Rotary kilns are available in both direct-fired and indirect-fired configurations. Each type offers its own unique advantages and disadvantages. This presentation gives an overview of the two types and the advantages and disadvantages each has to offer.
Rotary kiln design is a complex process, with a variety of factors and material characteristics influencing the sizing and design. This presentation gives an overview of the sizing and design process, including the many factors that will need to be considered during the design stage.
Rotary kilns are diverse thermal processing machines. This presentation looks at the many options available to customize a rotary kiln to promote improved processing efficiency. This includes, rotary kiln dams, bed disturbers, flights, and more.
While rotary kilns are often engineered around the characteristics of the material to be processed, the base of a rotary kiln can be somewhat standard. This presentation looks at the construction and components of both indirect-fired and direct-fired rotary kilns.
Rotary kilns have become the backbone of many industrial processes, with new applications being developed all the time. This presentation gives an overview of what types of processes rotary kilns are used for, as well as how both direct-fired and indirect-fired rotary kilns work.
Rotary kiln design is a complex process, with a variety of factors and material characteristics influencing the sizing and design. This presentation gives an overview of the sizing and design process, including the many factors that will need to be considered during the design stage.
Rotary kilns are diverse thermal processing machines. This presentation looks at the many options available to customize a rotary kiln to promote improved processing efficiency. This includes, rotary kiln dams, bed disturbers, flights, and more.
While rotary kilns are often engineered around the characteristics of the material to be processed, the base of a rotary kiln can be somewhat standard. This presentation looks at the construction and components of both indirect-fired and direct-fired rotary kilns.
Rotary kilns have become the backbone of many industrial processes, with new applications being developed all the time. This presentation gives an overview of what types of processes rotary kilns are used for, as well as how both direct-fired and indirect-fired rotary kilns work.
Air flow configuration is an important consideration in the design of a rotary kiln. This presentation looks at the different types of air flow available, and the benefits each has to offer.
A Rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process. Materials produced using rotary kilns include: Cement. Lime.
First approach design procedure of a direct heated rotary dryer.
Now I know why nobody was publishing this kind of works, well it takes a lot of time to upload them ;)
PS: If you get bored skip to the end, there is something that you will definitely like.
Influences of Poter’s five forces model in an industryMasum Hussain
Porter’s Five Forces model is a powerful management tool for analyzing the current industry profitability and attractiveness by using the outside-in perspective. Within the last decades, the model has attracted some criticism because of the developing Internet economy. Due to an increasing significance of Digitalization, Globalization and Deregulation, the industry structure of the ‘Old Economy’ changed fundamentally. The ‘New Economy’ is not comparable with the ‘Old Economy’, which is the basis of the Five Forces model. Moreover the last decades have shown that Information Technology became more and more important. Nowadays Technology is one of the most important drivers for change and not only important for the implementation of change. Today new technology is one of the most important drivers for change. Furthermore Porter also couldn’t take the growing significance of ‘Government Deregulation’ into account. In 1979 the government was able to regulate the market by defining and enforcing “property rights and the rules of competition”. In the past 20 years, governmental influence on industries decreased steadily. Therefore the most of the concerned industries (airlines, communication, or banking industry) were able and constrained to search for alternatives and to structure their business in a new way.
Air flow configuration is an important consideration in the design of a rotary kiln. This presentation looks at the different types of air flow available, and the benefits each has to offer.
A Rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process. Materials produced using rotary kilns include: Cement. Lime.
First approach design procedure of a direct heated rotary dryer.
Now I know why nobody was publishing this kind of works, well it takes a lot of time to upload them ;)
PS: If you get bored skip to the end, there is something that you will definitely like.
Influences of Poter’s five forces model in an industryMasum Hussain
Porter’s Five Forces model is a powerful management tool for analyzing the current industry profitability and attractiveness by using the outside-in perspective. Within the last decades, the model has attracted some criticism because of the developing Internet economy. Due to an increasing significance of Digitalization, Globalization and Deregulation, the industry structure of the ‘Old Economy’ changed fundamentally. The ‘New Economy’ is not comparable with the ‘Old Economy’, which is the basis of the Five Forces model. Moreover the last decades have shown that Information Technology became more and more important. Nowadays Technology is one of the most important drivers for change and not only important for the implementation of change. Today new technology is one of the most important drivers for change. Furthermore Porter also couldn’t take the growing significance of ‘Government Deregulation’ into account. In 1979 the government was able to regulate the market by defining and enforcing “property rights and the rules of competition”. In the past 20 years, governmental influence on industries decreased steadily. Therefore the most of the concerned industries (airlines, communication, or banking industry) were able and constrained to search for alternatives and to structure their business in a new way.
