The

ROTARY DRYER
HANDBOOK
OPERATION | PROCESS & EQUIPMENT CONSIDERATIONS | MAINTENANCE | TESTING

a product of
Contents
INTRO
About FEECO 1

Intro to Rotary Dryers 3

ROTARY DRYER OPERATION

How Rotary Dryers Work 5

Direct Drying vs. Indirect Drying 8

Sizing & Design 10

CONSIDERATIONS IN DRYING
Rotary Dryer or Fluid Bed Dryer? 16

Challenges in Rotary Dryer Processing 18

Drying Test Studies 19

INSTALL & MAINTENANCE

Ensuring A Smooth Rotary Dryer Installation 23

The Importance of Proper Rotary Drum Alignment 25

Avoiding Downtime with Proactive Maintenance 26

CONCLUSION
What Makes an Industry Leading Rotary Dryer Manufacturer 29

The FEECO Commitment to Quality 31

 THE
ROTARY DRYER
HANDBOOK

Introduction
FEECO International was founded in 1951 as an engineering and manufacturing company. We quickly became

known as the material experts, able to solve all sorts of material processing and handling problems, 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 material testing, process

development, and custom thermal processing equipment, including rotary dryers, since the 1950s. We’ve helped

our customers process hundreds of materials into value-added products, eliminating handling and transportation

problems, improving product characteristics, and creating marketable products.

For further information on drying, contact a FEECO expert today.

FEECO US Headquarters
3913 Algoma Rd. Green Bay, WI 54311, USA
Phone: (920)468.1000
Fax: (920)469.5110
FEECO.com/contact
 Intro to

ROTARY
DRYERS

FEECO.com/contact
An Intro to Rotary Dryers
The field of industrial drying has been around for For over a century, their robust build, reliability, and
centuries, even if rudimentary at first. Drying began aptitude for handling variation in feedstock has made
with only the wind and sun as its tools, but as them an ideal choice for efficiently drying bulk solids of
civilization demanded faster drying methods, people nearly all types.
began to use these tools in a more controlled manner
to maximize the drying process. Soon, basic ovens The flexibility of rotary dryers has allowed them to
were tasked with drying goods and materials, and expand into nearly every industry, from food and
as industrial needs continued to expand, so too did specialty chemicals, to minerals, fertilizers, and nearly
drying technologies. 1
everything in between.

Today, advanced drying systems allow us to produce And while rotary dryers are commonplace in many
materials and products at unprecedented speeds. industries, they are still surrounded by a multitude of
Industrial drying systems continue to become questions and opportunity for confusion.
more advanced, further increasing efficiency and
effectiveness of the drying process. This resource serves to give a basic overview of rotary
dryers and the industrial drying process, as well as
When it comes to drying bulk solids, rotary dryers answer some of the common questions asked about
are often the industrial drying equipment of choice. these robust industrial drying systems.

1. R. B. Keey. Drying: Principles and Practice. Oxford, 1972. Print.

FEECO.com/contact ROTARY DRYER HANDBOOK | 3

ROTARY DRYER
OPERATION
HOW ROTARY DRYERS WORK | DIRECT VS. INDIRECT | SIZING & DESIGN

FEECO.com/contact
How Rotary Dryers Work components, and add-ons, among other items.

Rotary dryers use a tumbling action in combination

The diagram on the next page shows some of the
with a drying air in order to efficiently dry materials.
basic standard components found on a rotary dryer.
Most often, rotary dryers are of the direct-fired type,
meaning that the drying air is in direct contact with
Shell:
the material. Some dryers, however, are of the indirect
The shell of a rotary dryer can be made from a
type, whereby the dryer is heated externally, to avoid
variety of materials, including carbon steel, stainless
direct contact between the material and the
steel, hastelloy, Inconel, and a variety of other alloys.
drying air.
The shell may also be customized in different ways,
depending on the needs of the material and the
Rotary dryers are comprised of a rotating drum, into
process. For example, shell thickness can be adjusted
which the material is fed, in combination with the
for situations where heat retention inside the dryer is of
drying air. Flights, or lifters, pick up the material from
the utmost importance. The shell may also be insulated
the bed, carrying it over, and dropping it through the
in order to aid in retaining heat. Manufacturing
air stream to maximize heat transfer between the
techniques are vital on the shell; the shell needs to
material and drying air.
run true and concentric in order to work properly. A
poorly manufactured drum will promote wear on all
Material is processed for a specified amount of
components and reduce equipment efficiency.
time, referred to as the retention time, at the desired
temperature, in order to produce a product with the
The Combustion Chamber:
required moisture content.
The combustion chamber houses the actual
combustion reaction and directs the airflow of the
While rotary dryers are available in standardized
rotary dryer. Combustion chambers can be integrated
models, designing a rotary dryer around the unique
into either co-current (airflow in direction of material
characteristics of the material and process needs will
flow) or counter current dryers. The goal is to keep
produce the best results and offer the most reliability.
the material from coming into direct contact with the
Various aspects of the dryer are considered during
burner flame. A variety of combustion chambers are
initial design in order to reach the exact desired
available, with customizations ranging from single or
parameters of the end product.
double shell, refractory lined, and angled. Combustion
chambers can also accommodate a wide variety
Rotary Dryer Construction of burners. Finding a quality combustion chamber
While FEECO rotary dryers are custom designed
is important to the quality of the product, and the
around the material to be processed, the basis of a
energy consumed to get to the end product. When
rotary dryer is somewhat standard, with customizations
a low-quality combustion chamber is used, many
coming in terms of sizing, materials, mechanical

FEECO.com/contact ROTARY DRYER HANDBOOK | 5

 Combustion
Chamber Raw Material
Burner Feed Chute Exhaust Handling
Riding Ring/Tire System
Gear/Sprocket
Guard

