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Henan Hongke Heavy Machinery Co., Ltd. recently completed the design, manufacture, installation, and commissioning of a 1.2 m × 10 m chemical sludge dryer production line for a chemical-industry client in Hubei Province, China. This case study outlines the project background, technical solution, equipment specifications, and final results — demonstrating how Henan Hongke Machinery delivers reliable sludge drying systems tailored to complex industrial requirements.
1. Project Background
1.1 Client Overview
The client operates a mid-scale chemical manufacturing facility in Hubei Province. As a by-product of its production processes, the plant generates a significant volume of wet chemical sludge with a moisture content of approximately 75–80 %. Prior to engaging Henan Hongke Machinery, the client relied on natural air-drying and third-party disposal — methods that were slow, land-intensive, and increasingly expensive due to tightening environmental regulations.
1.2 The Challenge
High initial moisture content (75–80 %): Chemical sludge is viscous, cohesive, and difficult to handle.
Strict discharge targets: Local environmental standards required the dried product to reach a moisture content of ≤ 15 % for safe landfill, incineration, or reuse.
Limited footprint: The available installation area within the existing plant was constrained.
Continuous operation: The client needed a system capable of running 24 hours a day with minimal downtime.
The client therefore sought a robust, energy-efficient industrial sludge dryer that could handle the physical and chemical properties of their specific waste stream.
2. Solution: 1.2 m × 10 m Rotary Sludge Dryer
After a detailed site survey, material testing, and thermal-drying analysis, the engineering team at Henan Hongke Heavy Machinery proposed a single-cylinder rotary dryer with the following design highlights:
| Parameter | Specification |
|---|---|
| Model | Φ1.2 m × 10 m rotary dryer |
| Drum diameter | 1,200 mm |
| Drum length | 10,000 mm |
| Capacity | 3–5 t/h (depending on feed moisture) |
| Initial moisture | 75–80 % |
| Final moisture | ≤ 15 % |
| Heat source | Coal-fired hot-air furnace (customizable) |
| Rotary speed | 3–8 r/min (variable-frequency drive) |
| Power | ~22 kW (main motor) |
| Installation angle | 3–5° |
2.1 Why a Rotary Dryer?
Rotary dryers are widely recognized as the most versatile and proven technology for high-moisture industrial sludge. Compared with paddle dryers, belt dryers, and fluidized-bed systems, a rotary dryer offers:
Superior handling of sticky, cohesive materials — the tumbling action inside the rotating drum prevents material from adhering to the walls.
Scalable throughput — drum dimensions can be adjusted to match production demand.
Simple, rugged construction — lower maintenance cost and longer service life.
Flexible heat-source options — coal, natural gas, biomass, or waste heat can all be used.
2.2 Key Design Features for Chemical Sludge
Because chemical sludge can contain corrosive or adhesive substances, Henan Hongke Machinery incorporated several design upgrades:
1.Anti-stick internal flights (lifting boards): Specially shaped lifting plates ensure the sludge is continuously lifted and showered through the hot-air stream, maximising heat transfer while preventing caking.
2.Corrosion-resistant drum material: The inner cylinder and key contact parts were fabricated from wear-resistant manganese steel with anti-corrosion treatment, extending the service life in a chemically aggressive environment.
3.Sealed feed and discharge ends: To prevent fugitive dust and odour emissions, both the feed chute and discharge hood incorporate multi-stage sealing with labyrinth and rubber-seal structures.
4.Variable-frequency drive (VFD): The drum speed is adjustable via an inverter, allowing the operator to fine-tune residence time based on real-time moisture readings.
5.Integrated dust collection: A cyclone dust collector + bag filter system was installed downstream to ensure particulate emissions comply with national and local environmental limits.
3. Production Line Configuration
The complete chemical sludge drying system delivered to the Hubei site includes the following components:
| No. | Equipment | Function |
|---|---|---|
| 1 | Belt conveyor (feed) | Transports wet sludge from storage yard to dryer inlet |
| 2 | Screw feeder | Controls and regulates feed rate into the rotary drum |
| 3 | Φ1.2 × 10 m rotary dryer | Core drying unit |
| 4 | Coal-fired hot-air furnace | Generates hot gas at 600–800 °C |
| 5 | Induced-draft fan | Maintains negative pressure inside the drum |
| 6 | Cyclone dust collector | Primary particulate separation |
| 7 | Bag filter (pulse-jet) | Secondary fine-dust filtration |
| 8 | Discharge conveyor | Transports dried sludge to stockpile or downstream process |
| 9 | PLC control cabinet | Automated temperature, speed, and feed monitoring |
The entire line is controlled from a centralised PLC panel, giving the operator real-time visibility over exhaust temperature, drum speed, feed rate, and motor current.
