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Brazilian Journal of Chemical Engineering
PrintversionISSN 0104-6632
Braz. J. Chem. Eng.vol. 15no. 3So PauloSept.1998
doi: 10.1590/S0104-66321998000300002
CALCULATING CAPACITY TRENDS IN ROTARY
DRYERS
C.R.F. PACHECO
1
and S.S. STELLA
2

1
Escola Politcnica da USP - Departamento de Engenharia
Qumica,
Caixa Postal 61548 - CEP 05424-970
Phone (011) 818-5765 - Fax (011) 211-3020 - S.Paulo - SP-
Brazil
2
Hercules Inc., Av. Roberto Simonsen, 500 CEP 15140-000 -
Paulnea - SP - Brazil
(Received: August 15, 1997; Accepted: April 19, 1998)
Abstract - This paper provides a methodology developed for the calculation of the feed rate
and of the exit air conditions in an adiabatic rotary dryer, which operates with granular, non-
porous solids having only unbound surface moisture. Some aspects related to the algorithm
are also discussed in greater detail, such as the behavior of the wet-bulb temperatures along
the dryer and the selection of initial values for the iterative loops. The results have been
compared with published data from commercial rotary dryers, and predictions compare within
10% of the available data. The methodology can be used to evaluate trends in the behavior
of a rotary dryer where the operating parameters vary, and it is useful for the practical
engineer, who has to manage several problems commonly encountered in the operation of a
rotary dryer installed in a chemical plant.
Keywords: Rotary dryers, drying systems, drying analysis.
INTRODUCTION
Ongoing market globalization has been pushing companies for a reduction in prices, along
with an increase in quality. For any industrial operation this scenario implies a reduction of
production costs and a tightening of the specification ranges.
The rotary dryer is a piece of equipment which is of relatively common use in the chemical
process industries, due to its simplicity and versatility in handling different types of solids.
The ability to estimate its operating characteristics is of major importance either in the
production planning of an existing plant or in the design of a new one.
The purpose of this paper is to develop an algorithm for estimating the production capacity of
existing rotary dryers.

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For a practical engineer involved with either operation or design of chemical plants, this
algorithm may be helpful in several situations:
If one or more process conditions of an existing rotary dryer change, what is the new
capacity for the same product specifications?
a.
During the process of purchasing a new rotary dryer several proposals are normally
received. Can the offered systems do the specific job?
b.
There is a possibility of buying a second hand rotary dryer from a given supplier. In this
case, how much product in specific conditions could be processed?
c.
Literature on rotary dryers is primarily focused on design methodology and on fundamental
parameters needed to understand the physical phenomena involved in this equipment. In this
paper we consider an alternative point of view which represents a contribution to the analysis
of the performance of existing rotary dryers.
We developed a new algorithm using an integral analysis methodology and assuming an
adiabatic dryer operating with granular, non-porous solids. A comparison between the results
obtained using our procedure and the available data from commercial rotary dryers was
shown to be quite satisfactory for the purposes above.
This paper is organized as follows: firstly, we present the equations which describe the
behavior of a rotary dryer; secondly, a careful discussion of the temperature profiles in the
drying region is performed. Then, we develop the structure of the algorithm and an analysis
of the physical conditions which establish the restrictions needed to assure convergence. A
comparison to commercial rotary dryers is performed, and finally, an example of utilization is
given. A copy of the executable program is available to the reader upon request.
THEORETICAL BACKGROUND
Tsao and Wheelock (1967) presented a set of general equations which describe the behavior
of a rotary dryer.
Here, we use those equations to calculate the production capacity of an existing rotary dryer
of known diameter and length in different scenarios.
A rotary dryer operating with granular, non-porous solids with unbound surface moisture may
be divided, in a simple scheme, in three zones:
I - a first one where the solids are heated to the wet-bulb temperature of the drying air
without losing any moisture,
II - a second one where the solids lose all the desired moisture while remaining at the wet-
bulb temperature of the air and
III - a third one where again the temperature of the solids rises without any further moisture
loss.
Figure 1 sketches the temperature profiles in the three before mentioned zones of such
simplified model, for both counter flow and parallel flow. In the equations below, the
distinction between the two stream arrangements is made labeling the variable S
g
which
assumes the value +1 for the counter flow arrangement and -1 for the parallel flow.

