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Volume 112
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Experimental and DEM analysis of transverse particle motion in a rotary drum with segment internals (Open Access)
Jannes Hahne a *, Claudia Meitzner a, Linus Matz Zeller a, Haozhi Jie a, Andreas Bück b, Fabian Herz a
a Applied Biosciences and Process Engineering, Anhalt University of Applied Sciences, Bernburger Str. 55, Köthen, 06366, Germany
b Thermal Process Engineering, Otto von Guericke University Magdeburg, Universitätsplatz 2, 39106, Magdeburg, Germany
10.1016/j.partic.2026.02.023
Volume 112, May 2026, Pages 24-35
Received 28 November 2025, Revised 2 February 2026, Accepted 24 February 2026, Available online 7 March 2026, Version of Record 14 March 2026.
E-mail: jannes.hahne@hs-anhalt.de
Highlights

• Segment internals reduce average bed surface velocities by over 60 % compared to conventional rotary drums.

• Maximum particle velocities are reduced by approximately 50 %, indicating potential for gentler processing.

• Distinct active/passive particle layers typically observed in conventional rotary drums are eliminated.

• Compared to conventional rotary kilns, segment internals create additional particle–wall heat transfer surfaces.

• Higher filling degrees and rotational speeds increase the average rate of contact surface length.


Abstract

Rotary kilns are essential for thermal and mechanical treatment of various bulk materials in different industries. They enable high throughput rates, continuous mixing and controlled process conditions. Heat transfer is enhanced through installation of internals often leading to particle abrasion and dust formation. To address this issue, a new internals design featuring a cross section has been developed, dividing it into several smaller, separate segments. This design increases the particle-wall and free bed interfaces which improves the heat transfer while reducing the mechanical stress on the particles. Experiments were conducted in rotary drums with diameters of 300 mm and 500 mm to analyze the particle motion. Glass and polypropylene beads with particle diameters ranging from 2 mm to 4 mm were used as test materials. A parameter study was performed for various filling degrees (5 % – 30 %) and rotational speeds (0.5–8 rpm). Additionally, the motion behavior was simulated using the discrete element method (DEM) and validated against experimental data. This approach enabled a numerical description of particle interactions, particle velocities and heat transfer-relevant surface areas. These results show the potential of employing segment internals in rotary kilns for the gentle and efficient thermal treatment of bulk materials.

Graphical abstract
Keywords
Rotary kilns; Segment internals; Particle motion; Gentle processing
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