4. Installation and Commissioning
4.1 Project Timeline
| Phase | Duration |
|---|---|
| Design & engineering | 2 weeks |
| Manufacturing | 5 weeks |
| Shipping to Hubei | 1 week |
| On-site installation | 3 weeks |
| Cold commissioning & hot test | 1 week |
| Total | ~12 weeks |
Henan Hongke Machinery dispatched a senior installation team to the Hubei site to oversee foundation alignment, drum assembly, furnace connection, ductwork, and electrical wiring. All work was completed within the agreed schedule.
4.2 Commissioning Results
During the 72-hour continuous hot test, the production line achieved the following performance:
| Metric | Guaranteed | Actual |
|---|---|---|
| Feed moisture | 75–80 % | 78 % (average) |
| Discharge moisture | ≤ 15 % | 12.3 % (average) |
| Throughput | ≥ 3 t/h | 3.8 t/h |
| Exhaust dust concentration | ≤ 30 mg/m³ | 18 mg/m³ |
| Noise at 1 m | ≤ 85 dB(A) | 79 dB(A) |
All parameters met or exceeded contractual guarantees. The client formally accepted the production line and it has been in continuous commercial operation since commissioning.
5. Project Results and Client Feedback
Since the sludge drying system went into operation, the client has reported:
Over 60 % reduction in sludge disposal costs — dried sludge can now be sent directly to co-processing facilities or landfilled at a fraction of the cost of wet-sludge disposal.
Elimination of open-air drying yards — freeing up valuable land within the plant boundary.
Stable compliance with environmental discharge limits — the bag-filter system consistently keeps particulate emissions well below the regulatory threshold.
Minimal operator intervention — the PLC-based control system allows one operator to manage the entire line.
The client's Plant Manager commented:
"Henan Hongke Machinery delivered exactly what they promised — on time, on spec, and on budget. The dryer runs smoothly around the clock, and the dried sludge now meets the standards for further processing. We are very satisfied with the result."
6. Why Choose Henan Hongke Heavy Machinery?
Henan Hongke Heavy Machinery Co., Ltd. is a professional manufacturer of industrial drying and calcining equipment, serving clients across the chemical, mining, metallurgy, environmental, and building-materials sectors. When you partner with Henan Hongke Machinery, you benefit from:
Tailored engineering — every drying system is custom-designed based on your material properties, moisture targets, and site conditions.
In-house manufacturing — all core components are fabricated in our own facility under strict quality control.
Turnkey delivery — from design to commissioning, we manage the entire project lifecycle.
Responsive after-sales support — spare parts, remote diagnostics, and on-site service are available throughout the equipment's service life.
Proven track record — hundreds of successful drying-system installations across China and in overseas markets including Southeast Asia, Africa, the Middle East, and South America.
7. Related Products
Henan Hongke Machinery manufactures a full range of rotary dryers for various industrial applications:
Biomass rotary dryer — for wood chips, sawdust, and agricultural residues
Sand rotary dryer — for river sand, manufactured sand, and mineral sand
Mineral concentrate dryer — for iron ore concentrate, copper concentrate, and more
Limestone rotary dryer — for limestone, gypsum, and calcium carbonate
Sludge rotary dryer — for municipal, chemical, and industrial sludge
Contact us to discuss your project requirements or request a free quotation.
Frequently Asked Questions (FAQ)
Q1: What moisture content can a 1.2 × 10 m sludge dryer achieve?
With proper feed control and heat-source configuration, a Φ1.2 m × 10 m rotary sludge dryer from Henan Hongke Machinery can typically reduce moisture from 75–80 % down to 10–15 % in a single pass.
Q2: What heat sources are available for the sludge dryer?
Henan Hongke Machinery offers multiple heat-source options including coal-fired furnaces, natural-gas burners, biomass furnaces, diesel burners, and waste-heat recovery systems. The choice depends on local fuel availability, cost, and environmental regulations.
Q3: How much space is required for a 1.2 × 10 m sludge drying line?
The rotary dryer itself occupies approximately 12 m × 4 m. Including the furnace, conveyors, dust collector, and control room, a total footprint of roughly 25 m × 10 m is recommended. Exact dimensions are confirmed during the detailed engineering phase.
Q4: Is the sludge dryer environmentally compliant?
Yes. Every sludge drying system we supply includes an integrated dust-collection package (cyclone + bag filter) designed to meet China's national emission standards. We can also design systems to meet EU, US EPA, or other international standards upon request.
Q5: How long does it take to manufacture and deliver a sludge dryer?
A typical 1.2 × 10 m rotary dryer system requires approximately 7–12 weeks from order confirmation to factory delivery, depending on configuration complexity and current production schedule.
Request a Free Quote
Looking for a reliable chemical sludge dryer or a complete sludge drying production line? Henan Hongke Heavy Machinery Co., Ltd. is ready to help. Share your material data (type, moisture content, throughput target), and our engineering team will prepare a tailored proposal — typically within 48 hours.
