IN-HOUSE TRAINING 2006

POWER CALCULATION FOR

DRYER / ROTARY KILN
JUNE 15TH, 2006

1
I. INTRODUCTION
Rotary dryer/Rotary Kiln use in:
- mineral industries including cement plant
- some kind of chemical plant
- paper and agro industry.

A. Rotary Dryer

• Used to separate liquid from solid by heating method.

• Drying is accomplished by contact material with hot gasses.
• Rotating cylindrical assembly which wet material in inlet is
introduced slightly elevated.
• Tires are mounted on shell and supported rollers.
• Thrust Rollers are installed to take up the axial downward
thrust on the tires.
• Girth Gear encircling shell engages a driving pinion to provide
the rotation.
• Lifters and other internal attachments to shell aid to passage of
material through the dryer and accelerate the drying process.

B. Rotary Kiln

• Used for burning and calcining many kind of materials.

• Also use for incinerating process for material sludge.
• Construction of Rotary kiln is almost same as Rotary dryer,
except for combustion unit and refractory.

2
For example
CEMENT ROTARY KILN
3 Major Zones:

Figure -1

1. Zone 1 ; Drying and Pre-heating Zone (250 oC to 900 oC)

Water is evaporated and calcination driving off carbon
dioxide from limestone begin.

2. Zone 2 ; Calcining Zone (600 oC to 900 oC)

Calcination is complete, removing carbon dioxide
from calcium carbonate to produce the lime (calcium
oxide) needed for subsequent reactions.

3. Zone 3 ; Sintering or Burning Zone (1200 oC to 1480 oC)

Calcium oxide reacts with silicate to form dicalcium
silicates and tricalcium silicate. Small amount of
tricalcium aluminates and tetracalcium aluminoferrite
are also formed. Those two compounds, in liquid
phase, meld solids together into the pellets called
clinker. Remaining calcium oxide reacts with
dicalcium silicates to form tricalcium silicate

3
All of those process occurred related with heat exchange inside of a rotary
dryer or rotary kiln. Those can be divided into six parts, such as:

1. Convection and radiation from gas to solid

2. Convection and radiation from gas to wall
3. Radiation from free wall to solid
4. Radiation and conduction from the covered wall to solid
5. Conduction through the wall
6. Mixing from the surface of the solid into the mud

Figure - 2

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II. MAIN EQUIPMENT

ROTARY DRYER:

- Hot Air Generator

• Burner
• Combustion Air Fan
• Dilution Air fan

- Shell, incl. Insulation

• Charging Hood
• Discharging Hood
• Air Seal

- Supporting Device
• Tire
• Roller
• Moveable Thruster

- Driving device
• Electric Motor
• Gear Reducer
• Coupling
• Girth gear and Pinion

- Gas Exhaust treatment

• Multi-cyclone or EP
• Exhaust Fan
• Stack

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ROTARY KILN:

- Kiln Shell
• Refractory

- Combustion Unit
• Burner
• Primary air fan
• Secondary air fan

- Supporting Unit
• Tire
• Roller
• Moveable Thruster

- Driving equipment
• Electric Motor
• Gear Reducer
• Coupling
• Girth gear and Pinion

- Kiln End Hoods

• Charging Hood
• Discharging Hood
• Air Seal

- Gas Exhaust treatment

• Multi-cyclone or EP
• Exhaust Fan
• Stack

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III. DESIGN

PARAMETER DESIGN:
- Feed capacity t/hr
- Moisture content %
- Specific gravity material kg/m3
- Specific heat Kcal/kg. oC
o
- Material temperature C
o
- Gas temperature C
- Humidity Nm3/Nm3
- Heat transfer unit capacity Kcal/hr
- Effective dia. (Inside lifter) m
- Shell length m
- Inclination m/m
- Holding time min.
- Rotation rpm
- Filling volume m3
- Volume ratio %
- Lifter quantity
- Power HP, kW

Several parameters could be shown on a datasheet

(see attachment-5)

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PROCESS ANALYZING

- Material Balance
- Heat Balance
- Exhaust Gas

CALCULATION

1. Equipment Sizing
2. Strength Calculation
3. Power Calculation

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IV. DRIVING EQUIPMENT
DRIVING TYPE

• Large rotary kiln/dryer usually use girth and pinion and made of
cast steel, fixed on the kiln shell by steel spring plates, welded
tangentially to the kiln/dryer and fitted to the gear rim by hinge
bolts

For example, see attachment-3

• Small rotary kiln/dryer will use a chain drive type with the girth
sprocket.

