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ASME Power
June28-July2, 2015, San Diego, California, USA
PowerEnergy2015-49155
ECONOMIC OPTIMIZATION OF INDIRECT SEWAGE SLUDGE HEAT DRYER UNIT FOR
SEWAGE SLUDGE INCINERATION PLANTS
Sinan Demir
West Virginia University
Mechanical and Aerospace Engineering
Morgantown, West Virginia, United States
Orkun Karabasoglu
Electrical and Computer Engineering
SYSU-CMU Joint Institute of Engineering
Pittsburgh, Pennsylvania, United States
SYSU-CMU Joint Research Institute
Shunde, Guangdong, China
V'Yacheslav Akkerman
West Virginia University
Mechanical and Aerospace Engineering
Morgantown, West Virginia, United States
ABSTRACT
This paper presents the economic optimization of indirect
sewage sludge heat dryer for sewage sludge incineration plants.
The objective function based on two-phase heat transfer, and
economic relations is provided to demonstrate the optimum size
for the minimum investment cost. De-watered sludge is fed into
the dryer with a mass flow rate of 165 tons per day and consists
of 27% dry matter. After the sludge drying process, the dryness
of sludge increases up to 40%. In the indirect sludge dryer unit,
thermal oil is used to heat the dryer wall and to prevent heat
loss. Thermal oil is circulated in a closed cycle and gathered
into an oil tank. Total cost of the sludge dryer unit changes
proportional to the dryer area. The optimum dryer area is found
as 32.54 m2. The corresponding minimum cost is found as
$35,700.
INTRODUCTION
Wastewater treatment plants (WWTPs) produce a large
amount of sewage sludge every year. Sewage sludge contains
pathogenic and toxic substances, which makes its disposal and
processing a complex environmental issue for engineers [1].
Even so, sludge has an important energy recovery potential with
some processes. Some of these processes include; anaerobic
digestion, production of biofuels from sludge, direct electricity
production in microbial fuel cells, co-incineration of sludge in
coal-fired power plants and incineration of digested or
Aysegul Abusoglu
Gaziantep University
Mechanical Engineering
Gaziantep,Turkey
area for a sludge dryer. Although there have been many studies
of thermal dryers, the optimization of an indirect sludge dryer
has not been studied in open literature. Among the some studies,
Chai [4] proposed a statistical dynamic framework to analyze
the physical mechanisms of sludge drying process based on the
new method. The fractal dimension of a drying structure was
derived analytically and its relationship with some controlling
factors was analyzed. Ferrasse et al. [6] describe an
experimental set up specially designed for the investigation of
drying kinetics, of heat transfer coefficient evolution, and of the
mechanical torque necessary for stirring. Kasakura et al. [7]
provides a brief introduction to the conventionally utilized
drying methods/equipment (i.e, hot gas drying, fluidized bed
drying, pneumatic conveyor drying, and steam drying) for
treating dewatered sludge cakes. Peregrina et al. [8] in their
paper present a fry-drying thermal drying process for sewage
sludge for lifecycle assessment and so on. As seen in the
literature, presented articles related with sludge drying process
consists of overview and a few dynamic studies and not focused
much attention on economic optimization. This paper intend to
present an economic optimization for an indirect sewage sludge
heat dryer to find minimum cost with respect to minimum heat
transfer area. First, system thermal modeling, by considering
two- phase heat transfer, is presented in order to obtain
objective function. After that, improved methodology and
procedure are applied to indirect thermal dryer of an actual
sludge incineration plant.
SYSTEM MODEL AND FORMULATIONS
A sludge incineration power production plant (SIPP)
flow schematic is given in Fig. 1 in appendix section. In this
plant, first de-watered sludge comes to the SIPP with 25-27%
dry matter (DM) from the WWTP. Before the incineration
process of the sludge, its DM ratio should have increased for
efficient combustion. The indirect sewage sludge dryer (ISSD)
unit is used to increase sludge DM up to 40%. In this process,
thermal oil is used to heat the dryer wall, simultaneously
preventing heat loss, and facilitating the heating and
evaporation process. Thermal oil circulates in a closed cycle
and finally gathers in an oil tank. Hot exhaust gas obtained from
the fluidized bed incinerator is used for heating the thermal oil.
Evaporated water (steam) can be used in a steam turbine for
energy production.
Tc,o_2
Tc,i_2
Th,i_1
Temperature
Th,o_2
Tc,o_1=Tc,i_2=Tc,o_2
II
Steam outlet
sludge
Tc,o_1
heated sludge
I
Tc,i_1
Th,i_2
II
Tc,i_1
Th,o_1
Tc,o_1
partial dried sludge
The main assumptions for the thermal analysis are listed below:
Total required annual heat energy rate for the drying process is
calculated by,
Qtotal ((mc p )min Tmax mwater h fg )t
(1)
1 e NTU
(2)
NTU
UA
UA
(3)
r3
r2
cptwo phase
1 dQ
dQ / dL
m dL m dT dP
dP dL
(4)
(5)
dP
which is total local pressure gradient per unit
dL
length of the dryer (friction, momentum and gravity) for twophase and one dimensional flow based on homogenous model is
calculated by the following equation,
The term
dL
dL
dL
dL
friction
momentum
gravity
1
ln(
r
r 1
1
2 / r1 )
r1
1
htp
kW
r3 h2
ln(r2 / r1)
2k w L
1
h2 2r3L
Mh fg
htp
larger of ............................................................
hsp
0.45 0.72
0.08
1.136 f g x (1 x) f ( Frf )
q ''s
0.8
667.2 Mh (1 x) Gs , f
fg
(8)
Frf
(6)
1
h12r1L
length of the dryer (friction, momentum and gravity) for twophase and one dimensional flow based on homogenous model is
calculated by the following equation,
dPsat
h fg
r1
f ( Frf ) ........................................................
