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INTRODUCTION
For many years, rotary kilns have been used across various industries to drive chemical reactions by
thermal processing. Rotary kilns have become very established in fields such as cement, lime, and
minerals. Because these thermal processing tools have been used almost exclusively in these industries,
they have been designed to meet the needs of these particular materials. However, there are countless
untapped applications for the use of a rotary kiln.
Rotary kilns can be custom-engineered to meet the thermal processing needs of just about any
material. At Feeco International, we are bringing custom-designed rotary kilns to new industries and
applications. Unlike most rotary kiln manufacturers, our ability to run an array of batch tests allows us to
be very nimble in terms of designing rotary kilns around specific problems or materials.
What follows is a general overview of things to consider before entering the process of designing a
rotary kiln. This is by no means meant to be a practical guide, but rather an introduction to the many
considerations involved in the design of a rotary kiln.
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com
CHEMICAL ANALYSIS
Knowing the chemical composition of a material
is a valuable asset in rotary kiln design for several
reasons. One important reason is that many
materials will combust inside the rotary kiln at
high temperatures, creating more heat than was
put into the rotary kiln. In this case, the rotary kiln
needs to be designed to be able to withstand
those amounts of heat. In other cases, materials
may need a particular chemical atmosphere for
a reaction to occur. For example, an atmosphere
devoid of oxygen, or rich in carbon dioxide. Still
another reason to understand the chemical
SIZING
After the material has been thermally and
chemically analyzed, we can begin sizing the rotary
kiln. The size of a rotary kiln is not only a function of
capacity, but also the amount of heat that will be
generated or required inside of the rotary kiln from
the volatizing of the material. Using the thermal
analysis, we can determine an approximate
retention time. Using our predetermined guides,
we use retention time to establish the length of the to control this. Another advantage to using an
rotary kiln.
indirect rotary kiln is that there are fewer exit gases
that need processing, because less gas is going
The diameter and length of the rotary kiln are into the rotary kiln.
calculated based on the maximum feed rate,
the required retention time, and what we want
the bed profile(how full of material the rotary kiln REFRACTORY
is) to look like. Once we have a rough design of
the rotary kiln, we use several computer programs Once we have our preliminary rotary kiln size, we
to help predict how the material will behave can start to think about the details of the rotary kiln
in the rotary kiln we have designed. We review internals. In the case of a direct fired rotary kiln, in
the combined analyses and if our design does which the hot stream of gas flows directly through
not meet the appropriate criteria, we adjust our the interior of the rotary kiln, refractory is usually
design accordingly.
needed.
Arguably one of the most critical components
of a direct fired rotary kiln, the refractory is what
Another aspect of rotary kiln design is deciding protects the carbon steel shell from the high
whether to go with a direct fired rotary kiln, or an
indirect fired rotary kiln. The difference between
the two is how the heat is introduced. In a direct
fired rotary kiln, the heat is introduced directly into
the internals of the kiln, via a stream of hot gas.
This means there is high heat transfer between
the material and the heat. However, it also means
that there is more gas exiting the rotary kiln that
needs to be processed. In an indirect fired rotary
kiln, the heat comes through the shell of the rotary
kiln, and the heat transfer comes from the material
being in contact with the rotary kiln shell. One of
the big advantages to an indirect fired rotary kiln
is that the temperature can be tightly controlled
along the length of the rotary kiln. For example, if
a material needs to reach a certain temperature,
and be held there for a specific amount of time,
an indirect rotary kiln is ideal, because it is easy
CONCLUSION
ROTARY KILN DESIGN
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com
In a bed that only slips along the interior of the rotary kiln, the
inner part of the bed never really gets exposed to the rotary kiln
shell, creating major temperature discrepancies.
Fixed to the interior of the rotary kiln, a bed disturber turns over
the bed of material by creating a place for the material to build
up and tumble over, redistributing what was on top to the bottom, and vice versa.
to create this efficient heat transfer can be done whose design can vary considerably, are can be
with what is called a bed disturber.
attached to the interior of the rotary kiln, to disturb
the bed and turn it over. However, what seems like
A bed disturber, often custom designed to a simple task, can get complicated quickly, as
create maximum, material-specific efficiency, thermal stressors come into play.
is anything affixed to the inside of the rotary kiln
that helps to mix the bed of material. Ideally, the A common bed disturber is merely a bar, that runs
bed should tumble, turning over and minimizing the length of the interior of the rotary kiln. Material
dead spots, or temperature variations within the pushes up against the bar, building up and rolling
bed. Unfortunately, not all materials tumble well over it, so material that was on the top of the bed
which results in a slipping bed with poor mixing now gets redistributed to the bottom of the bed.
and large temperature variation. Bed disturbers, The disadvantage to using a bar bed disturber is
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com
DAMS
For various reasons, it is often desirable to increase
retention time in the rotary kiln. In order to do this,
the loading, or how much material is in the rotary
kiln at one time, needs to be increased. This is done
by adding what is called a dam to the interior of
the rotary kiln.