Flights

Discharge
Breeching

Drive Assembly

Product Discharge

Riding Ring
Graphite Block
Lubrication Assembly

Coupling Girth Gear

Thrust Roller
Trunnion Wheel Assembly Guarding
Pinion Gear
Gear
Reducer CLOSE-UP:
CLOSE-UP: DRIVE ASSEMBLY
DRUM BASE
Trunnion
Pillow Block
Guard
Bearing

problems can result, from inefficiency, to product burner specifications is essential for proper and
breakdown, and in some cases, a short combustion efficient drying of the material.
chamber lifespan.
Raw Material Feed:
Burner: The raw material feed area, also called the feed
The burner is the engine behind any dryer, determining chute, is where feedstock is fed into the system,
the output of BTU’s/Watts. Burners can be designed typically by a feed screw or chute. The feed chute is
for a multitude of fuel sources, including natural gas, specifically designed to be robust, resistant to wear,
propane, diesel, and more. Choosing the appropriate and to reduce material build-up.

FEECO.com/contact ROTARY DRYER HANDBOOK | 6

Air Seal riding ring rides on the support roller.
Where the combustion chamber and discharge
breeching meets the drum, a seal is needed to Thrust Rollers
connect the stationary component to the rotating Thrust rollers push on the riding ring to stop the drum
drum. The purpose is to keep air and material from from drifting, or moving horizontally.
leaving the drum prematurely. Many different seal
options exist, again, depending on the needs of the Trunnion Wheels
material being processed. The trunnion wheels act as the cradle for the rotating
drum shell. They ensure smooth and concentric
Drive Assembly rotation during operation. They also act as a wear
The drive assembly is the mechanism that causes piece since they are cheaper and easier to replace
the drum to rotate. Several options are available than the riding ring itself. The wheels are mounted to
here: a chain and sprocket, gear and pinion, friction steel support bases with sealed roller bearings. Support
drive, or direct drive setup. A chain and sprocket rollers bear the weight of the drum.
setup is ideal for smaller rotary drums, running up to
75 horsepower. Gear and pinion drive assemblies are Flights
reserved for more heavy-duty applications, running Available in several designs, material lifters, or flights,
above 75 horsepower. A reducer decreases the help to maximize efficiency of heat transfer between
speed of the motor for higher torque applications with the material and the drying air. Flights pick up material,
both drive assembly types. Friction drive assemblies carry it over, and shower it through the air stream as
are used for very small drums with low horsepower, the drum rotates, promoting efficient heat transfer
typically drums around 6’ and under. In this setup, two between the material and drying air. Both flight design
of the four trunnion wheels are connected by one and flight pattern are customizable.
shaft and driven by a shaft mounted reducer and
motor arrangement. The direct drive setup is used for Product Discharge
small to medium size drums with motor sizes up to 75 The product discharge area is where product exits the
horsepower. The design consists of a shaft mounted to dryer. Here, product can move on to the next step in
a solid, discharge end plate at the outlet of the dryer. the process flow. A common step is a rotary cooler to
The motor and reducer are either directly connected cool the material for packaging or storage.
to this shaft with a coupling, or a shaft mount
arrangement. Discharge Breeching
The discharge breeching is where two main functions
Riding Ring occur: product exits the dryer, moving on to screening,
Riding rings add structural support for the drum, and cooling, storage, or shipping, and the exhaust gas
serve as a place for pressure to be absorbed. The system removes off-gases from the system. Exhaust

FEECO.com/contact ROTARY DRYER HANDBOOK | 7

 Ball and Tube Knocking System

gas systems provide a place for spent gases and hot

air (and small particulates) to exit the system. This then
Direct vs. Indirect Drying
Direct dryers are used far more frequently than their
typically goes to a scrubber or bag house to remove
indirect counterparts, because of the efficiency
contaminants before exhaust gas is discharged into
they offer. And while direct-fired rotary dryers are
the atmosphere.
most often the selected drying method, indirect
rotary dryers are a valuable alternative for specific
Common Add-Ons: processing needs.
Advancing Flights
Advancing flights help to advance material into
Operation
the drum, in order to prevent buildup near the wet
While both types of dryers are comprised of a rotating
feed discharge. Incorporating advancing flights into
drum in which the processing occurs, these two types
a rotary dryer also gives material a chance to dry
of dryers utilize very different methods to process
before it hits the next flights, a process which can help
the material.
prevent potential sticking issues.

Direct-fired dryers rely on direct contact between

Knocking Systems
the material and drying air to efficiently dry materials.
Knocking systems help to prevent build-up within the
Efficiency is further increased by the addition of lifting
dryer, by “knocking off” material as the drum rotates.
flights affixed to the internal walls of the dryer.
Various options are available for knocking systems.
Conversely, indirect dryers do not utilize direct contact
For more information on knocking systems, see our
with the drying air to reduce the material’s moisture
Knocking Systems Brochure.
content. In fact, this is the precise advantage of an

FEECO.com/contact ROTARY DRYER HANDBOOK | 8

indirect rotary dryer; indirect drying allows you to Exhaust Gas / Furnace Exhaust

tightly control the processing environment, an ideal

characteristic when working with materials that can
be combustible in certain settings.

Indirect dryers rely on the heat transferred through

the drum’s shell to dry the material via conduction
and radiation. Subsequently, indirect dryers would not
Sweep Air
benefit from the addition of lifting flights, and instead
utilize tumbling flights, which aid in material rotation
and help to ensure process consistency.

