramatically improving drying efficiency while reducing energy requirements.
2Use of energy by moving object
If conventional granulation methods are used, then material processing is achieved, but kinetic energy consumption is high
Solution Approach 1:
The invention replaces high-energy mechanical impact granulation with a thermal-field-assisted granulation process. Heated roller shafts soften materials in place, reducing the kinetic energy required for granulation while maintaining or improving granulation capacity through controlled thermal softening and gentle compression.
3Speed
If intensive processing methods are used, then processing speed is improved, but equipment wear increases
Solution Approach 1:
The system replaces mechanical cutting and crushing operations with thermal softening and controlled deformation processes. Heated roller shafts gradually soften materials to facilitate flow and shaping, eliminating high-stress mechanical contacts that cause equipment wear while maintaining high processing speeds.
4Device complexity
If simple heating methods are used, then equipment complexity is reduced, but drying efficiency is insufficient
Solution Approach 1:
The invention introduces controllable thermal parameters (temperature, heating rate, residence time) to optimize drying efficiency. By precisely adjusting these parameters across different heating zones, the system achieves high drying efficiency without requiring complex equipment structures, relying instead on intelligent parameter management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces energy consumption and prolongs equipment life by maximizing moisture evaporation, effectively separating hard foreign matters, and transforming material characteristics into advantageous conditions for efficient drying, resulting in a simple, energy-saving, and wear-free process.
Implementation Method 1
the heating supply system comprises swivel joints 04 disposed on the roller shafts 06 of each layer of roller mills, which are matched with the air outlet 03 and the air inlet 12 to provide three kinds of heating supply forms, respectively steam, heat transfer oil and a hot gas; the steam and the heat transfer oil serve as indirect heat-exchanging heat sources, and the hot gas serves as a direct heat-exchanging heat source
Implementation Method 2
capable of directly quenching and drying wet and viscous materials such as cake materials, creamy materials, slurry materials and pasty materials into irregular monomer granules approximately hollowed out with minimum kinetic energy and heat consumption
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A combination pelletizer, comprising a temporary feed storage bin (1), a multi-layer multi-group rolling machine, a box body (11) for installing the rolling machine, and a support frame (16); and each group of rolling machines is equipped with a swivel joint (4), a cleaning blade (5), a corresponding transmission system, a striker plate (7) and a guide plate. The pelletizer has a simple structure, and transforms a wet material into non-sticky dry particles, thus improving a material drying efficiency.