Process and System for Drying and Heat Treating Materials

Abstract

This invention discloses systems and methods for conversion of high moisture waste materials to dry or low moisture products for recycle or reuse. The equipment systems comprise a gas turbine generator unit (preferred heat source), a dryer vessel and a processing unit, wherein the connection between the gas turbine and the dryer vessel directs substantially all the gas turbine exhaust into the dryer vessel and substantially precludes the introduction of air into the dryer vessel and wherein the processing unit forms the dried material from the dryer vessel into granules, pellets or other desired form for the final product. Optionally, the systems and methods further provide for processing ventilation air from manufacturing facilities to reduce emissions therefrom.

1 . A method of producing a soil builder/soil supplement product, the method comprising:
 operating a gas turbine to produce exhaust gases;   contacting the exhaust gases with paper manufacturing waste materials having a moisture content of at least about 30% by weight for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials.   
   
   
       2 . A method according to  claim 1 , wherein the paper manufacturing waste materials are in the form of a pulp. 
   
   
       3 . A method according to  claim 1 , wherein the gas turbine includes a gas turbine generator for producing electricity. 
   
   
       4 . A method according to  claim 1 , further comprising providing a dryer vessel for holding the paper manufacturing waste materials during treatment of the paper manufacturing waste materials, wherein outside air is substantially precluded from entering the dryer vessel. 
   
   
       5 . A method according to  claim 4 , wherein the dryer vessel is connected to the gas turbine so as to substantially preclude the introduction of outside air into the dryer vessel. 
   
   
       6 . A method according to  claim 4 , further comprising directing essentially 100% of the gas turbine exhaust gases into the dryer vessel. 
   
   
       7 . A method according to  claim 1 , further comprising contacting the exhaust gases of the gas turbine with the paper manufacturing waste materials to reduce the moisture content of the paper manufacturing wastes without significant oxidation of the paper manufacturing waste materials. 
   
   
       8 . A method according to  claim 1 , further comprising contacting the exhaust gases of the gas turbine with the paper manufacturing waste materials to reduce the moisture content of the paper manufacturing wastes without significant pyrolysis of the paper manufacturing waste materials. 
   
   
       9 . A method according to  claim 1 , wherein the gas turbine is operated to produce exhaust gases having a temperature of at least 700° F. 
   
   
       10 . A method according to  claim 1 , further comprising processing the paper manufacturing waste materials to form a compacted product after the moisture content of the paper manufacturing wastes has been reduced. 
   
   
       11 . A method according to  claim 10 , wherein the paper manufacturing waste materials are compacted through a granulating process. 
   
   
       12 . A method according to  claim 10 , wherein the paper manufacturing waste materials are compacted through a pelletizing process. 
   
   
       13 . A method according to  claim 1 , wherein the exhaust gases of the gas turbine are contacted with the paper manufacturing waste materials for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials to less than about 20% by weight. 
   
   
       14 . A method of making a soil builder/soil supplement product, the method comprising:
 operating a gas turbine to produce exhaust gases;   contacting the exhaust gases with paper manufacturing waste materials having a moisture content of at least about 30% by weight, in a dryer vessel for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials initially entering the dryer vessel, without significant oxidation of the paper manufacturing waste materials.   
   
   
       15 . A method according to  claim 14 , further comprising compacting the paper manufacturing waste materials to form a compacted product after the paper manufacturing waste materials have been contacted by the exhaust gases. 
   
   
       16 . A method according to  claim 15 , wherein the paper manufacturing waste materials are compacted through a granulating process. 
   
   
       17 . A method according to  claim 15 , wherein the paper manufacturing waste materials are compacted through a pelletizing process. 
   
   
       18 . A method according to  claim 14 , wherein the paper manufacturing waste materials initially entering the dryer vessel are in the form of a pulp. 
   
   
       19 . A method according to  claim 14 , wherein the gas turbine includes a gas turbine generator for producing electricity. 
   
   
       20 . A method according to  claim 14 , wherein outside air substantially precluded from entering the dryer vessel. 
   
   
       21 . A method according to  claim 20 , wherein the dryer vessel is connected to the gas turbine so as to substantially preclude the introduction of outside air into the dryer vessel. 
   
   
       22 . A method according to  claim 14 , further comprising directing essentially 100% of the gas turbine exhaust gases into the dryer vessel. 
   
   
       23 . A method according to  claim 14 , further comprising contacting the exhaust gases of the gas turbine with the paper manufacturing waste materials to reduce the moisture content of the paper manufacturing wastes without significant pyrolysis of the paper manufacturing waste materials. 
   
   
       24 . A method according to  claim 14 , wherein the gas turbine is operated to produce exhaust gases having a temperature of at least 700° F. 
   
   
       25 . A method according to  claim 14 , further comprising contacting the exhaust gases with paper manufacturing waste materials for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials to less than about 20% by weight.