For example, see attachment-4

SPEED CONTROL

A mechanical variable speed motor or inverter control motor will be

installed for speed control

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V. POWER CALCULATION

• Power Required to move material in the R/D (HP) :

P1 = 0,356 x M x D x N x K1

Where;
D = Inner Shell Diameter (m)
N = Rotation (rpm)
M = Material Hold Weight (ton)
K1 = Factor of material action (0.6 ~ 1.0)

• Friction resisting Power at supporting roller (HP) :

P2 = 0,697 x Dt x N x (M + W) x μ x ( Db ) x ( 1 )
Dr Cos β

Where;
Dt = Outer Diameter of Tire (m)
Db = Diameter of Bearing (m)
Dr = Outer Diameter of Roller (m)
N = Rotation (rpm)
M = Material Hold Weight (ton)
W = R/D Weight (ton)
μ = Friction Coefficient
β = Contact Angle

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• Power Required to Rotate R/D (HP) :

P3 = 1.868 . 10-3 x D2 x N2 x (M + W)

Where;
D = Inner Shell Diameter (m)
N = Rotation (rpm)
M = Material Hold Weight (ton)
W = R/D Weight (ton)

• Initial Power (kW) :

Po = (P1+P2+P3) x (1/η) x 0.75

Where;
η = Transmission efficiency

• Driving Power (kW) :

Pd = (P1+P2) x (1/ η) x 0.75

• Motor Power (kW) :

Pm = Po x 1.2

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ATTACHMENT-1
R/Dryer ARRANGEMENT (SAMPLE)

3 7 4E0D1 M1 - 0 2 2 0 0 4 R1
120 -

12
ATTACHMENT-2
R/Kiln ARRANGEMENT (SAMPLE)

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ATTACHMENT-3
GIRTH GEAR AND PINION TYPE (SAMPLE)

374E0D1 M1 - 0 2 2 0 0 7 R2
1202

14
ATTACHMENT-4
CHAIN DRIVE TYPE (SAMPLE)

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ATTACHMENT-5

ＴＳＫ ＲＯＴＡＲＹ ＤＲＹＥＲ ＳＰＥＣＩＦＩＣＡＴＩＯＮ ＳＨＥＥＴ

CUSTOMER PT. TBI JOB NAME FODDER PLANT

LOCATION LAMPUNG, INDONESIA JOB No. EB00052
Item name No.1 DRYER Item No. D401
Type Rotary Warm Air Dryer Required No. 1 set
Size φ4300×23000 L
Manufacture

ＯＰＥＲＡＴＩＮＧ ＣＯＮＤＩＴＩＯＮ
Material handled SWEET POTATO FLAKE Operation CONTINUOUS
liquid H2O Installed place OUTDOOR
Feed rate (Wet) 37,400 kg/Hr Apparent density 500 kg/m3
(Dry) 14,200 kg/Hr Specific Gravity 1.2 g/cm3
Liquid content (Inlet) 62 % Size distribution approx. φ 5～15mm
(Outlet) 40 %
Temperature (Inlet) 25 ℃ Average particle size φ 10
(Outlet) 80 ℃ Specific heat 0.3 Kcal/kg℃
Hot gas temperature (Inlet) 400 ℃ Allowable temperature 200℃ (Material Temp.)
(Outlet) 120 ℃
Hot gas flow rate approx. 2000 Nm３/min

ＳＰＥＣＩＦＩＣＡＴＩＯＮ
Main size φ4300×23000 L Material
Speed of revolution 1.2～2 rpm (INVERTER) Shell SS400 + SUS304
Inclination 2/100 Tire SCMn2A
Design pressure ATM Roller SCCrM3A
Design temperature 500 ℃ Gear SCMn2A
Air seal CLOTH SEAL/Labyrinth Type Pinion SCM440
Feed section SUS304
Effective Volume (at holdup rate 15% base) Discharge section SS400
approx. 50 m3 Air seal SS400
Gasket NON-ASBESTOS TYPE
Drive motor type Three-phase motor (INV. motor) Encl. TEFC Insul. class F
output 90 KW Volts 380 V Phase 3 φ
poles 4 P frequency 50 Hz speed of revolution 1500 rpm
Net weight 180 Ton
Operating weight 220 Ton
Insulation Air insulation
Painting prime 2 times finish 2 times

Accessories ・INLET BOX WITH SCREW FEEDER AND DISCHARGE BOX

・LUBRICATION UNIT (Tire, Roller, Gear, Pinion, etc.)
・SUPPORT OF FEED SECTION AND DISCHARGE SECTION
・SAFETY COVERS ・ANCHOR BOLTS ・TEMPLATE
・DRIVER (INVERTER MOTER) ・REDUCER ・COUPLING
・HOT GAS INLET ZONE (USE AS EXPANTION)
Spare parts
・1 years operation
Made by N . Kamiya Checked by Contrast No. Page
( SIKO Eng. )
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Attachment-6

Sampel Power Calculation for dryer

DATA:
Weight of material M ton 73.20
Inner diameter of dryer D m 4.20
revolution of dryer N rpm 1.50
Factor of material action K1 - 1
Outer diameter of tire Dt m 4.85
Weight of dryer shell with tire W ton 205
Friction of bearing μ - 0.018
Inner diameter of bearing Db m 0.38
Outer diameter of roller Dr m 1.35
Contact angle of tire and roller β deg 30
Efficiency of drive η - 0.85

CALCULATION:
1)Power required to move material in R/D
P1=0.356*M*D*N*K1 HP 164.17

2)Friction resisting power at supporting roller

P2=0.697*Dt*N*(M+W)*Db/Dr* μ*1/cosβ HP 8.25

3)Power Required to rotate R/D

-3 2 2
P3=1.868*10 *(D) *(N) *(M+W) HP 20.63

4)Power for normal operation

Pd=(P1+P2)*1/η*0.75 kw 152.14

5)Power for start-up operation

Ps=(P1+P2+P3)* 1/η*0.75 kw 170.34

6) Required motor power for instauration

Pm=Ps*1.2 kw 182.57

7)Actual motor kw 220