Indirect rotary dryers also require an internal air

Furnace Shroud
flow, referred to as sweep air. Sweep air carries
the evaporated moisture, along with dust particles
Diagram: The diagram above illustrates the air-flow in an
from inside the dryer, to the exhaust system at the indirect rotary dryer.
discharge breeching. This process ensures that the
material is being dried to the required moisture Industrial Use / Applications
percentage. Direct-fired rotary dryers account for most of the bulk
solids drying applications, and are used throughout a
Furthermore, because the furnace exhaust is kept multitude of industries, including agriculture, mining,
separate from the drying air, indirect dryers have the specialty chemicals, and more. They offer heavy-duty
added benefit of requiring less exit gas treatment. This processing and consistent reliability.
exit gas can be used to pre-heat the combustion air
and increase burner efficiency. Indirect-fired rotary dryers are better suited for niche
applications, and are ideal for processing dusty, fine
Material of Construction materials, or materials that cannot be exposed to
Unlike their direct-fired counterparts, which are drying air during processing. This is commonly seen
typically constructed of carbon steel, indirect-fired with highly combustible materials, organics such as
rotary dryers are constructed using a high temperature grains and pulps, and fine materials such as pigments.
alloy, in order to maintain the integrity of the drum,
despite the constant exposure to high temperatures
that the shell must endure.

FEECO.com/contact ROTARY DRYER HANDBOOK | 9

Rotary Dryer Bulk Density
The bulk density of a material will also figure into
Sizing & Design the equation for sizing a rotary dryer. Typically, this
The process of sizing a rotary dryer is one of precise is calculated in pounds per cubic foot in US units,
engineering, involving complex calculations and or kg/m3 in metric units, and refers to the weight of
meticulous design. While the process is not well a material per a specific volume. For example, a
simplified into a few paragraphs, an explanation can material with a high bulk density, such as bricks, will
be offered as to some of the concepts behind the require significantly more energy per cubic foot than
process of rotary dryer sizing. a material with a low bulk density, such as feathers.
How much energy is needed per cubic foot will in part
Many of the calculations behind sizing a dryer are determine how hard the dryer will have to work, and
based upon the characteristics of the material to be subsequently, will dictate the load on bearings, gear
processed. The combination of characteristics such as train, trunnion wheels, and the motor. This load will
moisture content, bulk density, specific heat, and heat determine the sizing of these components to ensure
transfer properties help predict how the material will they are fit to withstand the operational load.
behave in the dryer, and subsequently, how best to
address the needs of that material through design and Specific Heat
construction. These characteristics will not only help to The specific heat of a material also works into the
determine the sizing of the actual drum itself, but also sizing equation. Specific heat is defined as how much
the operational mechanics of the dryer as well. energy it takes to raise one gram of material by one
degree Celsius. In other words, it refers to how resistant
Characteristics that Affect a material is to heating. Put simply, the specific heat of
Rotary Dryer Design a material will help to figure out how much energy is
needed to cause the desired change in temperature
Raw Material Moisture
for that material.
Because the primary job of a rotary dryer is to dry the
material, the first material characteristic to look at is
Heat Transfer Properties
the percentage of moisture the material holds in its
The heat transfer properties of a material will also have
raw state, as well as the desired moisture percentage
an impact on dryer sizing and design. While some
of the output, commonly referred to as the outlet
materials carry their moisture on the surface, other
moisture. The difference between actual and desired
materials carry moisture on the inside of the material,
percent moisture sets the stage for what the rotary
making it more difficult to draw out. So while two
dryer will need to accomplish, and how hard it will
materials may have the same percentage of moisture,
have to work to reach the end product goal.
they can require very different amounts of energy to
reach the desired level of moisture.

FEECO.com/contact ROTARY DRYER HANDBOOK | 10

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:

• Fragility: Some materials may be too fragile to Diagram: The diagram above illustrates how flights create the
withstand lifting flights at the inlet of the dryer. curtain in a rotary dryer to maximize heat transfer.

Here, a “bald” section (a section where flights

Processing Environment
are not used) would allow the material a
In addition to material characteristics, the processing
chance to harden before gradually being
environment can also have an effect on dryer design
introduced to the dropping action.
and sizing. Things such as humidity, elevation, and
temperature can all change how a dryer will perform
• Consistency: Sludge-like materials, or other
and how much energy will be required to produce
sticky materials, have the potential to stick
the desired results.
to the shell of the dryer. The material then
continues to stick and dry, until it becomes
Flight Design
dry and poses a potential risk for fire. Materials
The flight design inside the rotary dryer is also
like these will require extra attention to ensure
engineered around the material’s unique
efficient drying.
characteristics. The objective with flight design is to
create the ideal “curtain” of material. The curtain
• Use: Some materials, particularly those that will
refers to the span of material created as the material is
be used by consumers, must remain sterile, and
dropped from the flights, through the drying air. Ideally,
drying with an air stream would not be an
the curtain will span the width of the interior of the
option. Again, in situations such as these, an
drum, evenly falling from one side to the other.
indirect dryer would be the drying method
The optimal curtain is created through designing
of choice.
the flights and flight pattern around material

FEECO.com/contact ROTARY DRYER HANDBOOK | 11

 Counter Current Rotary Dryer

Co-current Rotary Dryer

characteristics such as angle of repose, flowability, the drying air flows through the dryer in relation
and more. As mentioned, both flight design and to the material.
flight pattern can be customized to maximize
processing efficiency. Rotary dryers are available in two types of air-flow
configurations: co-current and counter current.
Air-Flow Both options have been developed through extensive
Another critical factor in designing a rotary dryer that research and development in order to maximize the
produces the desired end product characteristics is thermal efficiency of the rotary drying process. The
the air-flow configuration, or the direction in which selection of which air-flow configuration will best suit

