DRYERS

SOLUTION SYSTEM

Prompted by the need of a dryer that worked and worked well, we made our first dryer over 70 years ago. Our goal was an efficient, reliable unit that was built for high capacity jobs. As owner-operators of the same equipment you use, we started and continue making the toughest, longest lasting dryers out there. We’re honored to offer that same ingenuity and know-how to you in every dryer we build today. That’s Thompson tough. And we’re sticking to it.

Just as we built our first dryer to meet a specific need, our team of engineers proudly bring you that same service in every Thompson Solution System. Every dryer is fabricated to the same rigid criteria that has resulted in some Thompson systems running continuously for over 60 years. Let us design a solution that fits your needs.

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A Better Way to Process Your Feedstock

Industrial strength, direct-fired, and continuously-fed, a Thompson Solution Dryer can dry temperature-sensitive, organic and inorganic materials safely at a high capacity with thermal efficiency around 85%; it does so with minimal air pollution, little material degradation and low fire risk. A Thompson Solution Dryer is the most cost effective and energy efficient dryer available today. With Thompson’s proprietary internal flighting package, the dryer is able to dry a wide variety of sizes and types of material uniformly, inside and out, to the desired dryness. Also, they can do so for 8400 hours per year in excess of 10 years without major repairs. Thompson takes great pride in the design and manufacture of the Dryer Drum, which is the most crucial part of the operation and longevity of the whole system.

Feature: Thompson’s proprietary design of rotary dryer internals (flights/lifters)

Benefits:
The rotary material handling internals allows for the largest variance of product sizes
Even drying across particle sizes

Results:
You have a wider source of feedstock to choose from without having to invest in sizing equipment
Consistent product quality you and your customers can count on

Feature: No refractory

Benefit:
Quicker cool-down and start-up time for system
No stored energy in the refractory

Result:
Less downtime and less maintenance expense
Reduced risk of fires and explosions in shutdowns and upset conditions

Feature: Low oxygen drying environment

Benefit:
Fires need oxygen to burn, so low oxygen content means less risk of fires or high pressure events

Result:
Personnel and equipment are safer because fires and high pressure events are less likely.

Feature: Modulating exhaust gas recycle (also called flue gas recycle) – which reuses (recycles) hot gas from the system back into the front end of the drying process

Benefit:
Eliminates the need for make up air
Creates a consistent gas flow throughout the drying process
Allow drying process to use steam as the heat transfer medium
Use less fuel because there is no need to heat make up air
Reduces total gas volume entering and exiting the system (no make up air)
Either eliminates the need for, or reduces the size of secondary cleanup equipment (lower emissions)
Reduces the amount of oxygen entering the system (no make up air)
Increases consistency of final product quality
Allows for lower temperature drying which protects the quality of the end product

Result:
Lower fuel usage means lower operational costs
Lower emissions means lower capital investment
Lower emissions means happier neighbors
Consistent high quality products mean happy customers
Personnel and equipment are safer because fires and high pressure events are less likely

Feature: VFD controlled with no dampers

Benefit:
No dampers means less maintenance
Less pressure drop across system
Use only the horsepower needed

Result:
Lower operational costs
Lower maintenance costs
More reliable process controls

Feature: Inlet and outlet screws double as airlocks

Benefit:
Fewer pieces of equipment
Less complicated
Eliminates point for air (oxygen) to enter system
Lowers emissions

Result:
Lower operational costs
Fewer parts to break which means lower maintenance costs
Lower capital investment, no airlock here
Lower emissions means lower capital investment in secondary cleanup equipment
Lower emissions means happier neighbors
Personnel and equipment are safer because fires and high pressure events are less likely

Feature: Airlocks under each cyclone

Benefit:
Increased product separation from gas stream i.e. higher product retention
Eliminates point for air (oxygen) to enter system
Lower emissions

Result:
Higher revenues from having more product to sell
Lower emissions means lower capital investment in secondary cleanup equipment
Lower emissions means happier neighbors
Personnel and equipment are safer because fires and high pressure events are less likely

Feature: Negative pressure air system

Benefit:
Less dust (product) exiting the system at connection points, i.e. higher product retention
Drying gases stay in the dryer system or exit through the vent stack

Result:
Higher revenues from having more product to sell
Dangerous drying gases are not around plant personnel
Cleaner plant and surrounding area

