Problem

• The wire processing plant generated around 70 kg/hr of abrasive metal sludge at approximately 70% moisture.
• Previous paddle dryer and other drying attempts failed due to severe wear, sludge sticking, and transfer/discharge problems.
• External disposal continued, creating recurring operating cost and maintenance burden.

Proposed Solution

• Gem Drytech engineered a customized BELTOTHERM belt dryer specifically for abrasive sludge.
• The design reduced internal mechanical contact to minimize wear and improved sludge layering for smooth transfer.
• The system directly utilized existing plant flue gas, avoiding additional fuel requirement while maintaining continuous operation.

Result

• Moisture was reduced from about 70% to around 10%.
• Abrasion-related failures were eliminated.
• Material handling became smoother and more consistent through drying and discharge.
• Sludge volume and disposal cost were reduced, with zero additional fuel cost due to flue-gas integration.

Conclusion

When abrasion and transfer problems make agitation-based dryers unsuitable, a properly engineered belt dryer with controlled airflow and reduced mechanical contact can provide a more reliable long-term solution.

Applicability

Well suited to abrasive sludge streams, high-density residues, and applications where mechanical wear has already caused dryer failures.