Figure1:
Temperature profiles in the three zones of the rotary dryer as proposed by the model.
In both cases the following parameters are assumed to be known:

dryer geometry: length (Z) and internal diameter (D);
for the solids: specific heat (CS) , inlet and outlet moisture content (X1 and X2 for
counter flow or X
2
and X
1
for parallel flow) and temperature (T
S1
and T
S2
for counter flow
or T
S2
and T
S1
for parallel flow);
for the drying air: mass flow rate (G), inlet temperature (T
2
), ambient temperature (T
3
)
and relative humidity (W
R3
).
The algorithm calculates the mass flow rate of solids (L) that can be processed in the dryer
and the air temperature (T
1
) and humidity (W
1
) at the outlet.
For the situations sketched in Figure 1 the following equations apply:
Overall water balance:
(1)
Overall enthalpy balance:
(2)
where: H
S
= enthalpy of the solids
H = enthalpy of the air, calculated from its temperature and humidity
Enthalpy balance between points 2 and 4:
(3)
and between 4 and 5:
(4)
The kinetics of the process is expressed in terms of the Number of Heat Transfer Units (N
T
)
and the Length of a Transfer Unit (L
T
).
The Number of Heat Transfer Units (N
T
) is related to the fraction of the initial heat transfer
driving force existing at the air outlet. This is defined as:
(5)
In order to integrate equation (5), Tsao and Wheelock (1967) have assumed that the heat
capacities of both streams have little variation along the dryer. With this assumption, the
temperature profiles become linear and integration for each zone of the dryer gives,
respectively:
(6)
(7)
(8)
The Length of a Transfer Unit (L
T
) is defined by:
(9)
where: CG = specific heat of the air, kJ kg
-1

o
C
-1
G
S
= air mass velocity, kg m
-2
s
-1
,
U
a
= overall heat transfer coefficient, W m
-3

o
C
-1
.
Several methods for estimating the overall heat transfer coefficients have been described and
were summarized by Baker (1983). According to him, none of the correlations reviewed in his
article can be recommended with reasonable degree of confidence. However, the correlation
proposed by Friedmann and Marshall (1949) is considered the most reliable, since it is based
on extensive and careful experimental data. Their correlation has the following form:
(10)
where K=244.7 for U
a
in W m
-3

o
C
-1
, G
S
in kg m
-2
s
-1
and D in m.
The above correlation is valid for peripheral shell speeds between 0.2 and 0.5 m s
-1
and
holdups between 2 and 8 %.
The constant (K) takes into account factors that could influence the available heat transfer
area, namely: particle size distribution, shell rotation speed, material holdup in the dryer and
shape and number of flights.
The dryer length is related to N
T
and L
T
by:
, (11)
where
(12)
With this set of equations, it is possible to fully describe the behavior of a rotary dryer.
Analysis Of The Temperature Profiles

One point that needs to be discussed more profoundly is the behavior of the wet-bulb
temperature along zone II of the dryer.
The temperature profiles shown in Figure 1 suggest that the wet-bulb temperature decreases
in the direction of the air flow along zone II. In fact, the wet-bulb temperature can rise or fall
depending on the operating conditions. This behavior may be understood in the following
way:
The effect of drying on a material for a counter flow arrangement implies that:
X
5
> X
4
(13)
Developing this inequality using the enthalpy balance between points 4 and 5, one obtains:
(14)
where: C
w
= water specific heat, kJ kg
o
C
-1
TW = air wet-bulb temperature,
o
C
Rearranging the above inequality and taking into account that, for a given pressure, H can be
calculated as a function of T
W
only, the results are:
(15)
where:
(16)
The left-hand side of inequality (15) is a function of T
W4
and T
W5
, where r is a parameter.
Therefore, we can write:
f(TW4 ,TW5) >0 (17)
As stated above, drying can only occur if condition (17) is met.
Figure 2 shows a plot of the above inequality for three different values of r, in the full lines
represents the region where f(T
w4
, T
w5
) >0 and in the dotted lines the negative one. The
behavior of f(T
W4
,T
W5
) and the resulting wet-bulb temperature profile are summarized as
below.
The same analysis would show a similar behavior for a dryer operating in parallel flow
arrangement.
value of r f(T
W4
,T
W5
) wet-bulb temperature along zone II
0.04 >0 for any T
W4
> T
W5
increases
0.4 >0 for T
W4
> T
W5
in some regions and for
T
W5
> T
W4
in other regions
may increase or decrease
4.0 >0 for any T
W5
> T
W4
decreases
Figure 2a:
Study of the variation of the function f(TW4 , TW5 ) for a selected value of the parameter r= 0.04.
Figure 2b:


