Direct high temperature sludge energy recuperator transformer module

Abstract

Systems and processes for processing sludge and other natural waste are provided. In one example, the sludge or natural waste may be dried into a powder using high-temperature gas to absorb moisture from the sludge, causing the high-temperature gas to become an at least partially saturated gas. The at least partially saturated gas may pass through a scrubber before being heated in an air-heater and used in the moisture absorption process. The heat for the air-heater may be provided by a burner operable to burn the dried powder obtained from the sludge. The heated gas may be used to pre-heat the saturated gas and may be used to dry additional sludge.

What is claimed is: 
     
         1 . A system for processing dewatered sludge, the system comprising:
 at least one of a mill or grinder operable to:   receive high-temperature gas;   receive sludge; and   reduce a moisture content of the sludge by breaking the sludge into a dried powder in the presence of the high-temperature gas, wherein the high-temperature gas absorbs at least a portion of the moisture content of the sludge to form at least partially saturated gas;   a first separator operable to separate the dried powder from the at least partially saturated gas;   a first condenser operable to reduce a moisture content of the at least partially saturated gas by reducing a temperature of the at least partially saturated gas to form a reduced-temperature gas;   a heater operable to heat the reduced-temperature gas to form a heated gas;   a second separator operable to separate at least a portion of ash contained in the heated gas from the heated gas, wherein the second separator is further operable to direct a first portion of the heated gas to the at least one of the mill or grinder to be used as the high-temperature gas; and   an output system operable to discharge the ash and a second portion of the heated gas from the system.   
     
     
         2 . The system of  claim 1 , wherein the sludge comprises at least one of digested sludge, undigested sludge, fresh animal waste, aged animal waste, or agricultural food waste. 
     
     
         3 . The system of  claim 1 , wherein the heater comprises an air-heater jacket operable to receive the reduced-temperature gas from the first condenser, and wherein the air-heater jacket is further operable to cause the reduced-temperature gas to travel over at least a portion of a surface of the heater. 
     
     
         4 . The system of  claim 1 , wherein the heater comprises a burner operable to burn a mixture of ambient air and at least a portion of the dried powder. 
     
     
         5 . The system of  claim 4 , wherein the burner is further operable to burn a gas or oil. 
     
     
         6 . The system of  claim 4 , further comprising a hot wind box, wherein a portion of an output of the second separator is used to pre-heat the ambient air in the hot wind box. 
     
     
         7 . The system of  claim 1 , wherein the first condenser is operable to receive water at a first temperature, the water to be used to reduce the temperature of the at least partially saturated gas, and wherein the first condenser is further operable to output the water at a second temperature that is higher than the first temperature. 
     
     
         8 . The system of  claim 1 , wherein the first portion of the heated gas comprises a majority of the heated gas. 
     
     
         9 . The system of  claim 1 , wherein the output system comprises:
 a water-mist-cooling system operable to reduce a temperature of the second portion of the heated gas to form cooled gas;   a third separator operable to separate at least a portion of ash contained in the cooled gas from the cooled gas, wherein the third separator is further operable to discharge the ash separated from the cooled gas from the system;   a second condenser operable to reduce a moisture content of the cooled gas by reducing a temperature of the cooled gas to form a reduced moisture gas; and   a fan operable to discharge the reduced moisture gas from the system.   
     
     
         10 . The system of  claim 9  further comprising a sludge pre-heater, wherein an output of the second condenser is used to pre-heat the sludge in the sludge pre-heater. 
     
     
         11 . A system for processing dewatered sludge, the system comprising:
 at least one of a mill or grinder operable to:   receive high-temperature gas;   receive sludge; and   reduce a moisture content of the sludge by breaking the sludge into a dried powder in the presence of the high-temperature gas, wherein the high-temperature gas absorbs at least a portion of the moisture content of the sludge to form at least partially saturated gas;   a first separator operable to separate the dried powder from the at least partially saturated gas;   a condenser operable to reduce a moisture content of the at least partially saturated gas by reducing a temperature of the at least partially saturated gas to form a reduced-temperature gas;   a pre-heater operable to pre-heat the reduced-temperature gas to form pre-heated gas;   a heater operable to heat the pre-heated gas to form heated gas;   a second separator operable to separate at least a portion of ash contained in the heated gas from the heated gas; and   a first tapping duct operable to recirculate at least a portion of the heated gas by directing the at least a portion of the heated gas to the at least one of the mill or grinder, wherein the at least a portion of the heated gas is to be used in the at least one of the mill or grinder as the high-temperature gas.   
     
