~ ALLIS-CHALMERS

flow of
IDaterial

The flow of material through a rotary kiln is determined by its slope and rotational
speed, as well as the characteristics of the material being processed. The material is
preheated progressively by its passage from the feed end into the high temperature
"calcining zone". Here the flame is produced by combustion of the fuel introduced
through the kiln burners located in the firing hood at the discharge end.
The simplified formulas on the following pages will enable you to predetermine the
flow of material ... the most desirable slope ... and speed of a kiln for handling wet
or dry feed. They will also provide the method for calculating required horsepower.

22 8 1212
 FLOW OF MATERIAL THROUGH
'" ROTARY KILNS, COOLERS AND DRYERS

The formula covering the flow of materials through a rotary TABLE A

kiln, cooler or dryer is .~

T 1.77 X ye X L X Factor Slope per

S X D X N foot s e ve 1.77 y'e
When there are no obstructions or constrictions,
114" 1.192 15 3.873 6.855
factor is 1; otherwise it varies with feed, height
5/16" 1.491 20 4.472 7.915
of constrictions, ratio of diameter and length,
3/8" 1.790 25 5.000 8.850
and effect of chains or lifters.
7/16" 2.087 30 5.477 9.694
v 11r 2.385 35 5.916 10.471
T = Retention time of material in kiln in
2.684 _
minutes 9/16"-
Sis" 2.980
12-
45
6.324 -
6.708
11.193
11.873
e= Angle of repose of material, in degrees
Approx. 40° for blocky or granular feed, such
Example
as limestone. Assume kilo, 11 Y<l by 360 ft, is to dry and calcine a granular
material; desired production, 1000 net tons of finished prod-
Approx. 35° for material such as sand, oyster uct per 24 hours; free moisture in feed is 10%; specific
shell, dry fines, and cement slurry gravity of wet feed, and finis!ted product also is 2.0; loss in
weight on drying and calcining is 30%; optimum retention
L = Length of shell, in feet time for these operations is 3 Vz hours; kiln has 6 in. lining
throughout, without chain system or constrictions. Find
D = Inside diameter of shell, in feet. If shell is suitable slope and speed of kilo, with percent loading held
lined, use inside diameter of lining within proper limits.
S = Slope of shell, in degrees • Substituting known factors in flow formula
N = Speed of shell, in rpm
210 =1.77 y'40 X 360 X
1
Slope and speed of shell must be balanced to S X 10.25 X N
give reasonable retention time and % loading. S X N= 1.872
Percent loading is usually held below 12.5% Assume, for trial, slope of % in. per ft. From Table A
and above 6%. 10% loading is considered 1.872
S = 1.79, and N = - - = 1.05 rpm
normal. 1.79
1000 X 2000
The formula for ascertaining the percent loading Lbs product per hour = = 83,330
24
(the percent of kiln cross section area theoretically 83,330
filled with material) is Cu ft product per hour = = 668
2 X 6 2.4
CFH 100 83,330
Lbs wet feed per hour= - - = 119,040
60XFMXA X .70
C u f t wet Ieed per hour 119,040 -- 955
CFH = Cu ft per hour =
2 X 62.4
FM = Rate of travel of
material through 955
% loading at feed end =
shell, in ft per min. 6 0 X 1.714 X 82.5
= Shell length, in feet X 100 = 11.3%
divided by Reten- 668
% loading at discharge end = .,-----,-------
tion time in min- 6 0 X 1.714 X 82.5
utes. X 100 = 7.9%
A = Cross section area,
inside lining (if In the above example it should be noted that the speed
any), in sq ft. of the kiln is in line with best modern practice for a kiln
of this size. If the slope selected for trial had given a speed
below about .5 rpm or above 1.5, a different slope would
Source of above: U.S. Bureatt of Mines, be tried, percent loading permitting. If the retention time
thus arrived at would be too short, an alternative would be
Technical Paper No. 384. 1927. to select another size kiln which would better fit the de-
sired conditions.
 CALCULATION OF HORSEPOWER TO DRIVE
ROTARY KILN, COOLER OR DRYER
6 vz I
X /0
I
X"
.;2 I

