•The hydrothermal carbonization of sewage sludge process is developed.•Hydrochars are solid fuels with less nitrogen and sulfur contents.•The first order combustion reaction of hydrochars is derived.•Main combustion decomposition of hydrochars is easier and more stable.•Formation pathways of hydrochars during hydrothermal carbonization are proposed. Conventional thermochemical treatment of sewage sludge (SS) is energy-intensive due to its high moisture content. To overcome this drawback, the hydrothermal carbonization (HTC) process was used to convert SS into clean solid fuel without prior drying. Different carbonization times were applied in order to produce hydrochars possessing better fuel properties. After the carbonization process, fuel characteristics and combustion behaviors of hydrochars were evaluated. Elemental analysis showed that 88% of carbon was recovered while 60% of nitrogen and sulfur was removed. Due to dehydration and decarboxylation reactions, hydrogen/carbon and oxygen/carbon atomic ratios reduced to 1.53 and 0.39, respectively. It was found that the fuel ratio increased to 0.18 by prolonging the carbonization process. Besides, longer carbonization time seemed to decrease oxygen containing functional groups while carbon aromaticity structure increased, thereby rendering hydrochars highly hydrophobic. The thermogravimetric analysis showed that the combustion decomposition was altered from a single stage for raw sludge to two stages for hydrochars. The combustion reaction was best fitted to the first order for both raw sludge and hydrochars. The combustion of hydrochars is expected to be easier and more stable than raw sludge because of lower activation energy and pre-exponential factor.