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Demystifying Induction Furnaces | DelmerDelmer Group
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Rotary kilns are highly flexible thermal processing devices, capable of processing a multitude of materials. This presentation goes over the many processes that can be carried out using a rotary kiln, including calcination, thermal desorption, organic combustion, sintering, heat setting, and reduction roasting.
CONTENTS
1.Introduction
2.Applications
3.Classification
4.Types
5.Charachterstics of an Efficient Furnace
6. Economic Measure of Surnace
7. Modes of Heat Transfer in Furnaces
This presentation gives an overview on the equipment options available for the drying, cooling, and high temperature processing of bulk solids. Equipment covered includes direct and indirect rotary dryers and coolers, as well as direct- and indirect-fired rotary kilns (sometimes called calciners).
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Normal grinding processes which do not use a cooling system can reach up to 200°F.
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This presentation looks at the differences between direct-fired rotary dryers and indirect-fired rotary dryers, and covers topics such as operation, applications, and materials of construction.
Industrial furnace manufacturers – Most popular choice for your industrial ap...Shivang Furnace
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Open Coil Heaters, crafted from robust alloys like nickel-chromium, stand as versatile electric heating elements, prized for their efficacy in heating liquids and air across diverse industries. Their operational principle involves passing electric current through resilient coils, generating heat via resistance—a method ensuring rapid, precise heating for applications demanding consistent temperature control. Embracing these heaters unveils multiple advantages, including energy efficiency, cost-effectiveness, and adaptability to various environments. However, selecting the ideal Open Coil Heater warrants consideration of factors like environmental conditions, temperature requirements, and watt density. Ensuring proper installation and routine maintenance, guided by manufacturer specifications, is pivotal for sustained efficiency.
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NPK fertilizer is a key component in providing the nutrition plants need, and subsequently, plays a critical role in world food security. This presentation looks at what NPK fertilizer is made of and how it works. Organic and inorganic sources of each nutrient, as well as production methods are also covered.
This presentation gives an overview of the two main approaches to processing copper ore into a refined product: the pyrometallurgical approach (copper concentrates), and the hydrometallurgical approach (SX-EW). Process flow diagrams and key equipment are also highlighted.
This presentation is Part 1 of a 2-part infographic series on global copper production and processing. The presentation gives an overview on the top 20 copper mines in the world by capacity, including how much they produce annually, the processing method(s) they use, mine owners, and additional products. The infographic is available at FEECO.com/copper-processing, where Part 2 can also be found.
As large-scale farms become the future of agriculture, technologies are needed to help farmers manage increasing amounts of manure. This presentation looks at a unique approach to managing manure through one all-encompassing process that not only alleviates that challenges associated with manure, but also allows it to be used to its fullest potential. This process can yield various products, including biogas, a premium fertilizer product, and a Dried Manure Solids (DMS) bedding product.
As the granulation of manure into a premium fertilizer or soil amendment product becomes more popular, testing is needed to confirm feasibility and develop a process around the unique manure sample to be processed.
This presentation goes over why testing is important, and details the testing process that occurs in the FEECO Innovation Center, including the phases of testing, how testing works, and what particle characteristics can be targeted.
There are many factors to consider when developing a manure granulation process. While not an exhaustive list, this presentation goes over some of the main factors to consider, including return on investment, spatial needs and storage, emissions, fuel source, product off-take, automation, engineering, and more.
The granulation of manure into a premium fertilizer product is becoming an increasingly popular method of managing on-farm waste. However, before manure can be used as a feedstock in the granulation process, it must be pre-conditioned. This presentation looks at the many methods available for pre-conditioning both wet and dry manure sources for use as a feedstock in the granulation process.
The granulation of manure into fertilizer and soil amendment products is becoming a popular option for large-scale farms learning to deal with increasing amounts of manure.
This presentation looks at the various systems available for granulating manure, as well as the advantages and disadvantages each has to offer.
The granulation of manure into a premium fertilizer product offers a widespread solution to many of the issues faced by the global population today, including the pressure on farms to deal with increasing amounts of manure on smaller plots of land, nutrient runoff, and the Earth's depleted soils. This presentation looks at how the granulation of manure can help to resolve all of these issues.