Total Hor sepower Required = E x ample

Friction Horsepower plus Load Horsepower.
Assume a kiln, 81(2 by 10 by 81(2 by 300 ft; to handle a wet
process slurry of 35% moisture; desired production is 226
tons of kiln product per day; kiln has 6 in. lining except ·in
W X bd X t.d X N X F X .0000092
Frict ion hp enlarged zone which is 36 ft long and has 9 in. lining; kiln
rd has chain system (disregard effect on flow of material).
Weight of loaded kiln, approximately 700 tons; oil lubri-
cated roller shaft bearing dia, 16 in.; roller dia, 42 in.; tire
dia, 136 in. Determine slope and speed of kiln and power
W = total vertical load on all roller shaft bearings, in lb. required to operate.
bd = roller shaft bearing dia, in inches
rd = roller dia, in inches Substituting known factors in Bow formula,
td =tire (riding ring) dia, in inches
N = rpm of shell __ I.77,J;; X 300 = 10.471 X 300
S N 2 33
F = Co-efficient of friction of support roller bearings X . 7.5 X 180 7.5 X 180 .
= .018 for oil lubricated bearings
Assume for trial, slope of ~2 in. per foot. From Table A
= .06 for grease bearings
S = 2.385, and therefore N = ::: = .98 rpm
5
226 X 2ooo =
Lb product per hour 18 800
Load hp = (D X Sine 8) 3 X N XL X K 24 ,
18,800
Cu ft product per hour = ~ = 200
. 1200 X 923
D = shell dia inside lining ( if any) , in ft Lb feed per hour= = 46,150
24
Sine 8 =(read from Chart C-hased ·on %
46,150
loaded area) Cu ft feed per hour = = 440
N = rpm of shell 1..6 8 X 6 2. 4
L = Length of shell, in feet 440
% loading at feed end X 100 = 10%.
K = .00092 for lime (based on approximately 60 Xl.7X 6 44.2
40° angle of repose) Note that enlarged zone has been disregarded in above
.00076 for cement, wet or dry process (based calulations.
on approx. 35° angle of repose)
.0018 for sliell with lifters (cooler or dryer) % loading at discharge end is
-based on approx. 40° _angle of repose.
200 X 100 = 4.5%
60 X 1.67 X 44.2
% loading, enlarged zone (Chart B)-exactly 10%.
~ 1oad"mg
Approximate average 70 4.5 + 10.0 7.3%v.
2
For two or three diameter kilns, the load horsepower of Fnction hp =
the several diameters should be calculated separately. 1,400,000 X 16 X 136 X .98 X .018 X .0000092
42
=11.7 hp
Load hp = (7.5 X .725) 3 X .98 X 264 X .00076plus
( 8.5 X .725) 3 X .98 X 36 X .00076
Percent Loaded Area = 37.6hp
As noted on the preceding page, under "Flow of Material"
the normal percent loaded area is considered .ro be 10%,
and this figure is generally used in horsepower calculations Total hp = Friction hp + Load hp
unless analysis discloses it will be exceeded, in which case = 11.7 +
37.6
a higher figure is used. =49.3 hp
 CHART B
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I L
• 'II. 4 l5 E> 7 8 9 10 II 12. , .
LOADED AIEA IN EHLAIGED CALCINING ZONES
, .... 15 16

-
r7~ CHART c
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SINE

These calculations are based on normal operation of the
kiln, at which best performance will be maintained. How-
ever; to have a reserve for emergency condition, or allow
for changes in raw materials or operating procedures, it is
generally desirable to provide motor and drive large enough
to operate the kiln at a maximum speed of 1 V3 times
normal. Accordingly, the motor in this example should be
good for 1V3 times 49.3 hp, or 65.8 hp. The next standard
~ize would be a 75 hp motor.
Motors. Drive motors for rotary kilns, coolers and dryers
should be selected the next standard size larger than indi-
cated by the calculated horsepower. High starting torque
motors should always be used.
Motors for rotary kilns (which usually rotate at speeds
that can be varied as desired by the operato!$) should be
direct current, or alternating current, either multi-speed
cage·type, or slip ring, if the latter type will provide suffi-
cient speed control for the intended operation.
Motors for coolers, dryers, or kilns to be operated at
constant speed may be any type of constant speed motor
having high starting torque.

~ ALLIS-CHALMERS MILWAUKEE 1, WISCONSIN