Project Overview
Industry: Common Effluent Treatment Plant (Textile Cluster)
Sludge Type: CETP mixed biological + chemical sludge
Capacity: 160–200 TPD (wet sludge)
Technology: Hybrid System (Solar Sludge Dryer + Multi-Layer Mesh Belt Dryer)
Facts and Figures
Sludge Generation: 160–200 TPD
Input Moisture: ~75–80%
Output Dryness: Up to 85–90% DS
System Type: Hybrid (Solar + Waste Heat + Thermal)
Integration: Existing sheds utilized
Energy Source: Waste heat + solar
The Challenge
- Extremely high sludge generation (one of the largest CETP loads)
- High moisture content leading to massive disposal volumes
- Existing sludge storage sheds already constructed (fixed layout constraint)
- Severe space limitation despite high load
- Lack of sufficient thermal energy for full thermal drying
- Need for consistent drying for handling and co-processing
- Odour control critical due to surrounding communit
The Solution
- Implementation of hybrid drying approach: Solar drying for bulk load handling and MLMB dryer for controlled thermal drying
- Integration within existing sludge storage sheds (no major civil expansion)
- Waste heat utilization from aeration blowers (~95°C air)
- Dual heat exchange system (air-air + air-water)
- Solar parabolic concentrators for supplementary heating
- Automated sludge handling system with silo storage
The Benefits
- Massive reduction in sludge volume sent to landfill
- Significant reduction in disposal cost
- Conversion of sludge into alternative fuel for cement industry
- Optimal utilization of existing infrastructure
- Low OPEX due to renewable + waste heat integration
- Controlled odour and improved environmental compliance
