This document outlines the significance and applications of rotary kilns in thermal processing, highlighting their flexibility to handle various materials and the essential role of testing in process design. It details the importance of testing for commercial viability, product development, and improving existing processes, while describing different testing phases—batch and pilot testing. The Feeco Innovation Center is introduced as a facility offering comprehensive testing options and data collection to optimize rotary kiln processes.

1. Thermal Testing
Experts in process design and material
processing for over 65 years.
With Rotary Kilns

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 highly flexible and can be used
to process a wide variety of materials.

4. Rotary kilns are highly flexible and can be used
to process a wide variety of materials.
They are used for countless applications, with
new ones being developed all the time.

5. Testing plays an integral role in the
development of many industrial processes,
but is especially important when working with
rotary kilns, whether the process is new or
well-established.

6. Some of the most commonly tested
applications include:

7. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes

8. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes
• Sintering

9. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes
• Sintering
• Heat Setting

10. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes
• Sintering
• Heat Setting
• Organic Combustion

11. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes
• Sintering
• Heat Setting
• Organic Combustion
• Metal Recovery

12. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes
• Sintering
• Heat Setting
• Organic Combustion
• Metal Recovery
• Calcination

13. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes
• Sintering
• Heat Setting
• Organic Combustion
• Metal Recovery
• Calcination
• Mineral Processing

14. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes
• Sintering
• Heat Setting
• Organic Combustion
• Metal Recovery
• Calcination
• Mineral Processing
• Reduction Roasting

15. Some of the most commonly tested
applications include:
• Thermal Desorption of Organic/Hazardous
Wastes
• Sintering
• Heat Setting
• Organic Combustion
• Metal Recovery
• Calcination
• Mineral Processing
• Reduction Roasting
• And More…

16. Why is
Testing Important?

17. There are many reasons why it is both
necessary and desirable to conduct testing…

18. To Size and Design A Commercial Size Kiln
One of the most common reasons for
conducting testing is to gather the
necessary data for sizing a commercial size
unit for an intended application.

19. In this setting, the desired set of product
parameters has typically been determined,
and the customer needs to know how the
kiln will need to be designed to produce
those specifications.

20. To Aid in Product Development
Testing is also useful in the product
development stage.

21. To Aid in Product Development
Testing is also useful in the product
development stage.
Here, testing can be carried out on small
batches of material, in order to determine
what specifications will be needed for the
job at hand.

22. This is commonly seen in the proppant
industry, where proppants must be
carefully designed to perform under the
specific characteristics of the deposit.

23. To Confirm Viability of an Intended Process
Testing is also a valuable tool in determining
whether or not an intended process holds
potential for a commercial scale operation.

24. To Confirm Viability of an Intended Process
Testing is also a valuable tool in determining
whether or not an intended process holds
potential for a commercial scale operation.
Here, testing at various scales can be used
to determine if a process is both technically
possible, and economically viable.

25. A common example of this can be seen
in the recovery of metals from wastes:

26. A common example of this can be seen
in the recovery of metals from wastes:
Often times waste materials may contain
valuable metals, but are landfilled
because the metals are not accessible in
their current form.

27. A common example of this can be seen
in the recovery of metals from wastes:
Often times waste materials may contain
valuable metals, but are landfilled
because the metals are not accessible in
their current form.
In cases like this, the waste material can
be tested to determine if the metal can
be recovered in an economically
viable way.

28. To Test Variable Process Conditions
Testing is also helpful when a company
would like to improve their existing thermal
process, without having to use their
own kiln.

29. To Test Variable Process Conditions
Testing is also helpful when a company
would like to improve their existing thermal
process, without having to use their
own kiln.
Testing allows them to try out various
process conditions in a test setting, without
disrupting production of their existing
system.

30. How Testing
Works

31. Testing is commonly conducted first at batch
scale, and then at pilot scale.

32. Batch Testing
Batch, or feasibility testing, involves testing
small sample sizes in order to gather initial
process data, such as time and
temperature profiles.

33. Batch Testing
Batch, or feasibility testing, involves testing
small sample sizes in order to gather initial
process data, such as time and
temperature profiles.
This is a cost-effective way to gather initial
process data and help define process
parameters needed for pilot scale testing.

34. Pilot Testing
Pilot testing is carried out at a much larger
scale, allowing for a continuous process to
be tested and commercial process
conditions to be simulated.

35. During both types of testing, solid samples can
be regularly removed from the kiln to analyze
the physical and chemical properties of the
material at defined intervals.