FEECO.com/contact ROTARY DRYER HANDBOOK | 12

the process is based on the material’s properties, as current system is also beneficial for materials that
well as overall process requirements. Even though the retain moisture internally and require higher heat and
material characteristics are ultimately the deciding a longer drying cycle to draw out the moisture.
factor, it is important to understand how each air-flow
option is designed to fully understand the benefits Understanding how each airflow system works is only
each has to offer. one of the many steps in designing the most efficient
rotary dryer for the job. Both air-flow configurations
Co-current drying, which is also referred to as parallel have their unique and varying benefits for drying.
flow, is when the drying air flows in the same direction
as the material flow. This immediately puts the wettest A Note on Pre-Heating Combustion Air with Waste
material in contact with the hottest drying air, resulting Heat: Rotary dryer burners require combustion air,
in quick initial drying. This system also causes rapid dilution air, and a fuel source (natural gas, propane,
cooling of the drying air, which results in a cooler fuel oil, etc.) for proper combustion. In most cases,
surface temperature of the dryer shell compared this combustion air source comes from a blower that
to a counter current dryer. Furthermore, this design is forcing ambient air into the burner. This air is usually
makes it much easier to control the temperature of substantially lower in temperature than the process
the dried material, because it correlates directly with air temperature inside the rotary dryer. As a result, the
the air temperature. Co-current dryers work best with burner needs to fire at a higher rate to accommodate
materials that have high external/surface moisture, heating of the ambient air, which increases the
such as glass. These materials require immediate heat amount of combustion fuel needed and decreases
to efficiently dry the material, while minimizing the burner efficiency.
opportunity for overheating.
One option to reduce the consumption of combustion
Counter current drying is when the drying air flows fuel, is to use waste heat to pre-heat the combustion
in the opposite direction of the material flow. In air. The ambient air is introduced to the waste heat
this design, the wettest material comes in contact system before traveling to the dryer (usually with an
with the coolest drying air. Unlike the co-current air-to-air or steam-to-air heat exchanger), raising the
system, the material will come in contact with the temperature significantly, which in turn, lowers the
hottest drying air at the discharge end of the dryer, amount of combustion fuel needed for the desired
at its most dehydrated state. Because of this, the dryer temperature. This waste heat can come from
counter current method provides increased thermal a couple of different sources. For example, leftover
efficiency for materials that need to be heated to steam from another process in the facility could be
high temperatures. For example, some mineral and used. Or, in the case of an indirect dryer, the heated
ore processing applications require the material to furnace exhaust air can be recirculated into the
be heated up to several hundred degrees. A counter combustion process since the air does not come into

FEECO.com/contact ROTARY DRYER HANDBOOK | 13

contact with any of the material being dried. throughput may require a dryer that is larger in
diameter.
Recycling heated air from a direct-fired dryer is less
desirable, because the exhaust air leaving the dryer is Though highly simplified, the concepts above offer a
contaminated with dust particles that would need to basic explanation for some of the theories behind the
be filtered before entering back into the combustion design and sizing of a rotary dryer, and demonstrate
process. The filtering process (e.g., wet scrubber the importance that material characteristics hold in
system, baghouse, etc.) may drop the temperature of the sizing process. Sizing a rotary dryer often means
the recycled air to a point where it would no longer be finding the balance between how a material will
beneficial for pre-heating. behave in the dryer, the needed capacity, and the
desired end product.
Retention Time
Retention time is also an important consideration FEECO encourages that each material go through a
during dryer design. This is the duration of time that research and development process at our
a material will need to remain in the dryer in order on-site, concept testing facility, The Innovation Center.
to achieve the desired characteristics. Retention The information gained through our proven testing
time is determined through looking at the specific procedures allows us to design the most efficient and
heat, heat transfer properties, and moisture content beneficial drying system for our customer’s material
of the material, and can be controlled through a requirements.
combination of many factors, including dryer length,
drum slope, dam plates, and more. A material that
requires a lengthy retention time, for example, may
require a longer dryer, where a process with a high

FEECO.com/contact ROTARY DRYER HANDBOOK | 14

 Considerations in

DRYING
CHOICES IN EQUIPMENT| CHALLENGES IN PROCESSING | TESTING

FEECO.com/contact
Rotary Dryer or Conversely, fluid bed dryers have a very tight window
when it comes to variability in feedstock, requiring as
Fluid Bed Dryer? much uniformity in particle size distribution and mois-
When it comes to buying an industrial dryer, people ture content as possible. Where a rotary dryer will just
are often faced with the decision to choose between keep running with little to no process upset, variability
a rotary dryer, and a fluid bed dryer. Historically, rotary in feedstock with a fluid bed dryer has the potential
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- serious problems when processed in a fluid bed dryer.
tical, specialty chemical, and food industries. Despite
some industry preferences, the drying capabilities of Additionally, rotary dryers are better suited for
these two industrial dryers has allowed for a significant heavy-duty processing loads, such as those found in
amount of overlap in applications, and subsequently, the mining industry. Because it takes significant energy
confusion for what is ultimately the best choice when to fluidize large or heavy materials, it is not practical
comparing the two. to process these types of materials in a fluid bed dryer.
Fluid bed dryers are best reserved for applications
Though the choice between a rotary and fluid bed processing lighter-duty materials.
dryer can be material or industry specific, ultimately,
each dryer has its own advantages and disadvantag- Materials that must not suffer degradation are better
es. With comparable capital costs, the decision often served in a fluid bed dryer. Rotary dryers often result in
comes down to customer preference and what will some, albeit little, degradation to material, because
best suit the processing conditions, with a few of the fact that the material is being picked up and
considerations to keep in mind. dropped. This is not an issue with all materials, but can
be an issue with some.
Material Considerations
Rotary dryers have been called the “workhorse” of Rotary dryers do offer the advantage of “polishing”
the industrial drying industry, due to their heavy-duty granules; because of the rolling action on the bed of
construction, their high capacity capabilities, and material, loose edges are knocked off, and granules
most of all, their ability to accept significant variance are further rounded, or “polished.”
in feedstock. Because of this, rotary dryers are better
suited for heavy-duty materials where a lot of variety Spatial Footprint
in feedstock is a given, such as in the case of various Rotary dryers are typically larger than fluid bed dryers,
minerals. Rotary dryers are known for their ability to and therefore require a larger spatial footprint in the
take what is given, big or small, wet or dry, lumpy or processing plant. Fluid bed dryers are smaller, and
uniform, and produce a quality product. have the advantage of being modular, allowing them

