Axial dispersion in the three-dimensional mixing of particles in a rotating drum reactor

Horizontal drum reactors are widely used in industry for the processing of granular material. They are ideally suited for chemical processes that require high temperatures at near-atmospheric pressure. However, the complexities of these reactors have resulted in empirical design procedures that lead to very conservative and costly reactors. This study first reviews critically the extensive literature on experimental results obtained on rotary kilns (without flights) and proposes new design equations for the axial-dispersion coefficient in terms of rotational speed, degree of fill, drum diameter, and particle diameter. A total of 179 data points from the literature, encompassing both the batch and the continuous operational modes, yielded design correlations for slumping, rolling/cascading and cataracting bed behaviours. Additionally, new measurements were made on a pilot-scale rotary drum by tracking a single radioactive particle (emitting gamma-rays) using a battery of nine scintillation counters; these data confirmed the correctness of the proposed design correlations. (C) 2002 Elsevier Science Ltd. All rights reserved.