The frac sand industry relies on sand dryers to reduce the moisture content of washed sand for use in the hydraulic fracturing process.
Historically, both fluid bed and rotary dryers have been widely accepted throughout the industry, but that looks to be changing; listed here are some of the many reasons why rotary dryers are becoming the industry standard for drying frac sand.
Benefits of Rotary Dryers Over Fluid Beds
In many industries, the choice of drying equipment for processing bulk solids often comes down to rotary dryers and fluid bed dryers. Both dryers offer an efficient, effective option for processing bulk solids, each with unique advantages and disadvantages.
When it comes to frac sand, however, rotary dryers are quickly becoming the equipment of choice at frac sand drying plants around the country for the following reasons:
Tolerance to Variation in Feedstock & Processing Conditions
Perhaps the most common reason for choosing rotary over fluid bed is the rotary dryer’s continuity and reliability in unpredictable settings. Rotary dryers are highly adept at producing uniform results despite slight variation in feedstock.
Since frac sand often varies in particle size distribution and moisture content, rotary dryers are especially well suited to processing this material.
In addition to tolerating variance in the material, rotary dryers are also known to be reliable despite fluctuations in throughput, air flow, lapses in energy, and other factors that could be problematic for a fluid bed dryer.
Higher Capacity/Throughput
Another reason why rotary dryers are frequently chosen over fluid bed dryers for drying frac sand is their high-capacity capabilities. Rotary dryers allow for increased capacities over fluid beds – in excess of 300 TPH in a single unit.
Reduced Electrical Energy Consumption
Rotary dryers can also offer energy savings over fluid bed dryers, which can be especially critical when margins are tight.
This is because fluid bed dryers require a high volume of air in order to fluidize the frac sand – a volume that does not change when throughput is decreased. The fluid bed’s required air system is also much more costly, because it must be capable of handling this high volume of air.
Conversely, rotary dryers require a comparably lower air volume, which is reduced when processing lower capacities, so costs are further decreased.
Furthermore, fluid bed dryers generally run at cooler temperatures, further increasing energy consumption.
Robust Construction
Rotary dryers are the dryer of choice for processing difficult materials. They are frequently used for drying minerals, ores, and fertilizers, among other demanding industrial bulk solids. This is due to their heavy-duty build and construction; rotary dryers are incredibly robust machines and can be optimized for especially rugged applications, making them an ideal drying solution for frac sand.
Conclusion
While both rotary and fluid bed dryer types were once widely employed throughout the frac sand industry, the many advantages explained here have resulted in rotary dryers becoming the industry’s preferred approach.
Rotary dryers offer a more reliable, robust system for drying frac sand, requiring less energy and offering reduced downtime. As an expert in custom thermal processing solutions, FEECO has become a leading provider of both rotary dryers and fluid bed dryers for the frac sand industry. Our unique rotary dryer designs offer a number of advantages, including improved product integrity, a more complete utilization of fuel, and reduced carryover. For more information, contact us today!