Máquina de carbonización de lodos de depuradora | Planta de tratamiento de lodos de depuradora
| Marca | Shuliy |
| Materias primas | Lodos de depuradora, lodos de impresión y teñido |
| Capacidad | 500kg-3000kg |
| Método de trabajo | Carbonización continua |
| Poder total | 40-72 kw/h |
| Garantía | 12 meses |
| Servicio postgarantía | Soporte técnico por vídeo, soporte en línea, servicio de reparación y mantenimiento en campo |
| Países más vendidos | Japón, Alemania |
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Shuliy sewage sludge carbonization machine is an industrial sludge pyrolysis system designed for thermal treatment of dewatered municipal and industrial biochemical sludge. Our continuous sludge carbonization furnace processes 500-3 tons/h of dewatered sludge with 75-82% initial moisture content. The machine converts hazardous sludge into stable sludge biochar while recovering combustible pyrolysis gas as free fuel.
Compared with sludge incineration or landfill disposal, our sludge carbonization machine operates in an oxygen-limited environment at 450-650°C. This pyrolysis process fixes heavy metals inside the char matrix and completely eliminates pathogens. The system reduces sludge volume by 70-90% and produces reusable biochar instead of waste ash.
With 20+ years of thermal processing equipment experience and exports to 50+ countries, Shuliy provides complete sludge-to-biochar solutions. Our sludge carbonization machine systems help municipalities and industrial plants solve sludge disposal problems while creating value from waste.
What is a Sewage Sludge Carbonization Machine?
A sewage sludge carbonization machine is thermal treatment equipment that decomposes organic matter in dewatered sludge through pyrolysis. The continuous indirect-heating rotary carbonization furnace is the mainstream industrial model for medium to large sewage treatment plants.
The system consists of sludge feeding equipment, drying preheating unit, carbonization host, gas recovery system, water-cooled discharge unit, and multi-stage flue gas purification. PLC control monitors temperature, pressure, and oxygen content throughout the process.
Applications of Raw Materials
The sewage sludge carbonization machine can carbonize sewage sludge, municipal sludge, printing and dyeing sludge, industrial sludge, and so on. The size of solid materials should be less than 3mm. Moreover, the machine can also carbonize coconut shells, bamboo, and other biomass waste.
Complete System Components
The sewage sludge carbonization machine is supplied as a complete turnkey system. Each component plays a specific role in safe and efficient operation.
Drying and Preheating Unit
High-moisture sludge first enters the drying section. Waste heat from carbonization provides most of the drying energy. This pre-drying step reduces moisture before pyrolysis.
Carbonization Host
The double-layer indirect-heating rotary furnace or spiral pyrolysis reactor is the core unit. The outer furnace shell heats the inner drum indirectly. This design keeps combustion gases separate from pyrolysis gas.
Gas Recovery and Combustion System
Pyrolysis gas containing CO, H₂, and methane is collected and sent to the combustion chamber. This recovered gas provides heat for drying and carbonization after startup.
Sealed Water-Cooled Discharger
Finished sludge biochar exits through a closed cooling system. Circulating water jackets reduce temperature and prevent spontaneous ignition.
Multi-Stage Flue Gas Purification
Exhaust gas passes through a secondary combustion chamber, spray tower, bag filter, deacidification, and activated carbon adsorption. This ensures compliance with emission standards.
PLC Control and Safety System
The control panel monitors furnace temperature, pressure, oxygen content, and gas flow. Automatic alarms protect operators and equipment.
Especificaciones Técnicas
Our sewage sludge carbonization machines use continuous rotary carbonization technology. Standard configurations match different daily sludge volumes.
| Modelo | SL-0812 | SL-1015 | SL-1218 | SL-1320 |
|---|---|---|---|---|
| Hourly Feeding Capacidad | 500 kg/h | 0.8–1 Tons/h | 1.5–2 Tons/h | 2.5–3 Tons/h |
| Método de trabajo | Continuo Carbonizing | Continuo Carbonizing | Continuo Carbonizing | Continuo Carbonizing |
| Tamaño del reactor (Drum Dia.) | 800 mm | 1000 mm | 1300 mm | 1700 mm |
| Poder total | 40 kW | 55 kW | 60 kW | 72 kW |
| Materiales de calefacción | Charcoal, Wood, Diesel, Natural gas, LPG, Biomass pellets | Charcoal, Wood, Diesel, Natural gas, LPG, Biomass pellets | Charcoal, Wood, Diesel, Natural gas, LPG, Biomass pellets | Charcoal, Wood, Diesel, Natural gas, LPG, Biomass pellets |
| Floor Area (L×W×H) | 30×15×7 m | 35×15×7 m | 45×15×10 m | 50×15×10 m |
| Método de enfriamiento | Recycling Water Cooling | Recycling Water Cooling | Recycling Water Cooling | Recycling Water Cooling |
If calculated based on the actual industrial production standard of 20 hours/day:
| Modelo | Daily Processing Capacity | Moisture Input | Temperatura de carbonización | Power Range | Application |
|---|---|---|---|---|---|
| SL-0812 | 10-12 tons/day | Depends on sludge moisture | 450-650°C | 40 kW | Small sludge treatment plants |
| SL-1015 | 16-24 tons/day | Depends on sludge moisture | 450-650°C | 55 kW | Small and medium sludge plants |
| SL-1218 | 30-48 tons/day | Depends on sludge moisture | 450-650°C | 60 kW | Medium sludge treatment facilities |
| SL-1320 | 50-72 tons/day | Depends on sludge moisture | 450-650°C | 72 kW | Large sludge processing projects |
How Does the Sludge Carbonization Machine Work?
