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ROTARY DRYER
HANDBOOK
a product of
Contents
INTRO
About FEECO
10
CONSIDERATIONS IN DRYING
Rotary Dryer or Fluid Bed Dryer?
16
18
19
23
25
26
CONCLUSION
What Makes an Industry Leading Rotary Dryer Manufacturer
29
31
THE
ROTARY DRYER
HANDBOOK
Introduction
The following is a collection of articles surrounding the topic of industrial drying using a rotary dryer. This
comprehensive resource touches on a variety of topics surrounding the industrial drying process, including
installation and maintenance, processing challenges, and how processing in a rotary dryer works.
About FEECO
FEECO International was founded over 60 years ago, as an engineering and equipment manufacturer. We quickly
became known as the material experts, able to solve just about any material processing or handling problem,
and now serve nearly every industry, from energy and agriculture, to mining and minerals.
As experts in the field of thermal processing, FEECO has been solving problems through feasibility testing and
custom thermal processing equipment, including rotary dryers, since the 1950s. Weve helped our customers
process hundreds of materials into value-added products, eliminating handling and transportation problems,
improving product characteristics, and creating marketable products.
FEECO US Headquarters
Intro to
ROTARY
DRYERS
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drying technologies.
everything in between.
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ROTARY DRYER
OPERATION
HOW ROTARY DRYERS WORK | DIRECT VS. INDIRECT | SIZING & DESIGN
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Combustion
Chamber
Burner
Raw
Material
Feed
Exhaust Gas
System
Riding Ring/Tire
Ring Gear
Discharge
Breeching
Flights
Graphite
Block Lubrication
Assembly
Drum Shell
Riding Ring
Product
Discharge
Drive
Assembly
Drive
Guarding
Trunnion
Wheel
Gear
Reducer
Trunnion
Guard
Pillow Block
Bearing
Girth
Gear
Pinion
Gear
Thrust Roller
Assembly
chamber lifespan.
Raw Material Feed:
Burner:
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Air Seal
Thrust Rollers
Trunnion Wheels
Drive Assembly
Flights
Product Discharge
Discharge Breeching
The discharge breeching is where two main functions
Riding Ring
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Dryer or Kiln?
When looking for an industrial
drying solution, there is often
confusion on whether the best
solution would be a kiln or a dryer.
These products may share similarities,
but they are each intended for very
different applicaitons.
Rotary dryers are used primarily to draw
moisture out of a material and operate
at temperatures between 800 1400F.
Because of these low temperatures,
they are not used to cause a phase
change or chemical reaction
within a material.
Conversely, rotary kilns operate at
much higher temperatures typically
between 1000 - 3000F with their
primary objective being to cause a
phase change or chemical reaction.
While rotary kilns can sometimes aid in
the drying process, this is not their
primary objective. Therefore, customers
looking for an industrial drying
solution should stick with
rotary dryers.
Common Add-Ons:
Advancing Flights
Advancing flights help to advance material into
the drum, in order to prevent buildup near the wet
feed discharge. Incorporating advancing flights into
a rotary dryer also gives material a chance to dry
before it hits the next flights, a process which can help
prevent potential sticking issues.
Knocking Systems
Knocking systems help to prevent build-up within the
dryer, by knocking off material as the drum rotates.
Various options are available for knocking systems.
For more information on knocking systems, see our
Knocking Systems Brochure.
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Direct vs.
Indirect Drying
Direct dryers are used far more frequently than their
indirect counterparts, because of the efficiency
they offer. And while direct-fired rotary dryers are
most often the selected drying method, indirect
rotary dryers are a valuable alternative for specific
processing needs.
Operation
While both types of dryers are comprised of a rotating
drum in which the processing occurs, these two types
of dryers utilize very different methods to process
the material.
Direct-fired dryers rely on direct contact between
the material and drying air to efficiently dry materials.
Efficiency is further increased by the addition of lifting
Sweep Air
Material of Construction
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Rotary Dryer
Sizing & Design
Bulk Density
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Material Limitations
Materials are often accompanied by limitations
that will steer the design process in one direction or
another. Such is the case with materials that have the
potential for combustion in certain settings, or when
a material requires absolute sterility. In unique cases
such as these, a direct-fired rotary dryer would not be
an option, so an indirect-fired dryer would be used
instead. The need for sterility can also dictate the
material of construction used for the shell of the dryer.
Other examples of material limitations that can affect
the design process include:
Processing Environment
Flight Design
efficient drying.
choice.
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to the material.
Air-Flow
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burner efficiency.
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the recycled air to a point where it would no longer be finding the balance between how a material will
beneficial for pre-heating.
