Estimating the Lifetime of Rotary Dryer Flights Based on Experimental Data

The studies carried out address an important problem for the concrete and asphalt industry, referring to the wear phenomena that affect the elements (flights) of rotary dryers used to dry mineral aggregates. In this article, the authors propose a lifetime estimation method for rotary dryer flights. In order to benefit from greater credibility, the proposed method was applied based on the experimental results obtained, by the authors, in the laboratory, on a stand that reproduces a portion of the real equipment. Starting from these results, the authors identified the mathematical functions used to model the failure rates (wear) of the flights by referring to characteristic quantities for wear evaluation: mass loss of material; reduction in the thickness of the part; surface affected by wear. The experimental data—the input data for the proposed algorithm—correspond to six steels used in industrial applications. The wear phenomenon was modeled considering both the situation of uniform wear and the situation of differentiated wear on the flight surface. Therefore, the steel type with the highest service life values could be identified, namely, steel grades E and G. The method proposed in this paper can be extended to any category of material or part provided that the failure rate function is identified beforehand, possibly based on a laboratory experiment.