Manure can be processed into Recycled Manure Solids (RMS) or Dried Manure Solids (DMS) bedding. This presentation looks at the process of transforming raw manure into a dried manure solids bedding product, as well as the many benefits this can offer.
Bedding recovery from manure is becoming a popular alternative to more traditional bedding options. This presentation looks at the many benefits of utilizing a recycled manure solids (RMS) or dried manure solids (DMS) bedding.
The decision of whether to use a rotary dryer or kiln to reduce moisture in the feedstock often comes up during the design stages of a rotary kiln. This presentation examines the costs and benefits associated with each option.
Rotary kilns are a significant investment in any processing operation, requiring precise engineering around process and product goals. Finding a rotary kiln manufacturer that can design and fabricate a custom, quality solution can be difficult. This presentation provides a guide on some of the factors to consider when choosing a rotary kiln manufacturer for your processing application.
Maintenance is a key component in any industrial processing operation, but is perhaps especially important when working with phosphates, a material that presents unique and varying challenges to processors.
This presentation gives an overview of some of the key maintenance considerations to uphold process efficiency and prolong the life of phosphate processing equipment.
This presentation looks at the process equipment used in both phosphatic fertilizer and animal feed production. This includes major equipment such as rotary dryers, coolers, kilns, and granulation drums, as well as other equipment such as pipe reactors, hammer mills, and coating drums.
Material testing is a critical component in the success of many phosphate processing operations, whether a producer is looking to create a new product, improve an existing process, or otherwise.
This presentation looks at why testing is important, and what types of testing are available in the FEECO Innovation Center, as well as how the testing process works.
Phosphate rock is a key component to sustaining life on Earth. However, it is also a finite resource. This presentation looks at the opportunity to recycle phosphorus from existing waste streams such as manure and biosolids.
Rotary dryers are an integral component throughout the processing of phosphate rock into phosphatic fertilizers and animal feed products. This presentation goes over how rotary dryers are used in the phosphates industry, the benefits they can offer, and factors to consider during the phosphate dryer design stage.
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2. Rotary kilns are an advanced thermal
processing tool used to cause a chemical
reaction or physical change in a solid
material through the application of
high temperatures.
3. Rotary kilns are available in two configurations:
direct-fired, and indirect-fired.
4. Rotary kilns are available in two configurations:
direct-fired, and indirect-fired.
Each type offers distinct advantages and
disadvantages. And while there can be some
overlap in applications, in general, each type
is better suited for different applications.
5. The following will give an overview on each
type of configuration, as well as their
advantages and disadvantages.
8. Direct-fired kilns rely on direct contact between
the material and process gas to process the
material.
9. Combustion gas is pushed through the drum in
either a co-current or counter-current fashion,
efficiently processing the material inside
the drum.
10. The main advantage to the direct-fired kiln is
that it is highly efficient.
11. The main advantage to the direct-fired kiln is
that it is highly efficient.
The direct contact between the material and
process gas allows for optimal heat transfer.
12. The main advantage to the direct-fired kiln is
that it is highly efficient.
The direct contact between the material and
process gas allows for optimal heat transfer.
However, a few disadvantages to working
with this type of kiln do exist…
13. More Off-Gases
Because a process gas is used to heat the
material, direct-fired kilns produce more
off-gases that will require treatment than
their indirect-fired counterparts.
14. Risk of Entrainment
Similarly, the direct contact with the
process gas can be a problem when
working with fine materials. The process
gas could potentially pick up and entrain
the material, carrying it out through the
exhaust system.
15. Risk of Entrainment
Similarly, the direct contact with the
process gas can be a problem when
working with fine materials. The process
gas could potentially pick up and entrain
the material, carrying it out through the
exhaust system.
The degree of entrainment depends on a
variety of factors, including gas velocity,
gas density, particle density, and shape.
16. In situations such as this, the design of the
kiln must center around permissible gas
velocities instead of heat transfer
requirements.
17. In situations such as this, the design of the
kiln must center around permissible gas
velocities instead of heat transfer
requirements.
For this reason, when working with fine
materials, an indirect kiln may be a more
suitable option.
