Chemical & Processing
Oil & Gas
Pharma Biotech
Infrastructure & Design

Addressing Waste Disposal Issues with Turbo Spin Flash Drying System
Ultra Drytech Engineering Projects Pvt Ltd is a technically acclaimed pioneering organisation; engaged in the design, manufacture and export of specialised, custom-made, world class Thermal Processing Equipment, state of the art Specialised Drying and Calcining Systems and Total Turnkey Project Solutions. Under the dynamic leadership of its CMD Sanjive Prasad, UDEP has created path breaking technological revolutions by introducing highly advanced Rotary & Turbo Spin Calciners, Turbo Spin Flash Dryers & State of the Art Turnkey Projects.

In one of their Plants situated in the south of India, the Client, who is a World leader in Spice Oleoresins, and recognised as a premium source for Dehydrated Green Pepper, mustard seed powder and a host of spice powder varieties, was involved in the manufacture of mustard oil, from mustard seeds.

For the purpose of oil extraction, during the course of processing mustard seeds, in the final step of Filtration, a large amount of mustard residue was being generated after the actual oil had been removed. The wet sludge; that came out of the filter press, was a disposable product containing approximately 70 per cent of water.

This wet sludge needed to be disposed off. Being a biological product its intrinsic nature was such that this wet sludge would begin to decay within no time; causing a tremendously foul odour to be emitted. This further created major disposal problems as well as environmental issues. The practice that was followed by the client, for the disposal of this wet sludge was physical transportation and dumping of the same. The wet sludge was being loaded on to trucks which would travel almost 200-250 km. to the disposal areas (far away from inhabited areas) where the wet sludge would be dumped.

Considering that almost 30 tonnes of wet sludge was being produced per day, a minimum of three trucks per day, were required to collect the wet sludge. These were manually loaded with the sludge, which was then transported to the dumping ground and thus disposed. The odours generated, owing to the fast decaying action of the wet sludge, posed a severe challenge during the actual loading and transportation of the same; apart from huge costs involved, with regard to the transportation and disposal of large quantities of material on a day to day basis.

The Challenge
We, Ultra Drytech Engineering Projects Pvt Ltd (UDEP), were approached by the client, to propose an extremely energyefficient methodology for drying the product so that the dry product, in the absence of moisture, would not decay and disposal and environmental issues could be resolved cost-effectively. Considering that the dry product was basically mustard residues, that were full of proteins, one possibility being surveyed was also to somehow retrieve the protein rich residue, in order to use it as animal feed apart from various other profitable options.

The challenges posed by the wet sludge being discharged from the Filter Press were manifold:
• It Contained approximately 70 per cent moisture content.
• The material was extremely pasty and sticky in nature.
• It had an inherent nature that led to decay, within a very short period of time.
• Due to the decaying proper ty of the material tremendously foul odours were being emitted.
• Cost effective disposal of this wet sludge along with addressing all environmental issues was yet another concern.

The Solution provided by Ultra Drytech Engineering Projects Pvt Ltd:
When approached by the client thus, UDEP believed that from the variety of energy-efficient, state of the art, Drying systems designed and manufactured under its umbrella; one of its very recent innovations at the time, namely, the Turbo Spin Flash Drying System (TSFD), would be best suited for this application. However, it was important to validate this by means of Pilot Plant trials.

Considering that the clientĘs factory was situated in the hills of Kerala and UDEPĘs non-transportable Pilot Plant was situated at its factory premises on the outskirts of Mumbai; yet another challenge was to undertake pilot plant runs, without allowing the material to decay or degrade.

After much discussion, it was decided to air-freight the material within proper procedural parameters. This being done, the material was immediately taken to the Pilot Plant at the factory premises of UDEP.

Extremely successful pilot plant trials were conducted in the presence of the clientĘs technical personnel, on the basis of which, the order was placed and subsequently executed by UDEP.

The TURBO SPIN FLASH DRYING SYSTEM (TSFD) designed for this application was of 1000 Kgs/hr water evaporation capacity, giving an output of approximately 500 Kgs/hr.