Figure 2c:
ALGORITHM STRUCTURE
The algorithm developed in this work calculates the product flow rate and the exit air
conditions for an adiabatic rotary dryer operating with granular, non-porous solids having
only unbound surface moisture.
The methodology assumes the knowledge of the following data:
dryer geometry:
- length (Z)
- internal shell diameter (D)
solids conditions:
- specific heat (C
S
)
- dry-basis moisture content at the inlet (X
i
) and at the outlet (X
o
)
- temperature at the inlet (T
Si
) and at the outlet (T
so
)
drying air conditions:
- pressure (P)
- surrounding air temperature (T
3
) and relative humidity (W
R3
)
- temperature (T
2
) after the air heater
- mass flow rate (G)
stream arrangement: counter flow or parallel flow
Then the following assignments are done, based on the stream arrangement:
variable counter flow parallel flow
S
G
+1 -1
T
Si
T
S1
T
S2
Xi X1 X2
T
So
T
S2
T
S1
X
o
X
2
X
1
The algorithm follows the steps:
1.Calculate:
- the air mass velocity GS by the expression G / (p D
2
/ 4).
- the volumetric heat transfer coefficient U
a
using equation (10).
- the length of the transfer unit L
T
using equation (9).
- the number of heat transfer unit NT using equation (11).
2.With P, T
3
and W
R3
, calculate all psychrometric properties for the air at point 3 (ambient
air) (psychrometric chart).
3.With P, T
2
and W
2
= W
3
, calculate all psychrometric properties for the air at point 2 (dryer
inlet) (psychrometric chart).
4.Assume initial values of T
W4
and the solids mass flow rate L.
5.Calculate:
- W
1
using equation (1), the overall water balance.
- the solids enthalpy at point 2 HS2 by the expression ( CS + X2) TS2.
6.Assume T
S4
= T
w4
(model hypothesis).
7.Calculate:
- H
S4
the solids enthalpy at point 4 by the expression ( C
S
+ X
2
) T
S4
.
- H
4
using equation (3), enthalpy balance between points 2 and 4.
8.Assume W
4
= W
2
(model hypothesis).
9.With P, H
4
and W
4
, calculate all psychrometric properties for the air at point 4, and in
particular the recalculated value T
w4c
(psychrometric chart).
10.Use the values of Tw4 and Tw4c to calculate a new value of Tw4 and return to step 6 until
convergence is attained.
11.Assume the initial value of T
w5
.
12.Assume T
S5
= T
W5
(model hypothesis).
13.Calculate:
- H
S5
S
+ X
1
) T
S5
.
- H
5
using equation (4) enthalpy balance between points 4 and 5.
14.Assume W
5
= W
1
(model hypothesis).
15.With P, H5 and W5, calculate all psychrometric properties for the air at point 5 and in
particular the recalculated value T
w5c
16.Use the values of Tw5 and Tw5c to calculate a new value of Tw5 and return to step 12 until
17.Calculate the Number of Heat Transfer Units for zones I, II and III.
- N
TIII
using equation (8).
- N
TII
using equation (7)
- N
TI
using equation (12)
18.Assume the initial value of T
1
.
19.Calculate T1C using equation (6) in the form below:
20.Use the values of T
1
and T
1c
to calculate a new value of T
1
and return to step 19 until
21.With P, T
1
and W
1
, calculate all psychrometric properties for the air at point 1, and in
particular H
1
22.Calculate:
- H
S1
S
+ X
1
) T
S1
.
- The reiterative value of the solids mass flow rate Lc using equation (2) overall enthalpy
balance.
23.Use the values of the solids mass flow rate L and L
c
to calculate a new value of L and
return to step 5 until convergence is attained.
SELECTION OF INITIAL VALUES FOR THE ITERATIVE LOOPS

