Project Synopsis

Assist an engineering company client in the development of process models for a new style rotary cooler designed to also impart a surface additive to the crushed solids being processed.

Project Summary

A US-based engineering company was designing balance of plant equipment and utilities for a new rotary cooler being developed by the ultimate client, a specialty materials manufacturing company.  The cooler configuration is a first of a kind for the ultimate client. They were having the new cooler designed based on existing units but were unsure of how to characterize a few design parameters.  Process Engineering Associates, LLC (PROCESS) was hired to develop a process simulation model to assist in their rotary cooler design effort.

The ultimate client was expected to use the rotary cooler to dry crushed solids as well as to apply an additive to the solids that strengthens the particles and imparts other commercially attractive benefits.  The primary purpose of the simulation model developed by PROCESS was to evaluate how various air flow conditions impacted the expected temperature profile inside the cooler such that a specialty additive can be safely injected onto the material during the rotary cooling cycle.  The additive has some temperature sensitivity, and must be added in a narrow temperature window.

The tasks and deliverables for this job included a design basis and model development.  A design basis was written and the summarized items were agreed to with the ultimate client. A model was developed in an Excel spreadsheet.  Model results were discussed with the client and certain parameters were modified until there was collective agreement on the model output.  Once the model was refined by the group, it was applied to the new ultimate client configuration.

Rotary cooler modeling output took the form of tabulated results of the eight (8) cases examined.  Output data included calculation results on air flow rates, temperature profiles, humidity, and material inlet/exit conditions (temperature, pressure, and moisture content).  The results were discussed with the ultimate client and a second round of work was authorized.  The added work yielded a tabulation of modified model results that was utilized by the ultimate client.

Industry Type

Construction Aggregates Manufacturing


Utilized Skills

  • Specialty equipment modeling.

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