Abstract: Systems and processes provide for a thermal process to transform sludge (and a variety of other natural waste materials) into electricity. Dewatered sludge and other materials containing a high amount of latent energy are dried into a powdered biofuel using a drying gas produced in the system. The drying gas is recirculated and is heated by the biofuel produced in the system, waste heat (from turbines or internal combustion engines), gas (including natural gas or digester gas) and/or oil. The biofuel is combusted in a boiler system that utilizes a burner operable to burn biofuel and produce heat utilized in a series of heat exchangers that heat the recirculating drying air and steam that powers the turbines for electricity production.

Abstract: Integrated systems and processes are provided for drying and milling sludge and other natural waste using waste heat extracted from reheated gas through an air-air heat exchanger process. 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 separator- scrubber cycle before a first portion is heated in an air-heater and then used to heat a second portion of the at least partially saturated gas in an air-air heat exchanger. The heat for the air-heater may be provided by a burner operable to burn the dried powder obtained from the sludge. The heated second portion of gas may be used to dry and mill the sludge and other natural waste.

Abstract: Systems and processes provide for a thermal process to transform sludge (and a variety of other natural waste materials) into electricity. Dewatered sludge and other materials containing a high amount of latent energy are dried into a powdered biofuel using a drying gas produced in the system. The drying gas is recirculated and is heated by the biofuel produced in the system, waste heat (from turbines or internal combustion engines), gas (including natural gas or digester gas) and/or oil. The biofuel is combusted in a boiler system that utilizes a burner operable to burn biofuel and produce heat utilized in a series of heat exchangers that heat the recirculating drying air and steam that powers the turbines for electricity production.

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.