The algorithm has four iterative loops (T
W4
, T
W5
, L and T
1
) and some precautions had to be
taken in the selection of the initial values in order to assure the convergence of the loops.
The use of constant values would not assure convergence for any arbitrary set of operating
conditions. To overcome this difficulty, the initial values are calculated based on the analysis
of physical processes occurring in the dryer.
In that sense, the first estimate for T
W4
is made under the following assumptions (refer to
Figure 3):
At any point in the dryer the temperature T
S
of the solids must be above the dew point
temperature T
D
of the air in order to avoid condensation and in particular for point 4,
(TS4 > TD4).
1.
T
S4
= T
W4
as assumed by Tsao and Wheelock (1967). 2.
TD4 = TD2 since there is no change on moisture content between points 2 and 4 (the dew
point for the air inlet is represented by point 6 in Figure 3).
3.
Consequently, the air is cooled at constant moisture from point 2 to point 4, T
W4
< T
W2
. 4.
The first three conditions imply that T
W4
> T
D2
, and condition 4 implies that T
W4
< T
W2
.
Therefore, the first estimate for T
W4
is taken as the average between T
W2
and T
D2
.
The first estimate for L is calculated from the global mass balance, choosing a value for W1,
based on the following assumptions:
W
1
> W
2
because moisture is added to the air during the drying process. 1.
The value for T
W4
estimated as described above, determines the maximum outlet
moisture attainable in an ideal drying process (shown in Figure 3 as point 8). Then, it
follows that W
1
< W
8
.
2.
Therefore, W
1
is taken as the average between W
2
and W
8
, and the value of L is then
calculated.
Since T
W5
is close to T
W4
, the initial value for T
W5
is taken as equal to T
W4
(as in fact the
temperatures would be the same if the change in the total enthalpy of the solids stream were
negligible in an adiabatic dryer).
The initial value of T
1
is obtained from equation (6). But since it cannot be put in a form
where T
1
is isolated on one side, an iterative loop is used. Among the several forms of
rearranging equation (6) in order to have T1 on the right-hand side, we have chosen this
particular one with a unique root:
(17)
Figure 3:
First estimates for moist air wet-bulb temperature TW4 and moist air absolute humidity W1.
Since T1 must be greater than TS1, its initial value is taken slightly above TS1.
The use of these criteria on the selection of the initial values for the iterative loops assures
that the algorithm works properly.
COMPARING THE RESULTS OF THE METHOD WITH PUBLISHED DATA

As we discussed above, this algorithm was developed by assuming an adiabatic dryer. In
reality, commercial rotary-dryers have heat losses to the environment, and therefore, they
do not present rigorous adiabatic behavior.
Page 10 of 15 Brazilian J ournal of Chemical Engineering - CALCULATING CAPACITY TREN...
Nevertheless, a comparison between predictions from our algorithm and real world was made
to evaluate the difference between the ideal and real situations.
In order to perform such a comparison, a data set published by Perry (1984) (table 20-13,
page 20-33) for seven rotary dryers operating in parallel flow was used. This table furnishes:
dryer length and diameter
for the solids:
- inlet and outlet temperatures
- inlet and outlet wet-basis moisture content
- outlet solids mass flow rate (wet-basis)
for humid air:
- inlet and outlet temperatures
evaporation rate
Table 1 shows for the seven dryers the data needed to use the algorithm and the results
obtained.
The solids moisture content and its mass flow rate are presented in dry-basis as requested by
the algorithm.
The specific heat of the solids was not given, and we assumed: 1 kJ kg
-1

o
C
-1
, which is a
representative value for several materials (Perry (1984) table 20-14).
The air mass flow rate was estimated using the evaporation rate and the following
approximation:
(18)
where: E = evaporation rate in kg s
-1
l = water latent heat of evaporation at (T
S1
+T
S2
)/2 in kJ kg
-1
As can be seen from Table 1, the feed rates agree to within 10% and the air outlet
temperatures agree to within 5%. The results obtained are lower consistently than the real
ones, but these do not affect the validity of an evaluation of trends on dryer operation. In
addition, the agreement remains along a broad range of dryer sizes.
Table 1: Comparative results between published and calculated values for seven
commercial.
Rotary dryers
Experimental Data Used For Running the Program
X
i
: 0.3333
X
o:
: 0.005
C
S
: 1 kJ kg
-1

