Thermal Steel Ball-Enhanced Rotary Drum Drying of Sludge: Drying Characteristics, Moisture Diffusion Behavior, and Mechanisms
Municipal sludge with high moisture content and strong viscosity tends to form a dense crust during conventional rotary drum drying, reducing heat and mass transfer efficiency and prolonging drying time. This study proposes a thermal steel ball-enhanced rotary drum drying method that introduces high heat capacity, high thermal conductivity steel balls to achieve synergistic contact heat conduction and mechanical disturbance. An evaluation system incorporating dimensionless moisture ratio (MR), drying rate (DR), characteristic drying time (tdry), effective moisture diffusivity (Deff), and volumetric evaporation intensity (U) was established. Results show that compared with conventional drying, steel ball-enhanced drying increased maximum drying rate (DRmax) by 22.59%–41.19%, U by 38.06%–93.43%, and shortened tdry by 27.56%–48.30%, with more pronounced advantages under high load conditions. Deff was significantly higher throughout the process, with maximum increase up to 48.30%, indicating that ball rolling and collision effectively disrupt the crust and promote moisture migration. Mechanistic analysis reveals that the performance enhancement arises from the dual action of thermal-mechanical coupling and mechanical disturbance, which enhances local heat flux via contact conduction and dynamically renews the drying interface, shortening diffusion paths. This study elucidates the heat and mass transfer mechanisms of thermal steel ball-enhanced sludge drying, providing theoretical support and technical reference for efficient sludge volume reduction and dryer design optimization.