rotary sand dryer

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rotary sand dryer

A rotary sand dryer, also known as a sand drying machine or rotary drum dryer, is industrial equipment designed to reduce the moisture content of sand through efficient thermal processing. It is widely used in industries such as construction, foundry, and mining, where dry sand is essential for producing concrete, mortar, casting molds, and other applications.

The working principle of a rotary sand dryer is straightforward yet highly effective:

Feeding: Wet sand is fed into the rotating drum through a hopper or conveyor.
Drying: As the drum rotates, the sand is lifted by internal flights and cascaded through a stream of hot air generated by a burner or other heat source.
Heat Exchange: The hot air transfers heat to the sand particles, evaporating moisture.
Discharge: The dried sand is discharged at the other end, while the moisture-laden air is expelled through an exhaust system.

This continuous process ensures uniform drying and high throughput.

Model: SDH-200 (Sand Dryer, Horizontal, 200 kW)

The SDH-200 is a continuous, direct-heat, rotary drum dryer engineered specifically for high-efficiency drying of silica sand, foundry sand, frac sand, and other granular materials. It is designed for industrial operations requiring high throughput, consistent moisture removal, and precise control over the final product’s quality.

1. Operating Principle

The wet sand is fed into the elevated end of a slightly inclined, rotating drum. As the drum rotates, internal flights (lifters) pick up the sand and shower it as a curtain through the drum’s cross-section. A stream of hot gases, generated by a burner, flows concurrently (or counter-currently, depending on the application) through the drum, ensuring maximum heat transfer and rapid evaporation of moisture. The dried sand is discharged at the lower end, while the moisture-laden exhaust gases are treated by a dust collection system before being released.

2. Key Features & Design Advantages

High-Efficiency Burner System: Utilizes a modulated diesel/natural gas burner for precise temperature control (±5°C).
Lifting Flight Design: Custom-designed flights create an optimal “sand curtain” for superior gas-to-solids contact and heat transfer.
Tire and Trunnion Assembly: Robust support system with hardened steel trunnion wheels for smooth rotation and long service life.
Heat Insulation: The drum is insulated to minimize radiant heat loss, improving thermal efficiency and safety.
Intelligent Control System: A centralized PLC (Programmable Logic Controller) with an HMI (Human-Machine Interface) allows for automated operation and monitoring of all critical parameters.
Dust Collection Ready: Designed to integrate seamlessly with a cyclone separator and baghouse filter to meet environmental standards.

Detailed Technical Parameters & Specifications

A. General Specifications

Parameter	Specification
Model	SDH-200
Dryer Type	Single-pass, Direct Heat, Rotary Drum
Rotation Drive	Geared motor with variable frequency drive (VFD)
Drum Inclination	Adjustable, 1° to 3°
Air Flow Direction	Co-current (standard), Counter-current (optional)

B. Mechanical Dimensions & Construction

Component	Specification
Drum Diameter (Inner)	2.4 meters (7.87 ft)
Drum Length	12 meters (39.37 ft)
Drum Shell Thickness	16 mm (Mild Steel, A36 grade)
Drum Rotation Speed	3 – 8 rpm (adjustable via VFD)
Lifting Flights	Carbon steel, staggered arrangement for optimal cascading.

C. Thermal & Drying Performance

Parameter	Specification / Capacity
Heat Source	Natural Gas / Diesel / Heavy Oil (Burner is multi-fuel capable)
Burner Max. Power	200 kW (approx. 682,000 BTU/hr)
Inlet Gas Temperature	Up to 800°C (1472°F) (Typical operating range: 600-750°C)
Outlet Gas Temperature	100 – 120°C (212 – 248°F)
Evaporation Capacity	Up to 500 kg of water per hour (1102 lbs/hr)
Thermal Efficiency	75% – 85% (depending on initial moisture and insulation)

D. Material Handling & Throughput

Parameter	Specification / Capacity
Feed Material	Silica Sand, Foundry Sand, Frac Sand (Typical bulk density: ~1600 kg/m³)
Initial Moisture Content	Up to 8% (by weight)
Final Moisture Content	Adjustable down to 0.1% – 0.5% (by weight)
Nominal Feed Rate	15 – 20 Metric Tons per Hour (MTPH) of wet sand
Nominal Output Rate	13.5 – 19 MTPH of dried sand (depending on initial moisture)
Retention Time	20 – 40 minutes (adjustable via drum speed and inclination)

E. Power Requirements

Component	Power Rating
Main Drive Motor	18.5 kW (25 HP), 3-Phase, 380/480V
Induced Draft (ID) Fan Motor	15 kW (20 HP)
Burner Blower Fan	4 kW (5.5 HP)
Auxiliary Systems (Vibrating Feeder, Controls)	3 kW (4 HP)
Total Connected Load	Approx. 40.5 kW

F. Ancillary Equipment (Included/Recommended)

Equipment	Description
Feed Hopper	5 m³ capacity with vibratory feeder for consistent material flow.
Cyclone Separator	Primary dust collection to recover fine sand particles from exhaust.
Baghouse Filter	Secondary filtration to ensure emissions are below 20 mg/Nm³.
Discharge Conveyor	Enclosed belt conveyor to transport dried sand to storage.
Control Panel	PLC-based with HMI touchscreen for automated control and data logging. Monitors: temperatures, motor amps, drum speed, burner status.

G. Optional Features

Fluidized Bed Pre-Dryer: For extremely high moisture content (>10%).
Counter-Flow Configuration: For maximum thermal efficiency on low-temperature materials.
Advanced Emission Control: Wet scrubber for specific environmental regulations.
Remote Monitoring & Control: IoT module for real-time data access and diagnostics.
Customized Lining: Abrasion-resistant ceramic lining for extended drum life with highly abrasive sands.

Key Features of Our Rotary Sand Dryer

Robust Construction: Made from high-quality, wear-resistant materials for long service life.
Uniform Drying: Internal flights ensure even distribution and thorough drying.
Temperature Control: Advanced control systems maintain optimal drying temperatures.
Easy Maintenance: Designed for simple access to key components.
Flexible Configuration: Customizable drum size, speed, and heat source.

Advantages of Using Our Rotary Sand Dryer

High Efficiency: Rapid drying with minimal energy consumption.
Large Capacity: Suitable for small to large-scale operations.
Low Operating Costs: Optimized design reduces fuel and maintenance expenses.
Environmentally Friendly: Reduced emissions and dust control systems.
Versatility: Can handle various types of sand and other granular materials.

How We Design for Maximum Heat Source Savings

We prioritize energy efficiency in our rotary sand dryer designs through:

Insulation: High-grade insulation materials minimize heat loss.
Heat Recovery Systems: Recycled hot air from the exhaust is reused to preheat incoming sand.
Optimized Airflow: Carefully designed drum and fan systems ensure maximum heat transfer.
Adjustable Rotation Speed: Allows control of sand retention time for optimal drying.
Intelligent Control Systems: Automatically adjust temperature and airflow based on moisture levels.