o
C
T
Si
: 27
o
C
TSo: 65
o
C
T
2
: 165
o
C
P: 101234 Pa
Dryer
#1 #2 #3 #4 #5 #6 #7
D m 1.219 1.372 1.524 1.839 2.134 2.438 3.048
Z m 7.62 7.621 9.144 10.698 12.192 13.716 16.767
G
kg s
-1
0.957 1.276 1.595 2.233 2.871 3.829 6.062
Feed Rate
L
experim. kg s
-1
0.113 0.144 0.176 0.263 0.351 0.451 0.715
L
calculated kg s
-1
0.108 0.136 0.174 0.244 0.316 0.416 0.650
Difference % 4.42 5.55 1.13 7.22 9.97 7.76 9.09
Air Outlet Temperature
T
1 experim.
o
C
71 71 71 71 71 71 71
T1 calculated
o
C
67.7 72.6 70.4 70.3 69.7 70.7 71.9
Difference % 4.67 -2.25 0.84 0.99 1.83 0.42 -1.27
THE EXECUTABLE PROGRAM

An executable program, which runs in a user-friendly environment, where all the operations
can be followed in a single screen page, is available upon request to the reader.
This program uses a previous algorithm developed by Pacheco (1995) which calculates the
moist air properties and plays the role of the psychrometric chart. For the convergence of the
iterative loops, the Wegstein method as exposed by Franks (1972) was used.
The executable program is composed of two files:
ROTDRYER.EXE - the executable file
DATA.DAT - a file containing the last set of data entered in the program
The program is started by typing ROTDRYER
<enter> at the DOS prompt. The program screen, shown in Figure 4, is composed of three
sets of lines:
13 lines which contain input data that can be changed by the user
7 lines containing the results of the calculations
one line for modification of any of the inputs
The lines containing the results display the product flow rate, the exit air conditions, and the
accordance with the following guidelines given by practice:
0.1 D/Z 0.25
0.28 G
S
13.9 kg s
-1
m
-2
1.5 N
T
2.0
To change one of the inputs, just type the number of the item and press <enter>. A new line
appears, showing the parameter to be changed.
Type the new value, and press <enter>. The program then calculates the new outputs.
Repeat the process to modify other parameters.
1- pressure (Pa): 101234
2- solid initial moisture content d.b. (%): 33.33
3- solid final moisture content d.b. (%): 0.50
4- solid initial temperature (oC): 27.0
5- solid final temperature (oC): 65.0
6- solid specific heat (kJ/kg/oC): 1.000
7- ambient air temperature (oC): 27.0
8- ambient air relative humidity (%): 60
9- inlet air temperature (oC): 165.0
10- air flow rate (kg/s): 6.062
11- length (m): 16.8
12- diameter (m): 3.0
13- flow (1= counter flow 2= parallel-flow ): 2
Solid flow rate (kg/s): 0.650
Outlet air temperature (oC): 71.9
Outlet air relative humidity (%): 21.9
Dew-point temperature at the outlet (oC): 39.9
D/Z: 0.18 (0.1 <= D/Z <= 0.25)
GS (kg/sm2): 0.831 (0.278 <= GS <= 13.9)
NT: 1.53 (1.5 <= NT <= 2.0)
Modify item nr. (0 to end):
Figure 4:
Shows program single screen page, with the values of dryer #7.
The results can be printed out by pressing the" Print Screen" key. To exit the program, type
"0" (zero) and <enter>.
EXAMPLE
Consider a rotary dryer operating with the conditions displayed in Figure 4. Suppose that, for
some reason, the inlet moisture of the solids increases from 33.3% to 40%. What could be
done to obtain the same product flow rate (0.65 kg s
-1
) with the same outlet moisture (5%)?
It is also assumed that the system has some flexibility for changing the air flow rate and inlet
temperature.
Among the several possibilities, here we will only discuss two solutions:
a) Increasing the air flow rate by 10% (from 6.062 to 6.668 kg s
-1
) and increasing the inlet
air tempertaure from 160 to 181
o
C. The resulting product flow rate in this case would still be
0.65 kg s
-1
.
b) Increasing the air inlet temperature from 160 to 190
o
C, keeping the air flow rate
constant. The resulting product flow rate is also 0.65 kg s
-1
.
Although both alternatives satisfy the condition of maintaining the production rate and the
product specifications, the first one does the job with an N
T
of 1.41, while the second one
does it with an N
T
of 1.53. This means that the second alternative uses energy in a more
efficient way, and therefore, should be chosen. In fact, the first option operates with an air
flow rate of 6.67 kg s
-1
and gives an air exit temperature of 79.4
o
C, while the second
operates with a lower air flow rate (6.06 kg s
-1
) and a lower air exit temperature of 78.4
o
C.
This was an example of an application of the presented algorithm, but several others can be
devised.
CONCLUSIONS
This algorithm, in spite of being rather simple since it consists basically of a set of algebraic
equations, permits a quick look at the performance of a rotary dryer.
However, several details had to be examined in order to assure that the algorithm would
work properly. The examination of these details actually uncovered rather interesting aspects
of the behavior of a rotary dryer.
The agreement between the algorithm and real data shows that our approach can help the
practical engineer to obtain a rapid diagnosis of the performance of a rotary dryer.
NOMENCLATURE
CG Air specific heat, kJ kg
-1