FEECO.com/contact ROTARY DRYER HANDBOOK | 16

to be added on to, and making them ideal for situa- mentioned, because material is fluidized, it is not
tions where there is a likelihood for operational growth. always practical to run high-volume, heavy materials
through a fluid bed dryer, because of the extra energy
Operational Considerations required to fluidize the material.
Rotary dryers require significantly less supervision than
their fluid bed counterparts. Rotary dryers are largely Rotary dryers require less energy to dry material, and
unaffected by fluctuations in feedstock and other energy consumption is reduced when running at
processing conditions, such as reduced feed, or lapses decreased capacities.
in energy. They offer a consistently reliable solution in
settings where inconsistencies in feedstock and Fluid bed dryers are considered to be more thermally
instabilities in processing are to be expected. efficient than rotary dryers, however. This is because
the heat transfer is maximized due to the fluidization
Fluid bed dryers are much less suited for these types effect; each granule is surrounded by the drying air.
of situations, requiring a consistent processing environ-
ment. Variations in feedstock, or power outages can Maintenance & Lifespan
cause major problems when working with a fluid While a rotary dryer is robust, it does require more
bed dryer. maintenance, because it is made up of so many
moving parts. However, when well maintained, rotary
Energy Consumption dryers can reliably last for decades.
The choice between a rotary dryer or fluid bed dryer is
also a matter of energy. Fluid bed dryers work by The chart below summarizes some of the most
fluidizing the material, which requires a high magni- important considerations to examine when choosing
tude of air. Additionally, because it takes a certain between a rotary and fluid bed dryer.
amount of energy to fluidize a material, energy is not
reduced when running at lower capacities. As

Rotary Dryer Fluid Bed Dryer

Energy Consumption Requires less energy Requires more energy
Thermal Efficiency Less thermally efficient More thermally efficient
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 Highly sensitive to variance
Industry Minerals Pharmaceuticals
Fertilizers Specialty Chemicals
Raw Materials Foodstuffs

FEECO.com/contact ROTARY DRYER HANDBOOK | 17

Challenges in Although there are many ways to keep build-up under
control, the best way to control it is to prevent it from
Rotary Dryer Processing the start. There are a couple of ways to approach this.

Rotary dryers may be the workhorse of the industrial

One way to prevent build-up is to adjust the
drying industry, but that does not mean they are
feedstock through what is called back-mixing.
without challenges. Different materials can present
Back-mixing takes place when dry material is added
unique challenges, and will require careful preparation
to the wet, raw material in order to make it less sticky.
in many cases, and routine maintenance in others, in
However, this is not always an option, as some mate-
order to prolong the life of the rotary dryer and ensure
rials remain sticky for a wide range of moisture levels.
processing efficiency is maintained. The most common
In cases such as this, a heated screw could be a more
challenges faced in rotary dryer operation include:
efficient choice over a rotary dryer.
build-up, abrasion, and corrosion.

Another way to prevent build-up is to design a less

Build-up
aggressive internal flight. Because build-up tends to
While rubber, ceramic, or even stainless steel liners
occur in sharp corners, a less aggressive flight can
offer an effective solution to preventing build-up in
lessen the propensity for build-up to occur. In this situa-
other rotary drum applications, where heat is used,
tion, some efficiency is lost, but the decline in build-up
such as in the case of a rotary dryer, liners are not
can be a compensating factor. Additionally, adding
typically an option. Because heat causes materials to
a bald section in the beginning of the drum allows the
expand, and different materials expand at differing
feedstock to dry a little before it hits the flights, also
rates, installing a liner into a rotary dryer would more
lessening the chances for build-up to occur.
than likely result in problems. For this reason, knocking
systems are the most common way to address
Abrasion & Corrosion
build-up in a rotary dryer.
Aside from build-up, abrasion and corrosion are also
common challenges faced by many rotary dryer
There are three basic designs for knocking systems:
owners. Though abrasion and corrosion can wreak
ball & tube knockers, hammer knockers, and pneu-
severe havoc on a dryer if left unattended, there are
matic hammer knockers. Each design is mounted to
ways to help prevent the potential for abrasion and
the exterior of the drum, and serves to “knock off”
corrosion, as well as ways to minimize damage.
potential build-up as the drum rotates. No matter
which design is chosen, a wear plate or band is also
Abrasion and corrosion can have similar effects, but
installed to protect the shell of the drum from the
they are very different in nature. While corrosion is
knocking, while still allowing the vibration from the
chemical in nature, abrasion is physical in nature.
knock to dislodge any potential build-up within
Many materials processed in a rotary dryer are
the drum.