36. Various material characteristics can be
analyzed to ensure a product is meeting
desired specifications. This might include:

37. Various material characteristics can be
analyzed to ensure a product is meeting
desired specifications. This might include:
• Flowability

38. Various material characteristics can be
analyzed to ensure a product is meeting
desired specifications. This might include:
• Flowability
• Compression Strength

39. Various material characteristics can be
analyzed to ensure a product is meeting
desired specifications. This might include:
• Flowability
• Compression Strength
• Bulk Density

40. Various material characteristics can be
analyzed to ensure a product is meeting
desired specifications. This might include:
• Flowability
• Compression Strength
• Bulk Density
• Crush Strength

41. Various material characteristics can be
analyzed to ensure a product is meeting
desired specifications. This might include:
• Flowability
• Compression Strength
• Bulk Density
• Crush Strength
• Chemical Analysis

42. Various material characteristics can be
analyzed to ensure a product is meeting
desired specifications. This might include:
• Flowability
• Compression Strength
• Bulk Density
• Crush Strength
• Chemical Analysis
• Gas Sampling & Monitoring

43. A number of data points can also be
collected during processing, including:

44. A number of data points can also be
collected during processing, including:
• Residence Time

45. A number of data points can also be
collected during processing, including:
• Residence Time
• Kiln Slope

46. A number of data points can also be
collected during processing, including:
• Residence Time
• Kiln Slope
• Temperature Requirements

47. A number of data points can also be
collected during processing, including:
• Residence Time
• Kiln Slope
• Temperature Requirements
• Kiln Speed

48. A number of data points can also be
collected during processing, including:
• Residence Time
• Kiln Slope
• Temperature Requirements
• Kiln Speed
• Emissions

49. A number of data points can also be
collected during processing, including
• Residence Time
• Kiln Slope
• Temperature Requirements
• Kiln Speed
• Emissions
• Feed Rate

50. A number of data points can also be
collected during processing, including
• Residence Time
• Kiln Slope
• Temperature Requirements
• Kiln Speed
• Emissions
• Feed Rate
• And more…

51. The FEECO Innovation Center offers
comprehensive testing options for thermal
applications. In addition to batch and pilot
scale direct and indirect kilns, FEECO offers a
range of optional testing equipment,
including:

52. The FEECO Innovation Center offers
comprehensive testing options for thermal
applications. In addition to batch and pilot
scale direct and indirect kilns, FEECO offers a
range of optional testing equipment,
including:
- Combustion Chamber

53. The FEECO Innovation Center offers
comprehensive testing options for thermal
applications. In addition to batch and pilot
scale direct and indirect kilns, FEECO offers a
range of optional testing equipment,
including:
- Combustion Chamber
- Thermal Oxidizer

54. The FEECO Innovation Center offers
comprehensive testing options for thermal
applications. In addition to batch and pilot
scale direct and indirect kilns, FEECO offers a
range of optional testing equipment,
including:
- Combustion Chamber
- Thermal Oxidizer
- Baghouse

55. The FEECO Innovation Center offers
comprehensive testing options for thermal
applications. In addition to batch and pilot
scale direct and indirect kilns, FEECO offers a
range of optional testing equipment,
including:
- Combustion Chamber
- Thermal Oxidizer
- Baghouse
- Wet Scrubber

56. The FEECO Innovation Center offers
comprehensive testing options for thermal
applications. In addition to batch and pilot
scale direct and indirect kilns, FEECO offers a
range of optional testing equipment,
including:
- Combustion Chamber
- Thermal Oxidizer
- Baghouse
- Wet Scrubber
- Removable Flights, Dams, and Bed Disturbers

57. The FEECO Innovation Center offers
comprehensive testing options for thermal
applications. In addition to batch and pilot
scale direct and indirect kilns, FEECO offers a
range of optional testing equipment,
including:
- Combustion Chamber
- Thermal Oxidizer
- Baghouse
- Wet Scrubber
- Removable Flights, Dams, and Bed Disturbers
- And more…

58. Test kilns can also be configured to test
co-current and counter current processing
conditions.

59. In addition, we have partnered with
Rockwell Automation to bring our
customers the best in process automation,
both as a service in the Innovation Center,
and as part of a system purchase.

60. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:

61. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)

62. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate

63. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate
- Flow Rates

64. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate
- Flow Rates
- Fuel Usage

65. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate
- Flow Rates
- Fuel Usage
- Gas Sampling & Analysis

66. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate
- Flow Rates
- Fuel Usage
- Gas Sampling & Analysis
- Horsepower

67. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate
- Flow Rates
- Fuel Usage
- Gas Sampling & Analysis
- Horsepower
- Speed

68. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate
- Flow Rates
- Fuel Usage
- Gas Sampling & Analysis
- Horsepower
- Speed
- System Pressure

69. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate
- Flow Rates
- Fuel Usage
- Gas Sampling & Analysis
- Horsepower
- Speed
- System Pressure
- Temperature

70. This allows us to track and adjust a variety
of data points in real-time, all from a single
interface. Data points include:
- Current (Amps)
- Feed Rate
- Flow Rates
- Fuel Usage
- Gas Sampling & Analysis
- Horsepower
- Speed
- System Pressure
- Temperature
- Torque

71. These data points can then be selected,
trended, and reported on, giving
customers an unparalleled process design
and optimization experience.

72. Conclusion
Testing is a critical component in the
development of both new and existing rotary
kiln applications.

73. Conclusion
Testing is a critical component in the
development of both new and existing rotary
kiln applications.
The testing process not only determines if a
process is technically and economically viable,
but it also gathers the data necessary for scale-
up to a commercial size unit.

74. 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.

75. Want to learn more?
Download our
Rotary Kiln Handbook
The Rotary Kiln Handbook
Rotary Kiln Sizing & Design
Processing Challenges
Service & Maintenance
And more…
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