rotary dryer have maximum efficiency efficiency

rotary dryer design & working principle

rotary dryer design & working principle

For evaporating moisture from concentrates or other products from plant operations, Rotary Dryers are designed and constructed for high efficiency and economy in fuel consumption.Whenever possible to apply heat direct to the material to be dried, Rotary Dryers of the Direct Heating Design are used. If it is not possible to apply heat direct to the material to be dried, Rotary Dryers of the Indirect Heating Design can be furnished so that the heated gases will not come in direct contact with the material.

Rotary Dryer is a simple, inexpensive unit for reducing the moisture content of flotation concentrates, as well as chemical and industrial products. Frequently the saving of shipping weight so effected will pay for the dryer in a few months. Difficulties from freezing while in transit are also eliminated. Many industrial projects are now using Dryers for control and production purposes on many materials.

Three main types of Rotary Dryers can be supplied. The direct heat unit is used when it is permissible for the drying gases to come in direct contact with the material being dried. Partition plates increase the heating surface. Drying may be by hot air or exhaust gases from other operations. If this drying gas has a deleterious effect on the product, then an indirect type of dryer can be supplied. A further derivation is the Tedrow Steam Dryer.

Of the different types of dryers that there are the most common is the ROTARY DRUM DRYER/Kiln, This type of drier is common not only in the mining industry but you will find them in fertilizer plants, Cement plants, and peat hogs to name but a few.

The theories behind these machines are very simple, heat an air space up, and then tumble the material to be dried through this space until it is dried. All though it sounds simple there are problems that have to be solved before the required results are met. But first, so you know what we are talking about lets go through the design of a drier.

First is the KILN, this provides the heat, The BURNER is inside this portion. The fuel for the burner is usually diesel although heavy crude oil could be used in some cases. To be able to generate enough heat to dry the concentrate air must be added by way of a BLOWER. In front of the kiln is the point that the wet concentrate enters the drier. It is put into the revolving SHELL. The shell is on a slight incline. As the Concentrate is tumbled through the hot air mass of the drier it travels down this incline to the exit of the drier.

At this exit point the concentrate is either deposited straight into a storage area or taken to the storage area by a conveyor. It is also at this point that there is an EXHAUST HOOD. This provides a controlled escape passage for the fumes and water vapor that is generated by the concentrate drying. This is a very important function and the operator will have to be sure that it is open at all times. If it should become blocked the water vapor will not be able to escape. The concentrate will become wet and sticky which will result in the discharge plugging. The wet sticky concentrate will also lower efficiency level of the drier for an extended period of time. This happens because inside the drier shell are what are termed FLIGHTS these are flat pieces of metal that are bolted onto the shell.

They are there to lift the concentrate up to the top of the shells rotation and drop the concentrate through the hot air. If the water vapor isnt taken away, the concentrate becomes sticky from reabsorbing the water. This sticky concentrate will fill the spaces between the flights.

The concentrate will not be lifted and dropped through the hot air. This results in a long term condition of poor performance even after the initial problem has been cured. These flights will remain buried in concentrate. This removal of the water vapor is one of the functions of the blower. It assists the natural process of air movement as the hot air mass expands. To prevent the buildup of concentrate on the flights there are often CHAINS attached to them. As the drier revolves the chains slap the flights preventing concentrate from building up on dryers walls.

The drier shell is rotated separately from the stationary kiln section. To achieve the rotation a BULL GEAR is attached around the shell section. There are also two flat rings attached to the shell. These provide surfaces for support rollers to roll on. There is another problem that the inclined shell has, the incline causes the shell to want to slide in the direction of the incline. To prevent this additional rollers are attached to the last set of rollers.

rotary dryers

rotary dryers

Weve built a reputation on building the best rotary dryers in the industry. All of our dryers are custom designed to suit the unique processing needs of your material. Whether you require low or high inlet temperatures, short or long residence times, counter current or co-current flow, FEECOs design team can design a rotary drum dryer for your application.

Rotary dryers are a highly efficient industrial drying option for bulk solids. They are often chosen for their robust processing capabilities and their ability to produce uniform results despite variance in feedstock.