The hot air generator system was designed to use a burner system based on bio-gas firing, thus ensuring that the bio-gas generated from the clientĘs own Effluent Treatment Plant was utilized for the Drying Process; thereby ensuring maximum energy recycling and optimum energy utilisation.

This TSFD, supplied by UDEP is in operation till date, and has had an extremely efficient track record.

Benefits accruing to the client, from UDEPĘs technologically advanced, environment-friendly, cost-effective solution:

1. A product which was creating tremendous disposal issues and environmental concerns, was now being processed in-house without any associated SHE (Safety, Health, Environment) problems.
2. Due to the uncontaminated methodology of drying of the wet sludge by UDEPĘs TSFD; the hitherto waste product itself became a value-added product; and hence became extremely saleable and capable of profit generation.
3. Whereas earlier the disposal of the wet sludge itself involved sizeable expense on a per day basis, after implementation of UDEPĘs drying solution; disposal was completely dispensed with and the recovered dried product itself became premium with respect to value and quality.
4. Wet sludge handling required a tremendous amount of labour and space; both of which were eliminated by UDEPĘs TSFD.

5. UDEP has pioneered the TSFD within the country and abroad. The TSFD is known to be extremely energy efficient, reducing up to 60 per cent energy consumption as compared to conventional Drying systems. In the clientĘs case, not only was this benefit made available, but also through the application of UDEPĘs advanced technology and innovative design approach, the internally generated bio-gas energy was harnessed; adding to further value addition as also addressing all environmental issues; making it a Zero Discharge Plant!
6. The material in question was extremely tricky as it was pasty, was producing foul odour and was decaying in an extremely short time. Conventional Dryers would not be able to address this problem. UDEPĘs TSFD was able to address this issue due to its advanced state of the art technological application and design; that of immediately dispersing wet sludge, into hot spinning air, to enable efficient drying, mesh sizing and conveying. All three processes take place instantaneouslyĘ with a retention time of approximately only a second. This Author Details Sanjive Prasad B. Tech, IIT Bombay; MS, Clemson University, USA CMD, Ultra Drytech Engineering Projects Pvt Ltd Email: info@ultraprojects.in instantaneous drying overcame all the negative factors associated with the wet sludge; as mentioned earlier.
7. UDEPĘs TSFD also ensured, in this case that since the sludge was being dried with the intention of ultimately being sold as an edible animal feed, the dried sludge remained uncontaminated and fit for consumption.
8. UDEPĘs TSFD is a self-operating system, requiring minimal attention while operating at capacity. In addition all operations are automated and require minimum space.
9. The TSFD is under negative pressure, hence there is no dusting, therefore no wastage. The process is free from environmental hazards.

Crucial Operational Challenges met by UDEPĘs path-breaking Drying Solution and fundamental implications on energy, environment, profitability, efficiency and productivity, for the client:

• UDEPĘs solution to the clientĘs problem addressed all three facets namely people, planet and profits thus subscribing 100 per cent to the fundamental principles of Triple bottom line.
• By cutting off completely the cost of disposal and by converting the hitherto disposed waste product into value added, profit generating item, UDEPĘs solution led to enhanced market competitiveness for the client.
• Without doubt, the multi-faceted advanced technological solution provided by UDEP, contributed to the Operational excellence of the plant in question as also for the organisation at large.
• Resource optimisation is an essential hallmark of UDEPĘs Drying systems and solutions and in the case of the client, recycling and harnessing of internally generated bio-gas is obvious proof of this.
• Drying solution and innovative use of recycling energy for process operations led to enhanced efficiencies in all respects.
• UDEPĘs TSFD are distinguished by the fact that they have the capacity to optimise energy utilisation and minimise energy utilisation and losses as compared to conventional drying systems.
• UDEPĘs ground-breaking solution to the clientĘs problem helped save energy, aided recycling of energy and led to zero waste!
• A Zero waste Process technology is a major environmental break-through due to tremendous reduction in carbon and water footprint.

Cost effectiveness of the clientĘs plant operations were improved multi-fold due to a complete cut-down of waste disposal costs, total elimination of waste and most importantly, due to the generation of value added products without utilising any external energy source!