Effects of layer inhomogeneities on the process of sewage sludge convective drying

Convective sewage sludge drying is often carried out in belt dryers, where the air flow is directed through the layer. In such a configuration, drying air properties, as well as the structure of the layer and its homogeneity are key factors affecting the drying process. In the present work, these factors were investigated using laboratory experiments on relatively large sludge samples with a mass of several kilograms. Drying was performed at relatively low drying air parameters (time-averaged temperatures of 65 to 80 °C and velocities of 0.44 to 0.78 m/s). The inhomogeneity of the sludge layer drying was observed by measuring the layer surface temperature with an IR camera. The reduction in layer thickness during drying was measured using an optical laser-based method. Analysis of the data included regression and fitting of the data to parametric drying curves, with the modified Nadhari drying law providing the best fit. The standard deviation of the layer surface thermograms (S) was used as a parameter that accounted for the layer homogeneity and consequently drying evenness. Higher values of S corresponded to lower drying rates and consequently longer drying times, highlighting the importance of producing layers with a homogenous structure. The measured layer thickness reduction rate indicated the overall drying intensity almost from the beginning of drying. Both the surface temperature unevenness and the layer height reduction measurement methods were demonstrated as viable approaches for real-time monitoring of the drying process with potential for application in real-scale dryers.