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Applications
for
the
PulverDryer
System
The PulverDryer System is more than a
materials reduction machine; it's a self-contained materials processing
product, which will save you time and money. It pulverizes, blends,
mixes, extracts moisture and homogenizes materials instantly!
The PulverDryer System is versatile, cost
effective, efficient and durable making it the ideal tool for a broad
range of de-watering and pulverizing applications in a variety of
global markets.
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Materials able
to be processed by the PulverDryerTM include:
Potential
Applications for the PulverDryer System™ to be tested:
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- Removal of old municipal lagoons
- Algae
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Soft Rock
Minerals
 The
PulverDryer™ System excels
in
pulverizing soft rock minerals into a fine particle size. Limestone,
gypsum, phosphate rock, zeolite, clay, and other soft-rock minerals are
all processed into fine, dry powders. Generally, the PulverDryer™
pulverizes soft rock minerals to particle sizes of less than 75 microns
(below 200 mesh) at production rates of 5-7 tons per hour. The energy
cost per hr/ton used by the PulverDryer™ to operate is less than
smaller horizontal ball mills that can not achieve the same fine
pulverization and particle size consistency or the supplemental drying
achieved by the PulverDryer technology. The PulverDryer System can be
used for pulverization of "solution grade" limestone, phosphate rock,
and/or gypsum. Solution grade fineness (less than 75 microns) is
necessary when soil amendments are distributed to crops through
irrigation systems. The PulverDryer is easily able to dry glacial clay
from initial moisture content of 10% down to 1% final moisture while
simultaneously pulverizing the material to sub-micron sizes.
Animal
Manures
The total volume of animal manure
(cow, hog, chicken, and horse) in the United States is approximately
130 times greater than that of human waste. Animal manure has a long
tradition of use as an effective fertilizer. However, with modern
intensive agricultural production, manure volumes can exceed the
capacity of nearby croplands to absorb the nutrients in the manure.
Numerous cases have been reported in the media of inappropriately
spread manure contaminating both surface and groundwater and seriously
affecting the environment and human health.
 The
PulverDryer System can
reduce
animal manures to a fine dry powder, which is virtually free of both
pathogens and offensive odors. In this dry state (approx. 10%
moisture), the odor is significantly reduced, and the manure can be
stored, efficiently transported, and sold as a fertilizer. The manure
can be blended, at the time of production, with a variety of other
minerals and chemicals for manufacture of custom fertilizers. Once
processed, the manure can also be easily applied to farmlands.
The key advantages of the PulverDryer™ System is
pathogen reduction and drying of both municipal and animal waste to 85%
solids.
The lower operating costs and small machine foot
print requirements of an average 400 sq feet . compared with
conventional hammer mill and rotary drum dryer systems is unmatched in
the industry.
A single stage
PulverDryer system is able to perform batch recycling to achieve
maximum dryness. The system comes with two cyclone product separators
and an in-feed hopper to control feed rate.
Conventional systems require significantly more
operating energy to dry manures compared to the PulverDryer™ System.
Dried manure and other biomass can have value as a
fuel source. PulverDryer and key engineering firms are now working on
methods to cleanly and cost effectively burn manure and generate
"green" power.
Paper Sludge
Sludge from paper making are generated in large
quantities throughout North America. Currently common sludge management
practices of land filling and land-application are under increased
environmental scrutiny and are increasingly more costly.
The PulverDryer™ can de-water sludge and enable
the separation of product and water or product in general such as paper
fiber from other paper components such as wall-board (sheet-rock).
The removal of moisture can also significantly
increases the fuel value of sludge and reduce the ash created during
combustion. PulverDryer engineers have designed turnkey solutions using
the PulverDryer™ System to recycle sludge from municipal waste to the
pulp and paper industry.
Coal
 About half of the electricity
generated in the United States comes from coal-fired power plants. In
all large power plants, coal is dried and pulverized in a ball mill to
under 75 microns (200 mesh) before being burned. The drier the coal,
the higher the value for burning. Coal's moisture content can vary
widely from 5 to 50 %. Recent testing by PulverDryer indicates that
bituminous coal can be dried from 15 % to 2 % final moisture content
and pulverized to a very small or a median diameter of less than 150
microns at a production rate of 5 or 7 tons per hour/per-unit. The
pulverization and moisture extraction energy consumption per hr/ton is
less than ball mills.
