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Volume 103
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Jie, H., Herz, F., & Liu, X. (2025). Analysis of the residence time distribution in rotary kilns and the effect of particle sizes. Particuology, 103, 193-205. https://doi.org/10.1016/j.partic.2025.05.016
Analysis of the residence time distribution in rotary kilns and the effect of particle sizes (Open Access)
Haozhi Jie a *, Fabian Herz a, Xiaoyan Liu b
a Anhalt University of Applied Sciences, Department of Applied Biosciences and Process Engineering, Bernburger Straße 55, 06366 Köthen, Germany
b College of Electrical and Information Engineering, Hunan University, Changsha 410082, China
10.1016/j.partic.2025.05.016
Volume 103, August 2025, Pages 193-205
Received 18 February 2025, Revised 3 April 2025, Accepted 12 May 2025, Available online 29 May 2025, Version of Record 7 June 2025.
E-mail: haozhi.jie@hs-anhalt.de; haozhi.jie1990@gmail.com
Highlights

• Developed a model for predicting residence time and velocity of bidisperse particles in rotary kilns.

• Validated the model using pilot-scale tests with various size ratios and mass concentrations.

• Measured RTD, MRT, Dz, and Pe via tracer tracking and statistical methods.

• Achieved high model accuracy by comparing predictions with experimental data.

• Evaluated size and mixing effects by changing size ratios and mass concentrations.


Abstract

In this study, a mathematical model based on the segregation-induced ring-core structure was developed to predict the residence time and axial velocity of particles of different sizes within a rotary kiln. Validation experiments were conducted using a pilot-scale rotary kiln with bidisperse particle systems comprising particle sizes of 0.7 mm, 2 mm, and 4 mm. The entire process was recorded using video analysis, which enabled the tracking of tracer particle movement from the inlet to the outlet. Based on the recorded data, the average axial velocity for each particle size across different kiln regions was determined. At the outlet, the tracer particles were analyzed using statistical methods and diffusion theory, allowing for the calculation of the residence time distribution (RTD), mean residence time (MRT), variance, axial dispersion coefficient (Dz), and Peclet number (Pe). The experimentally obtained MRT exhibited strong agreement with the predictions of the mathematical ring-core structure model, confirming its accuracy and reliability. Additionally, the influence of particle size and mixing behavior was systematically evaluated by varying particle size ratios and mass concentrations.

Graphical abstract
Keywords
Rotary kiln; Residence time distribution; Size ratio; Bidisperse particle
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