Determination of optimal air supply form on sludge convective drying process: A CFD-DEM study

Abstract

Convective thermal drying is usually used in sludge dryers, and the air supply forms significantly affect the sludge drying efficiency. In this work, the drying process of multi-layered sludge is numerically simulated using a coupled computational fluid dynamics-discrete element method (CFD-DEM) approach. Better than our previous work, the current CFD-DEM model further considers the dynamic process of humidity within the flow field. Firstly, the CFD-DEM model is validated based on the mechanistic experimental data. Then, extensive numerical simulations are carried out to investigate the two-layered sludge drying process in the dryer, and the effects of two conventional air supply forms (Top-to-Bottom and Bottom-to-Top) as well as a novel air supply form (Side-assist) on the two-phase flow system are discussed. The simulation results provide in detail the dynamic processes of momentum, heat and mass (moisture) in the convective drying system under different working conditions. Following recommendations are presented to facilitate the operation of the dryer: Bottom-to-Top is better for sludge drying and tends to utilize less heat from the heat source compared to the Top-to-Bottom. The drying efficiency can be further improved by supplying the Side-assist with an optimal flow ratio of side-wind to bottom-wind. Numerical results show that the optimal flow ratio is related to the total air volume, the deflection angle and the side-wind temperature. The present study reveals in depth the impact mechanism of the air supply form on the convective thermal drying process of sludge, which contributes to the design and optimization of high-efficiency dryers.