Inline particle size control for rotary drum drier recycle material

A method comprising:

• (a) drying a wet coated seed material stream (1712) comprising an incoming wet granular biosolids stream (1702) to produce a moist air and uncontrolled size dried pellet stream (1722), using a dryer (1714);
• (b) separating an uncontrolled size dried pellet stream (1734) from the moist air and uncontrolled size dried pellet stream (1722), using a separator;
• (c) diverting a recycle portion of the uncontrolled size dried pellet stream (1738b) to a recycle feed bin (1744) disposed vertically above a pugmill (1706) from the uncontrolled size dried pellet stream (1734), using a diverter (1736), wherein the recycle portion of the uncontrolled size dried pellet stream (1738b) is dropped vertically into a chute to be metered into the pugmill (1706) and mix with the incoming wet granular biosolids stream (1702);
• (d) diverting a remainder portion of the uncontrolled size dried pellet stream (1738c) to an outlet, using the diverter (1736);
• (e) resizing oversized pellets from the recycle portion of the uncontrolled size dried pellet stream (1738b) to produce a controlled size dried seed material recycling stream (1754), using a variable speed rotary crusher (1750) configured with a screen (1820) having apertures (1845) sized to retain the oversized pellets in the variable speed rotary crusher (1750) until the oversized pellets are crushed to produce reduced size pellets that fall through the screen;
• (f) mixing the controlled size dried seed material recycling stream (1754) with new incoming wet granular biosolids (1703) from the incoming wet granular biosolids stream (1702) to replenish the wet coated seed material stream (1712), using the pugmill (1706);
• and
• (g) repeating steps a-f.