o
C
-1

C
S
Solids specific heat, kJ kg
-1

o
C
-1

C
W
Water specific heat, kJ kg
-1

o
C
-1

D Internal rotary dryer diameter, m
E Evaporation rate, kg s
-1

G Air mass flow rate, dry-basis, kg s
-1

G
S
Air mass velocity, dry-basis, kg s
-1
m
-2

H Moist air enthalpy, kJ kg
-1

HS Solids enthalpy, kJ kg
-1

K Constant for the heat transfer coefficient
L Solids mass flow rate, dry-basis, kg s
-1

L
T
Length of a Transfer Unit
N
T
Number of Heat Transfer Units
P System total pressure, Pa
P
p
Water vapor partial pressure, Pa
Pss: Water vapor pressure at dry-bulb temperature, Pa
P
su
Water vapor pressure at wet-bulb temperature, Pa
r (G/L)/(C
S
+C
W
X
5
)
S
G
Counter flow; parallel flow identification variable
T Moist air dry-bulb temperature,
o
C
TD Dew point temperature,
o
C
T
S
Solids temperature,
o
C (Tsi- inlet; Tso- outlet)
T
W
Moist air wet-bulb temperature,
o
C
Ua Volumetric heat transfer coefficient, W m
-3

o
C
-1

W Moist air absolute humidity, kg/kg
W
R
Moist air relative humidity, %/100
X Solids moisture content, dry-basis, kg/kg (X
i
- inlet; X
o
- outlet)
Z Dryer shell length, m
Greek letters
l Water latent heat of evaporation at (T
S1
+T
S2
)/2 (kJ kg
-1
)
REFERENCES
Baker,C.G.J., Cascading Rotary Dryers, in Advances in Drying, McGraw-Hill, Vol 2, ch 1
(1983). [Links]
Franks, R.G.E., Modeling and Simulation in Chemical Engineering. Wiley-Interscience, (1972).
[Links]
Friedmann, S.J. and Marshall, W.R., Studies in Rotary Drying Part II - Heat and Mass
Transfer, Chem.Eng.Prog. Vol.45, pp.573-588 (1949). [Links]
Pacheco, C.R.F., Carta Psicromtrica para Computadores Pessoais - PC for PC, Revista
Brasileira de Eng. Qumica, Vol.XV, No.2, pp.21-26 (Nov.,1995). [Links]
Perry, R.H.; Green, D.W. and Maloney, J.O., Perry's Chemical Engineers'Handbook, McGraw-
Hill Book Co, 6
th
ed., New York (1984). [Links]
Tsao, G.T. and Wheelock, T.D., Drying Theory and Calculations. Chem.Eng. , pp. 201-214
(June 19,1967). [Links]
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(Received: August 15, 1997; Accepted: April 19, 1998)

Page 2 of 15 Brazilian J ournal of Chemical Engineering - CALCULATING CAPACITY TRENDS...

In both cases the following parameters are assumed to be known:

Analysis Of The Temperature Profiles

Page 6 of 15 Brazilian J ournal of Chemical Engineering - CALCULATING CAPACITY TRENDS...

SELECTION OF INITIAL VALUES FOR THE ITERATIVE LOOPS

COMPARING THE RESULTS OF THE METHOD WITH PUBLISHED DATA

THE EXECUTABLE PROGRAM

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