18. Applications
Direct-fired kilns are the most common
equipment of choice when it comes to
thermal processing, because of the
efficiency they offer. They are commonly
used to process a variety of materials,
including:
19. Applications
Direct-fired kilns are the most common
equipment of choice when it comes to
thermal processing, because of the
efficiency they offer. They are commonly
used to process a variety of materials,
including:
• Proppants
20. Applications
Direct-fired kilns are the most common
equipment of choice when it comes to
thermal processing, because of the
efficiency they offer. They are commonly
used to process a variety of materials,
including:
• Proppants
• Minerals (Bauxite, Gypsum, Phosphates)
21. Applications
Direct-fired kilns are the most common
equipment of choice when it comes to
thermal processing, because of the
efficiency they offer. They are commonly
used to process a variety of materials,
including:
• Proppants
• Minerals (Bauxite, Gypsum, Phosphates)
• Specialty Ceramics and Clays
22. Applications
Direct-fired kilns are the most common
equipment of choice when it comes to
thermal processing, because of the
efficiency they offer. They are commonly
used to process a variety of materials,
including:
• Proppants
• Minerals (Bauxite, Gypsum, Phosphates)
• Specialty Ceramics and Clays
• Iron Ore
23. Applications
Direct-fired kilns are the most common
equipment of choice when it comes to
thermal processing, because of the
efficiency they offer. They are commonly
used to process a variety of materials,
including:
• Proppants
• Minerals (Bauxite, Gypsum, Phosphates)
• Specialty Ceramics and Clays
• Iron Ore
• And more…
26. Unlike direct-fired kilns, indirect kilns do not
utilize direct contact between the
material and process gas to process
material.
27. Unlike direct-fired kilns, indirect kilns do not
utilize direct contact between the
material and process gas to process
material.
Instead, the drum is enclosed in a heat
shroud, which is externally heated. This
heats the drum itself, and the material is
processed through direct contact with
the shell of the drum.
28. The disadvantage to an indirect kiln is that it is
much less efficient than a direct kiln.
29. The disadvantage to an indirect kiln is that it is
much less efficient than a direct kiln.
However, processing with an indirect kiln offers
many advantages…
30. Inert Processing Environment
Indirect processing is beneficial because it
allows for the processing environment
inside the drum to be tightly controlled.
This is necessary when processing
materials that may form an undesirable
compound with nitrogen or oxygen at
high temperatures.
31. Inert Processing Environment
Indirect processing is beneficial because it
allows for the processing environment
inside the drum to be tightly controlled.
This is necessary when processing
materials that may form an undesirable
compound with nitrogen or oxygen at
high temperatures.
An indirect kiln allows for the processing to
occur in an inert environment.
33. Temperature Control
Indirect kilns also allow for the
temperature along the length of the kiln to
be tightly controlled as well.
This is beneficial when a material needs to
be brought up to temperature and then
held there for a specific amount of time.
34. No Risk of Entrainment
In addition to these advantages, indirect
kilns are also beneficial because they
avoid the risk of entrainment when
processing fine materials, which can be
an issue when processing in a direct kiln.
35. Applications
Indirect kilns are used throughout a variety
industries to process many different
materials. Commonly processed materials
include:
36. Applications
Indirect kilns are used throughout a variety
industries to process many different
materials. Commonly processed materials
include:
• Carbon Black
37. Applications
Indirect kilns are used throughout a variety
industries to process many different
materials. Commonly processed materials
include:
• Carbon Black
• Chemical Precipitates
38. Applications
Indirect kilns are used throughout a variety
industries to process many different
materials. Commonly processed materials
include:
• Carbon Black
• Chemical Precipitates
• Filter Cakes
39. Applications
Indirect kilns are used throughout a variety
industries to process many different
materials. Commonly processed materials
include:
• Carbon Black
• Chemical Precipitates
• Filter Cakes
• Finely Ground Solids
40. Applications
Indirect kilns are used throughout a variety
industries to process many different
materials. Commonly processed materials
include:
• Carbon Black
• Chemical Precipitates
• Filter Cakes
• Finely Ground Solids
• And more…
41. Conclusion
Both direct and indirect rotary kilns provide a
highly engineered solution to thermal
processing needs, each offering distinct
advantages and disadvantages that make
them better suited to different processes.
42. 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 kilns.
43. Want to learn more?
Download our
Rotary Kiln Handbook
The Rotary Kiln Handbook
Rotary Kiln Sizing & Design
Processing Challenges
Service & Maintenance
And more…
Download Now