Petroleum coke rotary dryer Introduction

Petroleum coke rotary dryer belongs to the drum type or rotary drum dryer equipment, which is a very mature drying equipment produced by the mining equipment manufacturer Tongli. It is suitable for drying Petroleum coke, sludge, metal and non-metallic ore concentrates, and clay in the coal mining, metallurgy, magnetic separation, flotation, and cement industries. It has the characteristics of high productivity and easy operation. The shell is a horizontal rotating cylinder, which is welded with various types of lifting plates with different angles from front to back. According to different user needs, the inside of the Petroleum coke rotary dryer cylinder can be designed and equipped with heat-resistant materials for insulation. At the feeding end, there is a ring and a spiral lifting plate to prevent backflow. It has the advantages of reasonable structure, excellent production, high output, and low energy consumption.

Petroleum coke rotary dryer structure

Dryer Shell: The rotary dryer shell is the main body of the dryer, where the material is loaded and rotated. It has a cylindrical shape and is equipped with lifting plates or flights to lift and disperse the material. The drum is heated by hot air or gas that flows through it, either in parallel or countercurrent direction. The drum transfers heat to the material and evaporates the moisture.

Dryer Flights: Rotary dryer flights, also known as "flights" or "lifters," are the inclined, curved structures that are attached to the internal shell of a rotary dryer. A rotary dryer is a device used to remove moisture from materials like powders, granules, and bulk solids through the process of drying. It consists of a large cylindrical drum that rotates while the material is fed into one end and is discharged from the other end after being dried.

Dryer thrust roller：The thrust roller is a critical part of the rotary dryer system. It serves the purpose of supporting the dryer's weight and maintaining its axial position, ensuring that the dryer remains properly aligned along its axis. The thrust roller is typically positioned on the downhill side of the dryer and is attached to the dryer shell, it consists of a central shaft or journal and a roller assembly.

Dryer pinion: The pinion is an essential part of the rotary dryer drive system, responsible for transmitting rotational motion and torque from the driving mechanism to the rotary dryer itself. It consists of a gear wheel with teeth that mesh with the teeth of a larger gear, often referred to as the "girth gear" or "ring gear." The girth gear is attached to the outer shell of the rotary dryer. When the pinion is rotated by the drive system, it drives the girth gear, causing the rotary dryer to rotate.

Dryer bearing housing: The bearing housing serves as the support structure for the dryer's rotating motion and is responsible for holding and guiding the dryer's trunnion bearings. Trunnion bearings are large, heavy-duty bearings that support the weight of the dryer and allow it to rotate smoothly. These bearings are subject to high loads, extreme temperatures, and potentially harsh environments due to the nature of the processes occurring inside the rotary dryer. The bearing housing provides a stable mounting point for the trunnion bearings and ensures proper alignment of the dryer's rotation. It is typically designed to accommodate the axial and radial forces generated during the rotation of the dryer.

Dryer Hood Cover: The rotary dryer hood is located at the discharge end of the kiln and provides sealing to retain heat and gases. The rotary dryer operates under the negative pressure, therefore Tongli implied SS304 lining plate and ceramic felt both in the front and back end to prevent heat leakage.

Rotary dryer Transmission device: The transmission device of the rotary dryer is mainly composed of main transmission, auxiliary transmission, mechanical thrust roller/hydraulic thrust roller, motor, gearbox and other components. The unique design of tongli transmission can greatly improve the service life and safety performance of the equipment.

PLC control system: A PLC is a digital computer-based system that is designed to control various industrial processes automatically. In the context of a rotary dryer, a PLC is used to monitor and control parameters such as temperature, rotation speed, air flow, fuel flow, and other critical variables that affect the performance of the dryer and the quality of the products being processed. Usually, the rotary dryer control system is integrated in the whole factory’s plc system, therefore we will provide the on-site cabin and a signal cable to the central plc.

Design principles of petroleum coke rotary dryer

Drying Temperature and Time: The drying temperature and residence time of petroleum coke within the rotary dryer are critical parameters. The design must ensure that the temperature is high enough to drive off moisture but not so high that it leads to the degradation of the coke quality.

