Rotary Dryer

Sizing & Design

Experts in process design and material

processing for over 60 years.
Rotary dryers are a critical component in
many industrial processes, capable of
processing all sorts of materials, from
chemicals and fertilizers, to minerals and
ores, and nearly everything in between.
The process of sizing and designing a rotary
dryer around a material’s unique processing
needs is one of precise engineering, requiring
careful consideration of a variety of factors.
The process of sizing and designing a rotary
dryer around a material’s unique processing
needs is one of precise engineering, requiring
careful consideration of a variety of factors.

A one-size-fits-all approach to an industrial

drying system may seem tempting, but as you
will soon see, a custom solution will produce
the best results.
Many of the material’s characteristics will play
an integral role in not only determining how
material will behave in the dryer, but also in
how the design of the dryer and other
operational mechanics will need to
accommodate the material in order to
produce desired results.
The following material characteristics all
play a role in dryer sizing and design:
The following material characteristics all
play a role in dryer sizing and design:

- Moisture Content
The following material characteristics all
play a role in dryer sizing and design:

- Moisture Content
- Bulk Density
The following material characteristics all
play a role in dryer sizing and design:

- Moisture Content
- Bulk Density
- Specific Heat
The following material characteristics all
play a role in dryer sizing and design:

- Moisture Content
- Bulk Density
- Specific Heat
- Heat Transfer Properties
The following material characteristics all
play a role in dryer sizing and design:

- Moisture Content
- Bulk Density
- Specific Heat
- Heat Transfer Properties
- Material Limitations
Moisture Content
Both inlet (raw) and outlet moisture will
need to be considered.
Both inlet (raw) and outlet moisture will
need to be considered.

The difference between actual and

desired moisture will in part determine
what the dryer will need to accomplish, as
well as how hard it will have to work to
achieve this goal.
Bulk Density
The bulk density of a material refers to the
weight of the material, per a specific
volume. This is an indicator on the
operational load the dryer must be able
to accommodate.
The bulk density of a material refers to the
weight of the material, per a specific
volume. This is an indicator on the
operational load the dryer must be able
to accommodate.

A material’s bulk density is critical to

determining sizing of components such as
bearings, gear train, trunnion wheels, and
the motor.
Specific Heat
Specific heat refers to how much energy it
takes to raise 1 gram of material by 1
degree Celcius.
Specific heat refers to how much energy it
takes to raise 1 gram of material by 1
degree Celcius.

In other words, the specific heat of a

material will help to determine how much
energy will be needed to cause the
desired change in temperature for that
specific material.
Heat Transfer
Properties
The heat transfer properties of a material
refer to how well a material will transfer heat.
The heat transfer properties of a material
refer to how well a material will transfer heat.

This is another factor that will help in

determining how hard a dryer will have to
work to remove the specified amount of
moisture.
Material Limitations
The limitations of a material also play a
critical role in dryer design. Factors such as
fragility, material consistency, end use,
and other characteristics, will steer the
design process in one direction or
another.
The limitations of a material also play a
critical role in dryer design. Factors such as
fragility, material consistency, end use,
and other characteristics, will steer the
design process in one direction or
another.

For example, some materials may require

a sterile processing environment. Others
may be too fragile to handle the dropping
action of flights and would require a
“bald” section at the inlet of the dryer.
Other factors to be considered include:
Other factors to be considered include:

- Processing Environment
Other factors to be considered include:

- Processing Environment
- Flight Design
Other factors to be considered include:

- Processing Environment
- Flight Design
- Air-Flow
Other factors to be considered include:

- Processing Environment
- Flight Design
- Air-Flow
- Retention Time
 Processing
Environment
The environment in which the dryer will
work will also need to be considered.

Factors such as humidity, elevation, and

climate can all influence how a dryer will
perform, and how much energy will be
required to reach desired results.
Flight Design
Both flight design and pattern can be
customized to work with the material’s
unique characteristics in order to reach
optimal processing efficiency.
Both flight design and pattern can be
customized to work with the material’s
unique characteristics in order to reach
optimal processing efficiency.

A material’s angle of repose, flowability,

and more, will all have an influence on
flight design.
Air-Flow
Air-flow refers to the direction in which the
drying air flows in relation to the material.
Air-flow refers to the direction in which the
drying air flows in relation to the material.

Rotary dryers are available in two types of

air-flow configurations: co-current and
counter current.
Air-flow refers to the direction in which the
drying air flows in relation to the material.

Rotary dryers are available in two types of

air-flow configurations: co-current and
counter current.

Which air-flow will best suit the process is

based on the material’s characteristics.
For materials that cannot come into
contact with drying air, indirect dryers are
also an option.
For materials that cannot come into
contact with drying air, indirect dryers are
also an option.

Indirect dryers are externally heated to

avoid contact between the drying air and
the material being processed. This could
be because the processing environment
must be inert, or the material is composed
of fines that could otherwise become
entrained in the air stream.
Retention Time
Retention time is another factor that will
need to be considered during the sizing
and design process.
Retention time is another factor that will
need to be considered during the sizing
and design process.

Retention time is the duration of time that

a material will need to remain in the dryer
in order to achieve the desired
characteristics.
Retention time is determined by looking at
the material’s specific heat, heat transfer
properties, and moisture content.
Retention time is determined by looking at
the material’s specific heat, heat transfer
properties, and moisture content.

Retention time can be controlled through

a combination of factors, including the
dryer length, slope, dam plates, and
more.
Many material characteristics will influence the
drying process, and how the dryer should be
designed to achieve desired results.
Many material characteristics will influence the
drying process, and how the dryer should be
designed to achieve desired results.

For this reason, feasibility testing is often

recommended in order to work out process
variables and other valuable processing data.
Conclusion
The process of sizing and designing a rotary
dryer to meet your material’s exact processing
needs is one of precise engineering.
Conclusion
The process of sizing and designing a rotary
dryer to meet your material’s exact processing
needs is one of precise engineering.

While a one-size-fits-all approach may be

tempting, as can be seen, a custom solution
will produce the best results, as many factors
will need to be accommodated for.
FEECO
has been a leader in the thermal processing
industry since the 1950s, providing process &
product development, feasibility testing,
maintenance services, and high-quality,
custom rotary dryers.
Want to learn more?
Download our
Rotary Dryer Handbook

The Rotary Dryer Handbook

Rotary Dryer Sizing & Design
Processing Challenges
Service & Maintenance
And more…

Download Now