2.63Fr 0.3 for horizontal
f
(9)
q ''s denotes heat flux for boiling, and can be calculated by the
equation,
(7)
g f g
q ''s l h fg
0.5
c p , f Te
n
Cs , f h fg Pr f
(10)
hsp
where
f,
TC
P2CA PC
t (mC p )min Tmax mw h fg
1 E
A
A
(16)
Re f Pr f ( f / 2)(kl / D)
friction factor,
calculated
(11)
Aoptm
from
(mc p )min
U
P2C A (mc p )
ln
(17)
f 1.58ln(Re f ) 3.28 .
The aim of this study is to decrease the total cost by seeking the
optimum area of a thermal heat dryer. Thus, the total cost of the
dryer consists of initial costs, and operational costs. The
relation can be express as,
TC IC OC
(12)
TC P2CA A PC
1 E Qtotal
(13)
1
d i 1 d
N
if i d
1 i
P2 1 P1 M s RV (1 d ) N
CASE STUDY
Obtained correlations can be applied for the considered an
actual ISSD. Related given data of the thermal dryer can be
summarized by considering Fig.1 and 2:
165 tons of sewage sludge comes to the indirect thermal dryer
daily with 27% DM content and at environmental conditions
(25C, 1 atm). After the drying process, its DM content
increases up to 40%. Thermal oil comes to the dryer at 240 C,
and turns back to the oil tank at 200 C. Mass flow rate of the
thermal oil is 43.65 kg/s. It is assumed that obtained steam from
the dryer process has 0.2 quality.
Dryers size, by considering Fig. 3 can be given as r1=550, r2=
584 and r3= 600 mm. Length of the dryer is 12 meters. Thermal
conductivity of the dryer wall is 17 W/mK. Using internal flow
correlations[12], the heat transfer coefficient of the sewage
sludge and thermal oil are calculated as 685 and 35 W/m2K.
Other properties related with substances can be taken from the
thermodynamic tables.
Economic parameters related with dryer are given as: i and d,
which are 7 and 8%, respectively. Energy present price is
2.03x10-8 US$/J. Area dependent first cost of the dryer is given
as 112 US$/m2. The system technical life time is 7 years, and
operation time is 7200 hours annually.
if i d
P1
(14)
As valid for the specific heat of the two phase fluid flow, two
phase heat transfer coefficient ( htp ) changes with respect to
4.5
250
225
Cp two phase
P
200
175
150
2.5
125
2
1.5
1
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
36000
75
0.85
33000
30000
optimum value
0.8
27000
0.75
24000
25
0
39000
0.95
0.9
42000
100
50
0.5
1.05
TC ($)
P (kPa)
3.5
0.7
21000
0.65
18000
0.6
TC
0.55
Figure 4. The variation of the specific heat and total pressure drop
with respect to vapor quality
15000
12000
0.5
0.45
12
15
18 21
A (m 2 )
24
27
30
33
36
9000
39
22000
CONCLUSION
The developed formulations and procedures are applied to an
actual ISSD system to find minimum total cost for the optimum
area. The following conclusions can be drawn based on the
analysis and the results obtained:
Specific heat and heat transfer coefficient of the twophase fluid flow are found as 2.3 kJ/kgK and 18735
W/m2K at 0.2 vapor quality.
60
55
h tp
Aoptm
20000
18000
50
45
16000
12000
30
10000
25
Aoptm (m 2 )
35
h tp (W/m K)
40
14000
20
8000
15
6000
10
4000
2000
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
APPENDIX
dPfr
dL
fg
g2 E
4 M2 2
g 2r1 2 gc g
Where f is the single phase friction factor, M denotes the total mass flow
rate as gas in kg/m2s. The two-phase frictional pressure drop is calculated
using the equation above. The single flow pressure drop is multiplied by
the two-phase friction multiplier, which is denoted as
g2 .
It can be
3.24 F H
Fr 0.045We0.035
E (1 x)2 x 2
f fg
g fl
E (1 x)2 x 2
f fg
g fl
F x0.78 (1 x)0.24
f
H
Fr
hom
0.91
0.19
g
1
f
0.7
M 2 2r1
M2
We
2
hom
gDi hom
1 x
f 1.58ln(Re) 3.28
dPmom d M 2 x 2
(1 x)2
dL
dz g c a g (1 a) f
1 x g
a 1 A
x f
dPgr
dL
g
sin a g (1 a) f
gc
The equation can be negative for downward flow and positive for upward
flow. is the angle with a horizontal axis.
NOMENCLATURE
A
cp
area (m)
specific heat (J/kgK)
CA
CE
Cmin
D
f
g
gc
h
h fg
Abbreviations
DM
dry matter
ISSD
indirect sewage sludge dryer
SIPP
sludge incineration power production plant
WWTP wastewater treatment plant
kw
L
m
M
N
P
r
t
T
q
Greek Letters
density (kg/m3)
dynamic viscosity (Pa.s)
surface tension (N/m)
specific volume (m3/kg)
angle ()
ACKNOWLEDGMENT
I would like to thank to GASKI Wastewater Treatment plant
engineer Eyup Anlatici for supplying data.
REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]