Unlike ball mills, the PulverDryer System creates
the energy to dry the coal: hence it is more efficient than competitive
systems. With the PulverDryer System, it is possible to increase the
value of low sulfur, high moisture grade coals, such as Power River
Basin Coal. PulverDryer engineers have conducted successful testing to
increase the BTU values of PRB Coal by extracting the moisture and
reducing the particle size of the material.
Bio
solids (Sewage Sludge)
 Sewage
sludge or "bio solids" are created at wastewater
treatment plants as sewage water is processed and purified. Currently
many municipalities are facing challenges to environmentally and
economically dispose of these solids. The PulverDryer™ System can
de-water bio solids to reduce their volume and the associated
transportation and disposal costs. The PulverDryer™ System is certified
to meet the US Environmental Protection Agency rules for the
destruction of pathogens including salmonella, e-coli, and fecal coli
forms. The dry powders produced by the PulverDryer™ System are suitable
for land application or for use as a fuel source where they can replace
fossil fuels. PulverDryer Engineers have conducted various BTU testing
on the dry powders in laboratory tests to verify this concept with
solid results. Additionally, as the PulverDryer can operate as a
"blender/homogenizer" of various materials, it is possible to dry and
resize the bio solids with moist coal and create a "blended" product of
50% coal and 50% bio solids that achieve optimum burning results with
maximum BTU's.
Gypsum
Wallboard
 Gypsum
wallboard
comprises about
10% of all the waste materials left over following
construction/renovations in North America.
When gypsum degrades in the low oxygen environment
of landfills, hydrogen sulfide is generated. This gas contributes to
both air and water pollution. As a result, government agencies are
looking to encourage recycling to keep drywall out of landfills.
Currently there are only a few specialized facilities for processing
waste drywall in North America. The PulverDryer System reduces drywall
to a powder that can be utilized as a soil amendment or recycled into
the production of new building materials. The powder produced from the
processing of drywall is compact, consistent in particle size, dry
(less than 10% moisture content) easily packaged or bulk loaded for
distribution.
Distiller
Grains
Distiller grains, a byproduct of the whiskey industry, have been used
as fodder for over 100 years. After the distillation process,
most all of the starches from the grains are removed, almost tripling
the nutrient value of the grain. The national supply of distiller
grains has increased significantly from the boom of the ethanol
industry. Drying the grains helps keep the shelf life of the
grain as well reduce the shipping cost by weight for water removed
increasing the value of the byproduct.
PulverDryer processing has proven to be a cost effective way of drying
the grains as compared to typical gas fired dryers. It's low
thermal drying produces a higher quality
product than conventional drying systems.
Wood
Waste
 In North America, wood waste,
unsuitable for timber or pulp can be a disposal problem for the
forestry industry. Wood waste can be efficiently burned and is a
renewable energy source; but wet wood or sawdust is often only
marginally economical. This is because 40% of the heat value in the
wood is used to dry the moisture in the wood product.
The PulverDryer System is an alternative to
traditional methods of drying small wood products, such as sawdust. The
PulverDryer combines both the pulverizing and drying operations in one
compact machine, thereby simplifying the process. Furthermore, the
system is tolerant of contaminants such as dirt and stones that can
cause sparking and fires in hammer mills.
The PulverDryer System can reduce sawdust from a
initial moisture content of 43% down to 15%, or less, while producing a
fine dry powder as an end product. The mechanical energy used by the
PulverDryer™ is less than any other conventional (heat) drying system.
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The food processing industry
produces millions of tons of wet (food waste) materials every business
day in the USA and the rest of the world. The food industry in
particular produces large amounts of by-products from both animal and
agricultural processing. Such companies typically manage these
materials utilizing pulverization and drying methods that involve
hammer mills, rotary drum dryers and spray dryers. PulverDryer has
proven to be a superior alternative to drying and resizing these
materials into forms that can create new products for marketing or
simply a more manageable and environmentally friendly method of
disposal. PulverDryer accomplishes this at a much lower cost per ton
then any of the other known methods. In many applications, users need
to dispose of animal bone residue in an economical and/or profitable
methods. PulverDryer resizes difficult animal bone configurations such
as hog bone, hog teeth, chicken and cow bone residue to a fine
particulate.