The drum is positioned at a slight horizontal slope to allow gravity to assist in moving material through the drum. As the drum rotates, lifting flights pick up the material and drop it through the air stream in order to maximize heat transfer efficiency. When working with agglomerates, the tumbling action imparted by the dryer offers the added benefit of further rounding and polishing the granules.

All FEECO equipment and process systems can be outfitted with the latest in automation controls from Rockwell Automation. The unique combination of proprietary Rockwell Automation controls and software, combined with our extensive experience in process design and enhancements with hundreds of materials provides an unparalleled experience for customers seeking innovative process solutions and equipment.

Rotary dryers are known as the workhorse of industrial dryers. They are able to process a wide variety of materials, and can lend a hand in nearly any industry requiring industrial drying solutions. Some of the most common industries and materials in which rotary dryers are employed include:

Unlike direct dryers, indirect dryers do not rely on direct contact between the material and process gas to dry the material. Instead, the rotating drum is enclosed in a furnace, which is externally heated. Contact with the heated drum shell is what dries the material.

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Our rotary dryers are built to the highest quality standards, with longevity in mind. The best part about buying a FEECO rotary dryer, is that you get the security of knowing your equipment is backed by over 60 years of experience, material and process knowledge, and a proven track record.

the truth about fluid bed dryer efficiency

the truth about fluid bed dryer efficiency

When it comes to processing bulk solids, the debate over which type of industrial dryer rotary or fluid bed is superior continues to plague the industry. Adding to confusion is the fact that there are many myths clouding the decision-making process when choosing between the two types of dryers.

The industry is particularly awash in myths regarding the energy efficiency of fluid bed dryers compared to rotary dryers. Here, well uncover some of the hidden truths behind these widespread beliefs, proving that in reality, rotary dryers are the more efficient option.

This myth stems from the fact that fluid bed dryers promote increased air-to-material contact (i.e., improved heat transfer) compared to rotary dryers. For this reason, manufacturers will often claim that fluid bed dryers are far more efficient in terms of fuel consumption by as much as 40%.

While it is true that fluid bed dryers offer some enhanced heat transfer compared to rotary dryers, fluid bed dryers use lower inlet gas temperatures (typically around 900 vs. the 2100 commonly used in rotary dryers). So while rotary dryers may offer less thermal efficiency in theory, the higher temperatures they employ allow for increased efficiency, making fuel consumption comparable for these two dryer types.

Fluid bed dryer manufacturers may claim that recycled exhaust air from the cooling portion of the unit can be recirculated to the inlet gas in order to give the appearance of additional energy savings.

Recirculating exhaust air from the cooling section of a fluid bed dryer allows entrained particles to be recirculated to the inlet system as well. This plugs duct work and blinds the perforated plate, reducing efficiency, as less air volume is able to perforate through the plate.

In addition to utilizing lower processing temperatures resulting in increased fuel consumption, fluid bed dryers require an additional amount of air in order to fluidize the material one factor that all fluid bed manufacturers fail to mention. Adding this additional air requires significant amounts of electricity to move the air, further driving up the associated energy costs sometimes by as much as 20%.

Furthermore, because of this need for a set air volume, variations in the particle size of the feed material will decrease the efficiency of the fluid bed dryer forcing the customer to only dry particles in a certain size range for maximum efficiency.

An additional myth regarding energy savings is that of the evaporative cooling effect. Fluid bed dryer manufacturers will often claim an energy savings of up to 10% as a result of evaporative cooling.

The effects of evaporative cooling are real; chilled or cooled air will evaporate a portion of the moisture when exposed to a warm, moist material. However, this figure is often severely exaggerated, again to give the appearance of a greater savings in energy. While somemanufacturers may claim up to 10% energy savings from evaporative cooling, this figure is, on average, closer to 2%.

While a better understanding of these principles will help in making a more educated decision during the dryer selection process, it can still be difficult to know what is fact and what is fiction. An easy way to work around this issue is to ask the manufacturer for a guarantee on the efficiency of the system.

FEECO has been serving the bulk solids drying industry since 1951. Weve tested and designed systems for hundreds of materials, giving us an unmatched expertise in industrial drying. We manufacture custom rotary dryers around the parameters of a given material to ensure the most efficient drying solution is reached. For more information on our custom rotary dryers, contact us today!

high efficiency soybean straw rotary drum dryer machine

high efficiency soybean straw rotary drum dryer machine

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