FEECO.com/contact ROTARY DRYER HANDBOOK | 18

 Flights corroded away
in a rotary dryer

abrasive, including limestone, potash, and sand. abrasive, careful monitoring is integral to preventing
As material rubs on the shell, the metal gets worn major damage. Routinely inspecting surface areas
down from the abrasive material. for any sign of damage goes a long way in avoiding
major problems. Catching potential problems early
Corrosion, on the other hand, is purely based on can mean the difference between a minor repair and
chemical reactions. Acid, for example, will erode a equipment replacement. Particularly with corrosion,
metal shell over time, because the carbon in the met- cracks, crevices, and rough surfaces all increase the
al reacts with the acid, leading to premature wear. opportunity for corrosion and should be carefully
inspected and repaired if necessary. Also when work-
In order to protect against abrasion or corrosion, it’s ing with corrosive materials, corrosive material should
important to choose materials of construction that are not be allowed to build-up, or sit for long periods of
more resistant to such phenomena. The correlation time. Again, this promotes corrosion and should be
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
Drying Test Studies
action, one must understand how the material being
Testing for drying processes offers valuable informa-
processed will react with the materials of construction.
tion when designing an industrial drying system. Test-
Choosing stainless steel or alloys when fabricating a
ing offers the opportunity to confirm the viability of
rotary dryer will help to minimize corrosion. Protective
your intended process, as well as to work out process
coatings can also be an option to protect the shell of
variables and other unknown data points, helping to
a rotary dryer, with a variety of choices available.
define a recipe for success, and reduce the opportuni-

When processing a material that is corrosive or ty for surprises after process scale-up.

FEECO.com/contact ROTARY DRYER HANDBOOK | 19

There are many reasons why it may be desirable to This is especially true when working with a process that
test your material prior to purchasing equipment or is not well established, or a material that is not often
investing in a full-scale production facility: (or ever) processed. Testing your material will not only
help to work out process variables, but will also provide
To Test Pre-Conditioning a starting point for scaling up the process, essentially
Material is often dried prior to further processing in offering a recipe for full-scale production.
order to prevent upset conditions in subsequent
processing equipment. Pre-conditioning a material What Can Be Tested?
also helps to improve the end product. Most processes During testing, a variety of characteristics can be
require a material feedstock within a specific range measured, depending on the needs of the process
of moisture. Testing will help to determine what drying and end product. Typically, the following points of
parameters are required to reach the target moisture data are tracked and analyzed during testing:
range. If that moisture range is not known, testing can
help to determine the ideal moisture range. • Inlet moisture content of material
• Outlet moisture content of material
To Confirm End Product Characteristics • Inlet material temperature
Most often, manufacturers and processers are looking • Outlet material temperature
to create a product with very specific characteristics. • Material feed rate
Testing can ensure that characteristics such as attri- • Residence time
tion, crush strength, compression, bulk density, and • Inlet process air temperature
moisture content are all met. Here again, testing also • Outlet gas parameters
defines the processing variables required to reach
these parameters. All of these parameters can be adjusted throughout
processing to reach ideal end product characteristics,
To Optimize An Existing Process including crush strength, compression, bulk density,
Test studies are also valuable to improve an existing and moisture content.
process. This might include testing a recycle loop, add-
ing in a back-mixing process prior to the rotary dryer, In addition to measuring these standard parameters,
or simply optimizing the operating parameters of the the FEECO Innovation Center has the capability to test
dryer from a process and/or energy standpoint. various flight designs and patterns. Optimizing the
design of the flight itself, as well as the pattern of the
To Design A New Drying System flights in the drum, helps to maximize drying efficiency.
Testing is particularly valuable when looking to design
a new industrial drying system. This will help define The Innovation Center can also test the impact of
process variables, ensuring the dryer will meet the residence times by adjusting speed and through the
exact needs of the material to be processed.

FEECO.com/contact ROTARY DRYER HANDBOOK | 20

insertion of dams in the dryer. and reported on, allowing users to select only the data
they need, from the exact time frame they need.
Automation
The FEECO Innovation Center offers an extensive Testing is a valuable component to designing a new
programmable logic control system. We have drying system, or optimizing an existing one. Whether
partnered with Rockwell Automation to bring our you’re looking to pre-condition a material for further
customers the best in process automation, both as processing, or you’d like to reduce transportation costs
part of testing in our Innovation Center, and as part made costly due to moisture-laden materials, testing
of a system purchase. provides the valuable information needed to reach
the ideal drying solution.
Our system allows for a variety of data points to be
tracked and adjusted from a single interface, in real
time. This includes:

• Horsepower
• Amps
• Feed rate
• Hertz
• Temperature
• Flow Rates
• Torque
• Gas Sampling & Analysis

In addition, data points can be selected, trended,

FEECO.com/contact ROTARY DRYER HANDBOOK | 21

 INSTALL &
MAINTENANCE
INSTALLATION TIPS | ALIGNMENT | PREVENTATIVE MAINTENANCE

FEECO.com/contact
Ensuring A Smooth • Damage to drum shell because it was
handled improperly
Dryer Installation • Re-work needed and/or voided warranties
A rotary dryer is a major investment and integral part because critical hold points/inspections were
of many industrial processing systems. And while a not done
significant amount of time and research is put into
finding the right rotary dryer manufacturer and However, there are a few simple steps you can take

engineering a solution that blends seamlessly into your that will help to achieve a smooth and successful

process, the work is far from done after the purchase. installation, avoiding the problems mentioned above.

The install of your new dryer requires just as much

planning and attention to ensure proper installation, Key Steps for A Smooth
optimal performance, and equipment longevity. Rotary Dryer Installation
Have A Service Technician On-Site
Why Proper Dryer Installation is Important
Having a service technician from the manufacturer
A properly installed rotary dryer is the first step in
on-site for installation offers many benefits. Service
prolonging equipment life and reducing potential
Technicians are well-trained in the exact specifications
downtime and maintenance. Problems that begin
needed for efficient installment and operation of your
at install can quickly turn into serious damage and
equipment. They know what to look for and any
downtime. A poorly installed rotary dryer can result in
potential places error can occur. Service technicians
a variety of problems, including:
can oversee installation, assuring that things are done
• Damage to wheels/tires from poor alignment right, and no warranties are voided in the process.

