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Thermal and Mixing Behavior of a Rotary Tube Furnace Under Low-Flow Inert Atmosphere

Rotary tube furnace with gas inlet are commonly used for powder calcination, annealing, and continuous material processing. These furnaces combine in-tube circulation with a controlled atmosphere to improve uniformity. However, when operating at low inert gas flows (<100 sccm), traditional assumptions about convective heat transfer and gas-solid interactions may not apply.

Challenges of Low Gas Flow

Reduced convective heat transfer may result in temperature gradients along the tube.

Despite rotation, powders may agglomerate or form particles in the channels, resulting in non-uniform processing.

Gas residence time is increased, which may affect the redox balance in certain areas.

Experimental Observations

Through controlled experiments using alumina powder and thermocouple arrays, the following observations were made:

Under low flow conditions, rotation alone does not fully equalize axial temperature gradients.

Slightly tilting the tube and gradually rotating it improves thermal mixing and residence time uniformity.

Preheating the gas before entry enhances lateral distribution without increasing flow.

Optimization Strategies

Spiral baffles within the tube enhance radial mixing even under laminar flow conditions.

Intermittent rotation (e.g., 10 s on/5 s off) improves powder bed circulation and balances heat transfer.

Integration of dual thermocouples (center and wall) provides real-time feedback for temperature correction.

Conclusions

Understanding the interaction between circulation dynamics, reduced gas flow, and thermal consistency is critical for researchers seeking to improve furnace operation and reduce gas usage. Future furnace designs may benefit from incorporating reduced flow compensation features as standard.

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