A dam in a rotary kiln works much like a dam in
a river. When a dam is put into place, material
builds up behind the dam, forcing retention time
to increase. Material then spills over the dam,
and discharges from the rotary kiln. Internal dams
can also be used if a discharge end dam is not
sufficient.
Dams are put in place when retention time needs to be increased using the same size rotary kiln. Dams allow the loading to be increased, which increases retention time by forcing the material to build up in the rotary kiln.
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com
SEALS
Holding the appropriate temperature within a
rotary kiln is what allows the desired chemical
reaction to occur. Sustaining that temperature,
however, can be difficult if the right seal is not
chosen.
Almost all rotary kilns run at a negative pressure,
meaning gas doesnt leak out, but rather air
leaks in. Because kilns are always running at a
higher temperature than the ambient air, any
ambient air leaking into the rotary kiln will cause
the temperature inside of the rotary kiln to drop.
Not only will this result in an unnecessary amount
of energy being used and wasted, but if the leak
is severe enough, it could potentially disrupt the
chemical reaction. This is why it is crucial to have
a quality seal.
Sealing the ends of a rotary kiln can be a
difficult task, because there is always going to
be something rotating attached to something
stationary. This breeching, or the stationary part, is
typically where leakage will occur. So how do you
seal a moving part against a stationary part? One
answer is a leaf seal. Leaf seals are the standard
seal used on rotary kilns and rotary dryers. But how
does a leaf seal work?
Leaf seals are similar to a fanned out deck of
cards. The cards, or leaves, are made out of a
spring steel. These fanned out leaves are bolted to
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com
As a leader in the thermal processing industry, The same is true for a change in the ambient
Feeco International knows how critical it is to run conditions. A drastic change in temperature can
efficiently. We can supply leaf seals and purged throw a rotary drum out of alignment.
double leaf seals to suit your needs.
Another potential problem area, typically specific
to rotary kilns is refractory failure. Recognizing
MAINTAINING YOUR ROTARY DRUM
potential refractory problems is much more
Rotary drums are a valuable investment with the difficult than recognizing problems with the rotary
potential to have a long productive life with proper drum itself. Unfortunately, many people are not
maintenance. While protecting this investment aware they have a problem until their refractory
is not hard, it does take know-how, and routine fails. If not attended to, refractory failure can have
maintenance. Luckily, this routine maintenance disastrous results.
and knowledge go a long way in recognizing
potential problems, and spotting when a rotary Learning to spot refractory issues in many cases
drum is in need of some first aid.
is as simple as using a temperature gun. Simply
picking a spot on the rotary drum as it rotates,
One of the most prevalent problems that can and making sure it is the same temperature for
cause rotary drum issues is mis- alignment. When the entire circumference of the rotary drum tells
a rotary drum is installed, whether it be a rotary you there are no hot spots in that area. If your
cooler, rotary dryer, or rotary kiln, great care is temperature gun were to read 600, 600, 600, 900,
taken to ensure that the rotary drum is in perfect 600, this would be an indicator that heat is making
alignment. While many rotary kilns and rotary dryers it through the refractory to the shell of the rotary
are running on a slope, aligning them makes sure kiln. This could mean a loss of refractory. Routinely
that there is even pressure on all wheels. Signs that temp gunning spots on the exterior of the rotary
a rotary drum is out of alignment include abnormal kiln can help keep up on some potential refractory
wear patterns or grooves on wheels and tires, issues, and help in preventing major failures.
and/or constant running on one thrust roller and
not the others. Watching for signs like these can Learning to look for some of the above issues can
help prolong the life of your rotary drum, and tell help extend the life of your rotary drum, and also
you when it is time for realignment.
help avert catastrophic failures and downtime.
Aside from caring for the rotary drum, routine
Knowing when to realign a rotary drum can also maintenance should be done on the mechanical
help in its longevity. If there has been a change components of the rotary kiln. Lubricating the tires,
in product, the rotary drum should be realigned. performing an oil change on the gear box, and
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com
3913 Algoma Rd. Green Bay, WI 54311 Phone: (920)468.1000 Fax: (920)469.5110 Email: sales@feeco.com