FEECO.com/contact ROTARY DRYER HANDBOOK | 23

In addition, service technicians are a valuable source process, should all be purchased and prepped for
of knowledge for answering installation and operation- install. It’s worth mentioning also, that the proper tools
al questions on the spot. Furthermore, they can train and equipment should be on-site. While most install
maintenance personnel on the ins and outs of the contractors will have the right tools and equipment at
equipment during their time on-site. their disposal, the importance of having them on-site
and ready for use cannot be emphasized enough. This
Plan Ahead too, will prevent wasted time waiting for the proper
Contacting the equipment manufacturer well ahead tools or equipment to arrive. An inadequate crane, for
of the installation date to begin planning is vital to example, could mean that technicians have to wait
carrying out a seamless rotary dryer installation. Ideally, for a new crane to arrive and be mobilized before
the equipment purchaser, manufacturer, and installa- work can begin.
tion contractor should be in contact with one another
prior to installation so that everyone knows what needs Pre-Alignment: The contractor should install and
to happen before install day arrives. This will help to pre-align the drum bases prior to installation day.
ensure that on-site service technicians and supporting Having the bases installed and pre-aligned will allow
manpower will have everything they need on-site, technicians to begin their work right away on installa-
and won’t waste valuable time waiting on things that tion day, instead of waiting a day or two for the
could have been prepared for. The items listed below pre-alignment to be completed.
should be considered during the planning stages
of installation: The proper installment of a rotary dryer is key to
process efficiency, prolonging equipment life, and
Appropriate equipment staging: In cases where the avoiding unnecessary downtime and maintenance.
dryer is a replacement and will need to be fit into Adequate planning for installation, such as having the
place, ensuring all ancillary equipment, such as feed appropriate materials, manpower, and equipment on
chutes and/or discharge chutes are in place and hand, will go a long way in ensuring a smooth rotary
pre-positioned, will prevent wasted time during install. dryer installation.
This is less of a concern when putting together a new
process where equipment will be fit around the drum, All of the items above can be planned for through a
but can still be prepared for. simple conference between the equipment purchas-
er, installing contractor, and original manufacturer.
Materials & Equipment: Having the right materials and Planning for these items will help to ensure that no
equipment on hand can mean the difference time is wasted on installation day and progress moves
between a smooth install and days wasted. according to plan.
Materials such as grout needed for pouring under
bases, or shimming materials used in the alignment

FEECO.com/contact ROTARY DRYER HANDBOOK | 24

 Laser Alignment

The Importance of Proper experiences normal wear and tear over time, causing
the drum to gradually fall out of perfect alignment. For
Rotary Dryer Alignment this reason, it is important to routinely have a drum
Misalignment is one of the most common problems re-aligned.
faced when working with rotary dryers. Though
aligning a drum is a simple solution, leaving a drum out How do you know if your drum is misaligned?
of alignment can result in major problems. Routinely Misalignment causes a drum to ride harder against the
having a rotary dryer re-aligned is an important part of thrust roller, therefore wearing faster on the tire sides.
preventative maintenance, and the overall longevity This excessive riding can result in grooves and/or
of the dryer. gouges on the face of the tire. There are several
telltale signs that can be a good indication that a
What causes a drum to be misaligned? rotary drum has fallen out of alignment:
As you’ve already learned, misalignment is often the
result of an improper base installation. Proper drum • Excessive tire/wheel wear

base installation will help to ensure that the dryer • Damage to the tire/wheel

properly ‘floats’ between thrust rollers. Misalignment • Excessive wear on the thrust roller

in a base will propagate through the rest of the drum, • Damage to the thrust roller

causing wear and damage to other drum • Pinion/girth gear wear

components, such as trunnion wheels, tires, • Pinion/girth gear damage

drive components, and thrust rollers.

In addition to this, watching a drum run can also help
to indicate that it is in need of re-alignment. A work-
Misalignment also occurs naturally, as a drum
ing drum that is properly aligned should have little to

FEECO.com/contact ROTARY DRYER HANDBOOK | 25

no contact with the thrust rollers. Drive components
should run smoothly, without excessive chatter or
Avoiding Downtime with
vibrations. Proactive Maintenance
Avoiding costly downtime for repairs is a top priority in
Ensuring proper alignment of your rotary dryer is an running a successful operation, no matter what indus-
integral part of preventative maintenance, helping try you’re in, or what equipment you’re working with.
to ensure a rotary dryer that stands the test of time. And while buying high quality equipment will help
Regular maintenance and inspection of your rotary to avoid downtime, this alone will not prevent it. The
dryer will only help in prolonging the life of your drum, same holds true for rotary dryers.
ultimately minimizing maintenance costs and
down time. Just like a car, a rotary dryer needs routine mainte-
nance in order to continue running properly. Though

Use a Laser Tracking System for this routine maintenance cannot prevent downtime
altogether, it is a step you can take to help keep your
Optimal Alignment
equipment running in good shape for a long time.
One way to ensure proper alignment is achieved is
For maintenance guidelines on your rotary dryer, you
through the use of a laser tracking system.
should consult the service manual provided to you by
the original equipment manufacturer. This will
While traditional alignment techniques can offer a
outline some of the routine maintenance you can
reliable alignment option, they leave much room for
perform on-site, such as lubricating bearings,
error. New laser tracking systems, however, provide an
changing the oil on the gear box, and rechecking
efficient, and accurate solution to alignment needs,
backlash, as well as some of the more major items that
offering fast, precise alignment. In a typical setting,
will require a service technician, such as retraining
laser alignment can get the bases to within +/- 0.005.
the dryer.