     
         12 . The system of  claim 11 , wherein the sludge comprises at least one of digested sludge, undigested sludge, fresh animal waste, aged animal waste, or agricultural food waste. 
     
     
         13 . The system of  claim 11 , wherein the heater comprises an air-heater jacket operable to receive the pre-heated gas from the pre-heater, and wherein the air-heater jacket is further operable to cause the pre-heated gas to travel over at least a portion of a surface of the heater. 
     
     
         14 . The system of  claim 11 , wherein the first tapping duct is operable to recirculate a majority of the heated gas received at the tapping duct. 
     
     
         15 . The system of  claim 11 , wherein the pre-heater is operable to pre-heat the reduced-temperature gas using at least a portion of the heated gas that is not directed to the at least one of the mill or grinder by the tapping duct. 
     
     
         16 . The system of  claim 15 , wherein the at least a portion of the heated gas that is not directed to the at least one of the mill or grinder is removed from the system. 
     
     
         17 . The system of  claim 11 , wherein the heater comprises a burner operable to burn a mixture of ambient air and at least a portion of the dried powder. 
     
     
         18 . The system of  claim 17 , wherein the burner is further operable to burn a gas or oil. 
     
     
         19 . The system of  claim 17 , further comprising a mixing valve operable to combine the mixture of ambient air and the at least a portion of the dried powder with a portion of the heated gas not directed to the at least one of the mill or grinder by the first tapping duct. 
     
     
         20 . The system of  claim 19 , further comprising a second tapping duct operable to direct, to the mixing valve, the portion of the heated gas not directed to the at least one of the mill or grinder. 
     
     
         21 . A method for processing dewatered sludge, the method comprising:
 reducing, in at least one of a mill or grinder, a moisture content of a dewatered sludge by breaking the dewatered sludge into a dried powder in the presence of high-temperature gas, wherein the high-temperature gas absorbs at least a portion of the moisture content of the dewatered sludge to form at least partially saturated gas;   separating the dried powder from the at least partially saturated gas;   reducing a moisture content of the at least partially saturated gas by reducing a temperature of the at least partially saturated gas to form a reduced-temperature gas;   pre-heating the reduced-temperature gas to form pre-heated gas;   heating the pre-heated heated gas to form heated gas;   separating at least a portion of ash contained in the heated gas from the heated gas; and   recirculating at least a portion of the heated gas by directing the at least a portion of the heated gas to the at least one of the mill or grinder, wherein the at least a portion of the heated gas is to be used in the at least one of the mill or grinder as the high-temperature gas.   
     
     
         22 . The method of  claim 21 , wherein a majority of the heated gas is recirculated to the at least one of the mill or grinder. 
     
     
         23 . The method of  claim 21 , wherein separating the dried powder from the at least partially saturated gas is performed using a first cyclone separator, and wherein separating at least a portion of the ash contained in the heated gas from the heated gas is performed using a second cyclone separator. 
     
     
         24 . The method of  claim 21 , wherein heating the pre-heated heated gas is performed using a burner operable to burn a mixture of ambient air and at least a portion of the dried powder. 
     
     
         25 . The method of  claim 24 , further comprising combining the mixture of ambient air and the at least a portion of the dried powder with a portion of the heated gas not directed to the at least one of the mill or grinder. 
     
     
         26 . The method of  claim 24 , wherein a weight of the ambient air is equal to a weight of the portion of the heated gas that is not directed to the at least one of the mill or grinder. 
     
     
         27 . The method of  claim 21 , wherein heating the pre-heated gas is performed using a heater comprising an air-heater jacket, and wherein the air-heater jacket is operable to cause the pre-heated gas to travel over at least a portion of a surface of the heater. 
     
     
         28 . The method of  claim 21  further comprising pre-heating the dewatered sludge before reducing, in the at least one of the mill or grinder, the moisture content of a sludge by breaking the sludge into the dried powder in the presence of high-temperature gas.