Material Handling and Feeding: Proper mechanisms for feeding the petroleum coke into the dryer should be in place to ensure an even and controlled distribution within the dryer. This prevents uneven drying and reduces the risk of blockages.

Airflow and Gas Flow Management: The design should account for the movement and circulation of hot gases within the dryer. Proper airflow management ensures uniform drying and prevents overheating in specific areas.

Control Systems: Advanced control systems are  integrated to monitor and control various parameters such as temperature, airflow, and moisture content. These systems help maintain optimal drying conditions and prevent issues like overheating or incomplete drying.

Material Handling After Drying: The design should also consider how to efficiently and safely remove the dried petroleum coke from the dryer. This might involve systems like discharge chutes, conveyors, or other handling equipment.

Safety Measures: Safety is paramount in any industrial process. The design should incorporate safety features to prevent accidents, such as fire and explosion prevention mechanisms.

Specifications of petroleum coke rotary dryer

Note: *The initial moisture is assumed to be 2~6% and final moisture is 1~4%; Inlet temperature of hot air is 150~250 Celsius and outlet temperature is 70~90 Celsius; Production Capacity will vary according to the composition and moisture of the material.

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Industry Knowledge extension

What is the application of dried petroleum coke? 

The primary application of a Petroleum Coke Rotary Dryer is to efficiently and effectively reduce the moisture content of petroleum coke to a level suitable for its intended use. Here are some specific applications and benefits of using a rotary dryer for petroleum coke:

Fuel Production: Petroleum coke can be used as a fuel source in various industries, including cement and power generation. However, its high moisture content can hinder its combustion efficiency. By using a rotary dryer, the moisture content of petroleum coke can be significantly reduced, making it a more efficient and viable fuel source.

Anode Production: Petroleum coke is a key component in the production of anodes for aluminum smelting. Anodes are used in electrolytic cells to produce aluminum. Low moisture content in petroleum coke is crucial for the quality and performance of anodes, as high moisture can lead to defects and reduced conductivity during the electrolytic process.

Industrial Processes: Petroleum coke is also used as a feedstock in various industrial processes, including the production of carbon electrodes, graphite products, and certain chemicals. In these applications, lower moisture content improves the efficiency and quality of the final products.

Environmental Benefits: Drying petroleum coke before its use as a fuel can have environmental benefits by reducing emissions and improving combustion efficiency. Lower moisture content leads to reduced emissions of sulfur dioxide (SO2) and other pollutants during combustion.

Storage and Transportation: Lowering the moisture content of petroleum coke makes it easier to handle, store, and transport. Reduced moisture minimizes the risk of material degradation, caking, and blockages during storage and transportation.

What is the difference between rotary dryer and rotary kiln?

Rotary dryer: A rotary dryer is used to remove moisture from materials, such as minerals, ores, chemicals, food products, and biomass. The primary purpose of a rotary dryer is to reduce the moisture content of the material through the application of heat and the movement of the material within the drum. In a rotary dryer, materials are fed into the rotating drum, and hot gases or air are introduced to evaporate the moisture. The material is tumbled and agitated as it moves through the drum, allowing for efficient drying. Rotary dryers operate at elevated temperatures to facilitate drying, the temperatures used are generally lower compared to those in rotary kilns. Rotary dryers are used in industries such as agriculture, mining, chemicals, and food processing to remove moisture from bulk solids, powders, and other materials.

Rotary Kiln: A rotary kiln is designed for high-temperature processes, such as calcination, sintering, pyrolysis, and other thermal treatments. It's used to process raw materials or products at elevated temperatures, often in a controlled atmosphere, to bring about physical or chemical changes in the material. In a rotary kiln, materials are typically fed into one end of the kiln and gradually move towards the other end. The kiln is heated to very high temperatures, and the material undergoes chemical reactions, phase changes, or thermal treatments as it progresses through the kiln. Rotary kilns operate at much higher temperatures, often reaching well over 1000 degrees Celsius (1800 degrees Fahrenheit), depending on the specific process. These high temperatures are necessary to achieve the desired chemical or physical transformations in the material. Rotary kilns are used in industries such as cement production, lime calcination, metallurgy, and waste incineration. They are designed for processes that require high-temperature reactions, phase changes, or material transformation.