The sewage sludge carbonization machine uses oxygen-limited pyrolysis to transform hazardous sludge into stable biochar. The complete process has five stages.
Stage 1: Pre-Treatment and Drying
Dewatered sludge with 75-82% moisture enters the crushing and conveying system. Large lumps break down for uniform feeding. The drying section pre-reduces moisture using recovered waste heat.
Stage 2: Oxygen-Limited Pyrolysis
Pre-dried sludge enters the carbonization furnace. Internal temperature reaches 450-650°C. Oxygen content stays below 2%. Under these conditions, organic matter undergoes thermal cracking.
Three reactions occur simultaneously:
Solid residue becomes sludge biochar.
Heavy metals fix inside the char matrix.
Volatile organic matter converts to combustible pyrolysis gas.
Stage 3: Energy Recycling
Combustible pyrolysis gas flows into the combustion chamber. After startup, this gas provides most of the thermal energy needed for drying and carbonization. External fuel is only required during initial heating.
Stage 4: Cooling and Discharge
Sludge biochar exits through the sealed water-cooled discharger. Output temperature drops to approximately 30-50°C. The closed system prevents oxygen contact and re-ignition.
Stage 5: Flue Gas Treatment
Remaining exhaust gas passes through secondary combustion at 850-1,100°C to destroy VOCs and dioxin precursors. Then cooling, dust removal, deacidification, and activated carbon adsorption clean the gas before release.
Key Advantages of Shuliy Sludge Carbonization Machines
Oxygen-Limited Pyrolysis Inhibits Dioxins
The absence of oxygen in the carbonization zone prevents dioxin formation. This is a major advantage over sludge incineration.
Heavy Metal Stabilization
High temperatures fix heavy metals inside the biochar structure. Leaching tests show significantly lower mobility compared with raw sludge.
Energy Self-Sustaining Operation
Pyrolysis gas recycling provides 60-80% of thermal energy after startup. This reduces external fuel dependency and operating costs.
Complete Harmless Treatment
Pathogens, odors, and organic contaminants are destroyed during pyrolysis. The output is stable and safe for storage or transport.
Flexible Sludge Adaptability
Our sewage sludge carbonization machine handles municipal sludge, food processing sludge, paper mill biochemical sludge, and river sediment.
Compact Integrated Design
The complete system including drying, carbonization, gas treatment, and control fits within a standard industrial building. Site installation time is 15-30 days.
Continuous vs. Batch Sludge Carbonization
| Feature | Continuous Sludge Carbonization Machine | Batch Sludge Carbonization Furnace |
|---|---|---|
| Operation Mode | 24-hour continuous feeding and discharge | Batch loading, heating, carbonization, cooling cycles |
| Daily Capacity | 10-120 tons/day | Less than 5 tons/day |
| Energy Efficiency | Continuous heat recovery, low unit energy consumption | Repeated heating and cooling, 30% higher energy use |
| Automation | PLC automatic control, 1 operator | Manual operation, batch quality variation |
| Initial Investment | Higher | Lower |
| Best Application | Large municipal plants, centralized sludge centers | Small pilot projects, testing sites |
Municipal sewage plants generally prefer the continuous sludge carbonization machine for its energy efficiency and stable daily output.
Puntos de Dolor del Cliente y Soluciones
Pain Point 1: High Sludge Disposal Costs
Municipal plants pay expensive landfill fees for dewatered sludge. Transportation costs increase as landfills move farther away.
Solution: The sludge carbonization machine reduces volume by 70-90%. Less material goes to landfill. Lower transport frequency cuts disposal costs.
Pain Point 2: Landfill Environmental Risks
Raw sludge contains pathogens, heavy metals, and odor compounds. Landfill leachate can contaminate soil and groundwater.
Solution: Pyrolysis stabilizes heavy metals and kills all pathogens. Biochar is chemically stable and safe for storage or reuse.
Pain Point 3: Incineration Air Pollution
Sludge incineration produces large exhaust gas volumes and requires complex air pollution control.