Feature: Product doesn’t go through a fan

Benefit:
Less wear and tear on fan
Less cleaning

Result:
Lower maintenance costs
More uptime

Feature: Thompson’s patented steam purge and steam snuff (where steam is available)

Benefit:
Ability to know what gas is inside the system at startup
Ability to snuff out fires with hot steam instead of cold water

Result:
Reduced risks of fires or explosions on start up from build up of unexpected gasses
Ability to fight fires with less damage to equipment

Feature: Thompson’s over pressure venting system

Benefit:
Reusable over pressure doors release to reduce pressure in over pressure events

Result:
Protects personnel by giving the system the chance to discharge at a lower pressure level
Project equipment by giving the system the chance to discharge at a lower pressure level

Feature: Carbon Steel, Stainless Steel, or special alloy construction depending on feedstock

Benefit:
The proper materials of construction can handle the harmful natures of the feedstock such as corrosion or abrasion
Less wear and tear on the system

Result:
Lower maintenance cost
Longer life for system

Feature:  Automated Control System with Human Machine Interface (HMI)

Benefit:
Provides data from instruments at key points of the system for information and control purposes to run safer and more efficient
Handles startups and shutdowns automatically to remove human error
Alarms or controls upset conditions automatically
Automated fire suppression system (on some systems)

Result:
Protects personnel and equipment
Consistent product quality which means happy customers

Lowers cost of operation

At a Glance

Thompson will work with you to determine the operational requirements and craft a system that specifically meets your needs.

Below are some specifications for our Solution Systems.

Performance Rates

Processing Capabilities

  • Crops: alfalfa, barley, whole plant milo, sorghum, wheat bran, corn bran, potatoes,
  • Inorganics – aggregates, rubber products, coal, coal powder, silica, glass, sand, soil
  • Molasses-coated mill feed
  • Distillers grains: wet cake (corn, milo, wheat, malt, barley) with or without solubles
  • Woody biomass: hardwoods, softwoods, bark, slash, whole tree, sawdust, hog fuel, paper mill sludge, construction & demolition (C&D)
  • Engineered board feedstocks: bark strands, wood wafers, wood chips, wheat straw
  • Non-woody biomass:
    • Grasses: elephant, switch, brome, miscanthus
    • Ag residuals: wheat straw, sugar beet pulp, potato waste, corn stover, bagasse, coffee bean
    • Municipal solid wastes (MSW)
    • Sanitary wastes: livestock, poultry

General Equipment Specifications for a Solution System

A Solution System will be made from the materials of construction needed for your product

Combustion & Burner Assembly
Wet solid fuel burners, waste heat, dry solid fuel burners, fossil fuel burners, and other heat sources available
Burner & combustion air fan tied into control system & automated sequences
Combustion system meets or exceeds NFPA 86 guidelines

14-ft diameter x 55-ft long single pass dryer drum
3/8-in thick shell
Internal flight/lifter support arms
Tires/tracks: 3-in thick x 10-in wide carbon steel
Trunnion wheels: 42-in diameter, 10.25-in wide with guards
Trunnion shaft: 8-in diameter thru wheel, steps down to 4-15/16-in
Self-adjusting pillow block bearings: 4-15/16-in
Drum drive assembly with VFD and guards

Separation and clean-up
Outlet hopper
Cyclones: 10-ga high efficiency
Clean-out doors in cyclone hoppers and outlet hopper
Compressed air inlets in cyclone hoppers
Combined outlet hopper and cyclone particle separation from gas stream 99%+

Fans
Designed for use in dusty environments
AMCA standard 205 & 211 compliant and 210 & 300 tested
Fan application category BV-3 and balance quality grade G6.3
Shafts sized for 1.43x max rated speed-ANSI/AMCA 204-96
Heavy duty, self-aligning, pillow block type bearings with AFBMA l-50 > 200,000 hours
Clean-out door
Drive guard
VFD controlled where applicable

Ducting
Double walled hot gas ducting
Sized for appropriate gas flow velocities
Bolt together sections for ease of assembly
Manways and cleanouts included for ease of access where applicable

Screw conveyors
Conveyors: auger-style, AGMA class 3
Housing & auger with flanged covers
Shaft mount speed reducer
VFD controlled where applicable

Project management
Installation oversight
Operator training
System start-up assistance
Work with your EPC to provide turn-key solution

Emissions control
Can supply or size a thermal oxidizer
Can provide options to meet emissions standards

Pictures

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