Retention Time
Retention time is also an important consideration
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Considerations in
DRYING
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Rotary Dryer or
Fluid Bed Dryer?
dryers have been used for more industrial applications, to leave an operation at a standstill. Feedstock with
such as minerals, fertilizers, and aggregates, while fluid lumps or inconsistencies in moisture content can cause
bed dryers have been used more in the pharmaceu-
Material Considerations
Rotary dryers have been called the workhorse of
Spatial Footprint
processing plant.
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Operational Considerations
Fluid bed dryers are much less suited for these types
of situations, requiring a consistent processing environment. Variations in feedstock, or power outages can
bed dryer.
Energy Consumption
Rotary Dryer
Energy Consumption
Thermal Efficiency
Capital Costs
Comparable
Spatial Footprint
Large footprint
Small footprint
Modular design allows for easy operational
growth
Maintenance
Requires more
Requires Less
Feedstock Variance
Insensitive to variance
Industry
Minerals
Fertilizers
Raw Materials
Pharmaceuticals
Specialty Chemicals
Foodstuffs
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Challenges in
Rotary Dryer Processing
Rotary dryers may be the workhorse of the industrial
drying industry, but that does not mean they are
without challenges. Different materials can present
unique challenges, and will require careful preparation
in many cases, and routine maintenance in others, in
order to prolong the life of the rotary dryer and ensure
processing efficiency is maintained. The most common
challenges faced in rotary dryer operation include:
build-up, abrasion, and corrosion.
Build-up
While rubber, ceramic, or even stainless steel liners
offer an effective solution to preventing build-up in
other rotary drum applications, where heat is used,
such as in the case of a rotary dryer, liners are not
typically an option. Because heat causes materials to
expand, and different materials expand at differing
rates, installing a liner into a rotary dryer would more
than likely result in problems. For this reason, knocking
systems are the most common way to address
build-up in a rotary dryer.
There are three basic designs for knocking systems:
ball & tube knockers, hammer knockers, and pneumatic hammer knockers. Each design is mounted to
the exterior of the drum, and serves to knock off
potential build-up as the drum rotates. No matter
which design is chosen, a wear plate or band is also
installed to protect the shell of the drum from the
knocking, while still allowing the vibration from the
knock to dislodge any potential build-up within
the drum.
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between the material of construction and the material prevented in order to prolong the life of the dryer.
to be processed is particularly important to understand
in preventing corrosion. Since corrosion is a chemical
action, one must understand how the material being
processed will react with the materials of construction.
Choosing stainless steel or alloys when fabricating a
rotary dryer will help to minimize corrosion. Protective
coatings can also be an option to protect the shell of
a rotary dryer, with a variety of choices available.
When processing a material that is corrosive or
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process scale-up.
production facility:
processed.
To Test Pre-Conditioning
ity lab will not only help to work out process variables,
production.
feasibility studies:
Residence time
energy standpoint.
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INSTALL &
MAINTENANCE
INSTALLATION TIPS | ALIGNMENT | PREVENTATIVE MAINTENANCE
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Ensuring A Smooth
Dryer Installation
not done
handled improperly
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of knowledge for answering installation and operation- install. Its worth mentioning also, that the proper tools
al questions on the spot. Furthermore, they can train
Plan Ahead
carrying out a seamless rotary dryer installation. Ideally, for a new crane to arrive and be mobilized before
the equipment purchaser, manufacturer, and installa-
pre-alignment to be completed.
dryer installation.
simple conference between the equipment purchaser, installing contractor, and original manufacturer.
according to plan.
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Laser Alignment
re-aligned.
of the dryer.
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Just like a car, a rotary dryer needs routine maintenance in order to continue running properly. Though
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Alignments
Gear replacements
Re-alignment
Annual inspections
Training programs
Tire Grinding
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CONCLUSION
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Material Knowledge
Flexibility in Customization
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development process.
High-Quality Fabrication
Choosing a manufacturer that will accommodate the
rigors of processing material in a rotary dryer is vital.
Rotary dryers should be built using high quality
materials so they can provide years of reliable
processing. Attention to details, such as a corrosive
material, can be the difference between a dryer
that lasts a few years, and a dryer that lasts for
decades.
Ongoing Support
An industry-leading rotary dryer manufacturer does
not just build rotary dryers; they service them too.
Choosing an equipment supplier that will provide
ongoing support in the way of install services, training,
maintenance, parts, and emergency services is
crucial to the life of your industrial drying system.
While they may be relatively low-maintenance, rotary
dryers still require routine maintenance to prolong the
life of the drum and continue efficient operation.
Routine maintenance such as oil changes,
re-alignment, and tire grinding will keep your rotary
dryer in operation for years to come. A leader in rotary
dryer manufacturing should have a solid service
department, staffed by experienced technicians.
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Lab Testing
+
Customer Service
Our Service Team is
ready to serve, from
routine maintenance,
to emergency service.
60
YEARS
of experience
Engineering
We engineer custom
solutions to meet
your unique needs.
Manufacturing
We manufacture the best
heavy-duty processing
equipment around.
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