While traditional alignment methods rely on manual

Working with your rotary dryer manufacturer to
measurements and mathematical equations to
develop an ongoing maintenance plan will provide
determine and execute proper alignment, advanced
the best prescription for preventative maintenance,
laser tracking systems eliminate the opportunity for
tailored to your specific process. Depending on the
human error by utilizing a laser beam to measure 3D
manufacturer you work with, a variety of field services
coordinates, and recording and analyzing the data
will likely be available to help in keeping your dryer
on a software program, resulting in faster alignment
running smoothly. This might include:
and extreme precision.

• Tire & trunnion wheel grinding

• Alignments
• Gear replacements

FEECO.com/contact ROTARY DRYER HANDBOOK | 26

 • Spare part installations
• Routine maintenance checks
• Re-alignment
• 24-hour emergency services
• Annual inspections
• Training programs

All of this routine maintenance will go a long way in helping you

to avoid unnecessary downtime and costly repairs resulting from
improper care. It’s also a good idea to ask the dryer manufacturer
what spare parts they recommend having on-hand. Having spare
parts on-hand is a good way to prevent unnecessary downtime
due to waiting on parts that could have been ordered from
the start.

Training programs can also be a valuable tool in preventing

catastrophes. Training your operators will help them get to know
the equipment, and teach them how to spot potential problems
before they have a chance to turn serious.

The FEECO Aftermarket Engineering Team offers a range of

services to assist you with all of your aftermarket needs, from start-
up and installation support, to process and equipment audits, and
even field services and custom retrofits.

Tire Grinding

FEECO.com/contact ROTARY DRYER HANDBOOK | 27

 CONCLUSION
WHAT MAKES AN INDUSTRY LEADING ROTARY DRYER MANUFACTURER?

FEECO.com/contact
What Makes an Industry and desired end product characteristics are all
factors that can make a big difference in designing
Leading Rotary Dryer the best possible drying solution for your specific

Manufacturer? process. There are innumerable factors that can be

adjusted to maximize drying efficiency, including

Rotary dryers are an essential component in a length, diameter, inlet temperatures, air-flow, flight

variety of industrial process settings. As the backbone design and pattern, slope, and many others.

of many industrial processes, efficiency, reliability, and

longevity are key to a successful operation. For these Flexibility in design and customization is a fundamental

reasons, when looking to purchase a rotary dryer, it is aspect in choosing a manufacturer that can meet the

of the utmost importance to select an industry lead- needs of your unique processing requirements.

er. But what makes an industry leading rotary dryer

manufacturer? Below are some of the key elements to Material Knowledge

consider when choosing where to put your trust when Material knowledge and experience play an integral

it comes to an industrial dryer manufacturer. role in the design and efficient operation of a rotary
dryer as well. Several material characteristics, such

Flexibility in Customization as bulk density, percent moisture, specific heat, and

A one-size-fits-all approach may seem like an attrac- more, will affect material behavior during processing.

tive, cost-effective solution, but this catch-all method For this reason, it is important to select a rotary dryer

does not consider a variety of factors that can make manufacturer that is experienced in processing a

a rotary dryer operate as effectively as possible. variety of materials, and ideally, with a working
familiarity of the material you are looking to process.

Material characteristics, the processing environment,

FEECO.com/contact ROTARY DRYER HANDBOOK | 29

Manufacturers offering a testing facility are of partic- FEECO has been designing and building custom rotary
ular value, as they can test material characteristics dryers for over 65 years. Our vast material processing
throughout the process. In addition, they can test knowledge, combined with our testing facility, allows
various configurations of equipment to achieve us to offer our customers the best possible drying
desired results, testing material throughout the solution for their needs. In addition, our experienced
development process. Aftermarket Engineers can service your rotary dryer to
help it last for years to come.
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.

FEECO.com/contact ROTARY DRYER HANDBOOK |30

THE FEECO COMMITMENT TO QUALITY
With 65+ years of experience, FEECO International has provided full-scale process solutions for thousands of
satisfied customers (including some of the world’s largest corporations, engineering firms, and start-ups). Cited
in over 250 US patents, the name FEECO has become synonymous with innovation and the reimagining of
efficiency. As the leading manufacturer of processing and handling equipment in North America, no company
in the world can move or enhance a concept from process development to production like FEECO
International, Inc.

The choice to work with FEECO means a well-rounded commitment to quality. From initial feasibility testing, to
engineering, manufacturing, and aftermarket services, we bring our passion for quality into everything we do.
FEECO International is in the process of working towards ISO 9001:2015 quality management system
compliance, with the goal of achieving ISO 9001:2015 Certification within the next calendar year.

Innovation
The FEECO Innovation Center can
aid in everything from feasibility
testing, to process design and
product development.

+
Aftermarket
Engineering
Our Aftermarket
We engineer custom
Engineering Team is Since 1951 solutions to meet
ready to serve, from
your unique needs.
routine maintenance,
to emergency
service.

Manufacturing
We manufacture the best
heavy-duty processing
equipment around.

FEECO.com/contact ROTARY DRYER HANDBOOK | 31

3913 Algoma Rd. Green Bay, WI 54311, USA • Phone: (920)468.1000 • Fax: (920)469.5110 • FEECO.com/contact
 For more information on rotary dryers, material testing, custom
equipment, or for help with your process or problem
material, contact FEECO International today!

US Headquarters
3913 Algoma Road | Green Bay, WI 54311 USA
Phone: 920-468-1000

FEECO.com/contact

© Copyright 2017 | FEECO International, Inc.

All rights reserved