Statistical Analysis of 3D-DEM for Steady State Conduction Heat Transfer in a Rotary Drum

The current research is based on the principles of three-dimensional discrete element method (3D – DEM) through simulations, by using heat transfer models in EDEM, to investigate the effects of fill level, rotation rate and particle size on the steady-state conduction heat transfer in rotary drums. The high heat and mass transfer rates obtained through rotary drums make them very useful for powder mixing and heating processes in metallurgical, cement, mining, pharmaceutical, detergent and other particulate processing applications. However, these complex processes are difficult to model and operate since the particles can have a wide range of properties, and there is currently no way to predict the optimal operating conditions for a given material.

Steady-state heat transfer by conduction forms the basis for understanding other steady-state and unsteady-state heat transfer in a rotary drum – conduction, convection and radiation. Statistical analysis is carried out to determine the effects of these process parameters and find optimal operating conditions, which will thereby improve the heat transfer efficiency in rotary drums. A stainless-steel drum with a diameter of 6 inches and a length of 3 inches was modeled in EDEM with silica beads of sizes 2 mm, 3 mm and 4 mm at fill levels of 10%, 17.5% and 25%, and at rotation rates of 2 rpm, 5 rpm and 10 rpm. It was found that the heating uniformity increased with decreasing particle size, decreasing fill level and increasing rotation rate. This research is the first step towards studying the other heat transfer modes and various other process parameters. Better understanding of the various heat transfer modes, when used in combination for heating the particles, will be beneficial in improving the operating efficiency, reducing material costs and leading to significant energy conservation on a global scale.