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A method of waste heat recovery and utilization was explored by incorporating a heat recovery system into an existing industrial-scale sludge drying system with handling capacity of 440 kg dry solid (DS) per hour. The recovered heat was used to preheat sewage sludge (and carrier gas) to lower sludge viscosity and flowing resistance during sludge transportation in pipeline, as well as the heat consumption during drying. 5.3% decrease of heat consumption in drying, 48% decrease of sludge flowing resistance, and 15% decrease of spraying water consumption in spray tower were fulfilled. Theoretical modeling of heating and flowing behavior of sewage sludge in pipeline, and cooling behavior of hot wet air in a type-III spiral plate heat exchanger were also conducted. The results showed that wall slip phenomenon occurred between sludge and inner surface of sludge pipe during sludge flowing process, which had marked influence on sludge preheating in pipeline.

Sludge preheating and viscosity reduction by waste heat from the exhaust gas of sludge paddle dryer