A novel continuous biodrying process has been developed whose goal is to increase the dry solids content of the sludge to economic levels rendering it suitable for a safe and economic combustion operation in a biomass boiler. The sludge drying rates are enhanced by the metabolic bioheat produced in the matrix of mixed sludge. The goal of this study was to systematically analyze the continuous biodrying reactor. By performing a variable analysis, it was found that the outlet relative humidity profile was the key variable in the biodrying reactor. The influence of different outlet relative humidity profiles was then evaluated using biodrying efficiency index. It was found that by maintaining the air outlet relative humidity profile at 85/85/96/96% in the four compartments of the reactor, the highest biodrying efficiency index can be achieved, while economic dry solids level (>45% w/w) are guaranteed. Crown Copyright (C) 2009 Published by Elsevier Ltd. All rights reserved.