This study analyzed convective drying of wastewater sludge cakes with three-dimensional cake structures probed using an X-ray micro-computerized tomography scanner (micro-CT), considering the development of cracks and cake morphology. The presence of artificial cracks on cake surface assist drying, but those occurred naturally cannot. The cake surface is noted far from saturation over drying. Moreover, the cracks transport easily moisture to cake surface, hence yielding high surface humidity (and rates) for drying. Comprehensive drying model has to incorporate real boundary conditions for success modeling. (c) 2008 Taiwan Institute of Chemical Engineers. Published by Elsevier B.V. All rights reserved.