Counter-Current vs Co-Current Airflow in Rotary Kilns

When looking for a rotary kiln for sale, there are several key considerations to make – but one of the most important is its airflow configuration.  That is, whether air flowing through the kiln is moving in the same direction as the heated material (co-current airflow) or whether it moves in the opposite direction (counter-current).  Kilns can only be designed to utilize one type of airflow, so it’s vital to understand their differences and which processes are best supported by each type.

Understanding Counter-Current vs Co-Current Kiln Airflow

I. Counter-Current Flow

When the airflow is moving in the opposite direction from the flow of material, the primary result is that it causes the material to be heated up relatively slowly and evenly. 

This can be highly advantageous in situations where you need the material to heat up in a highly controlled way, or if you need to prevent it from exceeding a certain temperature at any point.  As such, counter-current kilns are often used in situations where a chemical change is being induced.  Heat hardening is another process which benefits from this airflow.

Additionally, such kilns are also extremely heat-efficient.  However, they do require a higher initial temperature to heat the material as desired.

II. Co-Current Flow

In a co-current flow kiln, both the heated air and the material are introduced at the same end and move together across the kiln.  This means the coldest material will be put directly into contact with the hottest gases and creates an extremely rapid temperature change.  However, this change is also somewhat uncontrolled, compared to the control granted by a counter-current flow kiln.

Co-current flow is most commonly seen in kilns intended for organic combustion processes since those benefit from the rapid heating and -therefore- rapid combustion.  Likewise, there is no need for substantial fine control over the heating process.  So, such kilns can speed up any process where rapid heating is key.

However, many materials and processes do not benefit from such rapid, semi-controlled heating.  As such, co-current flow kilns are less commonly seen than counter-current models and have more specialized usage.

Need A Kiln for Sale?  Contact Kiln Technology Company

We are Texas’ leader in kiln sales, purchasing, servicing, and refurbishment, with more than twenty years’ experience creating excellent outcomes for our customers.  We stand by our work with industry-leading warranties, even on refurb jobs.  Contact us directly to learn more.