Solution: Pyrolysis generates smaller gas volumes. Oxygen-limited conditions reduce pollutant formation. Multi-stage treatment ensures clean emissions.
Pain Point 4: Energy Costs of Thermal Drying
Mechanical dewatering leaves high moisture. Thermal drying alone consumes large amounts of fuel.
Solution: Our system uses waste heat from carbonization for pre-drying. Recovered pyrolysis gas provides the main energy source.
Why Choose Shuliy for Sludge Carbonization Equipment?
Proven Thermal Technology
20+ years of experience in carbonization and pyrolysis equipment manufacturing.
International Certifications
ISO 9001, CE marking, and compliance with major environmental standards.
Custom Engineering
We design the sewage sludge carbonization machine based on your sludge type, moisture content, daily volume, and local emission standards.
Complete After-Sales Support
- 1-year full equipment warranty.
- Lifetime technical support.
- Multilingual service team.
- Spare parts inventory for fast delivery.
Frequently Asked Questions
What moisture content can the machine handle?
The system processes dewatered sludge with 75-82% moisture. Pre-drying is recommended for sludge above 80% moisture to improve energy efficiency.
Does pyrolysis destroy all pathogens?
Yes. Operating temperatures of 450-650°C completely destroy bacteria, viruses, parasite eggs, and other pathogens.
Is the biochar safe for agricultural use?
Biochar from municipal sludge can be used for landscaping and soil improvement when heavy metals meet local standards. Industrial sludge requires testing first.
How much does sludge volume decrease?
Volume reduction typically reaches 70-90% depending on initial moisture and sludge composition.
Can the system operate without external fuel after startup?
Yes. After reaching stable temperature, combustible pyrolysis gas provides most thermal energy. External fuel is only needed during startup and cold conditions.
What emission standards does it meet?
The multi-stage gas treatment system can be configured to meet GB 18485, EU, and local air emission standards. We adapt the purification train to your regulations.
Does high sand content damage the furnace?
Sandy sludge causes abrasion. We use wear-resistant materials in high-wear zones and recommend regular inspection schedules.
How long is the installation period?
Standard installation takes 15-30 days including equipment positioning, piping, electrical connection, and commissioning.
Related Equipment
Hoisting Vertical Carbonization Furnace
Also named vertical charcoal making kiln, this batch biomass carbonizing equipment adopts electric hoist lifting design, standard model SL-C1500 with single tank loading capacity 2600–3000kg and daily output of 2500–3000kg charcoal. The furnace shell uses 6mm thick Q245 carbon steel lined with refractory bricks and a high-temperature insulation layer, matched with 3 replaceable inner carbonization tanks and a complete flue gas purification & combustible gas recycling pipeline system. Stable oxygen-free dry distillation temperature ranges 280–500℃, with full automatic temperature segmentation control for drying, pyrolysis and carbon forming. It is mainly suitable for large-block biomass materials including logs, bamboo, coconut shells, fruit nut shells and thick branches, and also compatible with sawdust briquettes, corn cobs and furniture waste. Equipped with a remote control lifting mechanism and separated cooling design, it realizes cyclic batch carbonization without repeated preheating, producing high-integrity lump charcoal and by-product wood vinegar liquid for charcoal processing plants, biomass waste recycling factories and agricultural waste treatment manufacturers.
Core Advantages
- Wide Large-Block Material Compatibility: Perfect for log, bamboo, coconut shell and thick branch raw materials; matched charging baskets to keep charcoal intact without crushing, separately equipped continuous furnace for materials below 3cm.
- Cyclic Batch Mass Production: Three inner tanks for alternating carbonization and cooling, greatly shortening the production cycle; only 1–2 operators needed to cut labor intensity and labor cost sharply.
- Self-Circulating Energy-Saving Heating System: Recycles pyrolysis combustible gas for secondary combustion to realize self-heat supply; only a small amount of biomass waste required for initial ignition, lowering long-term fuel expenditure.
- Remote Hoisting Labor-Saving Design: Over 2-ton load-bearing electric lifting frame with remote control, fast loading and unloading of inner tanks, separated cooling structure avoids high-temperature operation risks for workers.
- Stable Uniform Carbonization Quality: Vertical 360° surrounding heating avoids local incomplete carbonization or overburning; finished charcoal features high carbon content, low ash and long combustion time.
- Eco-Friendly Sealed Purified Structure: Fully sealed furnace door plus multi-stage flue gas purification unit, waste gas meets environmental discharge standards without black smoke pollution during operation.
- Customized Layout & Complete After-Sales: 12-month full machine warranty with factory installation training and online technical support; furnace size, lifting frame structure and gas recovery system can be customized according to factory site and output demands.
Get Your Sewage Sludge Carbonization Machine Quote Today
Solve your sludge disposal challenge while creating value from waste. Shuliy’s sewage sludge carbonization machine delivers volume reduction, harmless treatment, and biochar production in one integrated system.
