Co-Current vs. Counter Current Drying

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processing/rotary-dryers/) ▶ Co-Current Vs. Counter Current Drying
This article was authored by:
Shane Le Capitaine (/author/shane/)
Thermal Processing Expert
Many factors are

(https://feeco.com/wp-
content/uploads/2019/07/Co-Current-vs- taken into
Counter-Current-Rotary-Drum-Dryers.jpg) consideration when
designing a rotary
drum dryer
(https://feeco.com/rotary-dryers/) that can both efficiently and

effectively dry a material. Factors such as the material’s bulk
density, heat sensitivity, particle size, and flowability, among others,
all interact to influence how the material will behave in the dryer,
and subsequently, how the dryer should be designed to optimally
work with those characteristics. One critical factor in designing a
rotary dryer that produces the desired end product characteristics
is the air flow configuration, or the direction in which the process
gas flows through the dryer in relation to the material.
Rotary dryers are available in two types of air-flow configurations:

co-current and counter current. Both options have been
developed through extensive research and development in order
to maximize the thermal efficiency of the rotary drying process. The
selection of which configuration will best suit the process is based
on the material’s properties, as well as overall process requirements,
making it important to understand how each air-flow configuration
works in order to
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fully grasp which type will best suit the drying
process at hand.
Below is an overview on the advantages and disadvantages of

these two types of rotary drum dryer designs.
THE CO-CURRENT ROTARY DRYER

Best for: Materials that are heat-sensitive, maintaining product
quality (NOTE: 90% of all rotary dryers are co-current for these
reasons)
Key Advantages: Greater control over solids temperature and

avoidance of overheating
Disadvantages: Slightly less thermally efficient than counter-current

air flow
Co-current or parallel flow drying occurs when the drying air flows in
the same direction as the material, or rather, when the material and
process gas enter the dryer at the same end of the drum, as shown
in the illustration below.
(https://feeco.com/wp-content/uploads/2015/05/Co-Curernt-Dryer.jpg)
ADVANTAGES OF THE CO-

CURRENT ROTARY DRYER
As mentioned, the majority of rotary drum dryers utilize the co-
current air flow design. This configuration is chosen for several
reasons:
RAPID REMOVAL OF FREE MOISTURE

By introducing the solids and process gas in the same location, the
process gas contacts the material in its wettest state, resulting in a

(https://feeco.com)
quick initial reduction of surface moisture. Because of this fast initial
drying, co-current dryers work best with materials that have high
surface/free moisture such as glass. The lower surface moisture at
the inlet of the drum also promotes improved flowability of the
material through the drum, as the solids are less likely to stick as they
tumble and cascade.
IDEAL FOR HEAT-SENSITIVE MATERIALS

The co-current dryer is ideal for drying heat-sensitive materials.
When a material is heat-sensitive, overheating can result in
unwanted reactions, undesirable color changes in product,
product degradation, or even a risk of fire. By utilizing a co-current
configuration with heat-sensitive materials, it is much easier to
prevent overheating, because the hottest gases are in contact with
the wettest material and the temperature of the solids instead
decreases as it moves through the dryer, preventing the potential
for overheating.
CONTROL OVER SOLIDS TEMPERATURE

Because the solids temperature correlates directly with the process
gas temperature, the co-current design makes controlling the
temperature of the dried material much easier. This is ideal for heat-
sensitive materials that must be kept below a certain temperature
threshold during the drying process.
IMPROVED DRYER LONGEVITY

The introduction of the material and process gas at the same
location of the dryer causes a rapid initial cooling of the process
gas, causing the dryer shell to run at a cooler surface temperature.
This lower temperature reduces stress on the drum shell, promoting
a longer life.
DISADVANTAGES OF THE CO-

HIGHER EXHAUST GAS TEMPERATURES
The primary disadvantage of the co-current design is that it is slightly
less thermally efficient, because the exhaust gas can never be

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cooler than the temperature of the solids, requiring more energy to
be spent on keeping the exhaust temperature up. The need to
ensure that the exhaust gas exceeds the temperature of the solids
therefore results in wasted energy and slightly greater fuel
consumption.
THE COUNTER CURRENT ROTARY

DRYER
Best for: Materials with bound moisture, or that require heating to a
higher temperature
Key Advantage: More efficient
Disadvantages: Less control over solids temperature, greater

potential for overheating
Counter-current drying occurs when the gas and material flow in

opposing directions (i.e., the material is fed into one end of the
drum, while the process gas is fed into the other end of the drum, as
shown in the illustration below).
(https://feeco.com/wp-content/uploads/2015/05/Counter-Current-Dryer.jpg)
ADVANTAGES OF THE COUNTER-

The counter-current air flow design offers several advantages:
GRADUAL REMOVAL OF MOISTURE

Because the material comes in contact with the hottest process gas
at its most dehydrated state, the counter-current configuration is

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ideal for materials with bound moisture. Bound moisture is typically
not affected by the initial “flash-off” of free moisture, instead
requiring more gradual heating to draw out moisture from within the
material.
HIGH HEAT CAPABILITIES

Similarly, materials that require high temperatures to release their
moisture are also best served in a counter-current rotary dryer, since
the solids are coming into contact with the hottest gases toward
the end of the drying process.
GREATER THERMAL EFFICIENCY (LOWER

EXHAUST GAS TEMPERATURES)
Counter-current dryers are often chosen for their efficiency,
because more heat is spent on drying the solids than ensuring the
exhaust gas temperature remains high. In other words, because
counter-current dryers can tolerate gas temperatures lower than
the solids, less fuel is required and excess energy is not wasted in the
exhaust gas.
It’s important to note that the exhaust gas temperature must always
be above the dew point. The potential for the exhaust gas
temperature to reach the dew point is greater with a counter-
current configuration and must be carefully managed; if the
temperature were allowed to reach the dew point, condensation
could occur in the ductwork and baghouse, clogging up the
system. This is especially likely if the ductwork is not insulated.
DISADVANTAGES OF THE
COUNTER-CURRENT ROTARY
DRYER
LESS CONTROL OVER SOLIDS TEMPERATURE
While a direct relationship exists between the material and process
gas in the co-current design, the opposing flow of the solids and
gas employed in the counter-current configuration makes it more
difficult to control the temperature of the solids.
RISK OF OVERHEATING

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Because the solids come into contact with the hottest gas in their
driest state, the counter-current air flow also makes it easier to
overheat the material.
If the inlet gas temperatures need to be lower to avoid overheating

the material, additional fuel will be required, because more air
which needs to be heated will be required, which can cut into the
initial energy savings.
OTHER CONSIDERATIONS WITH AIR

FLOW
While not directly related to the chosen configuration, there are a
few other air flow considerations that should be kept in mind during
the design process:
WHETHER OR NOT TO USE A COMBUSTION

CHAMBER
Combustion chambers (https://feeco.com/combustion-chambers/)
are often employed with direct rotary dryers in order to prevent
contact between the burner flame and the material being
processed. This is advantageous when working with heat-sensitive
materials, or materials that might form undesirable compounds if
exposed to the additional radiation of a flame. For more
information on employing a combustion chamber, see: Rotary
Dryers: When is a Combustion Chamber Necessary?
(https://feeco.com/rotary-dryers-when-is-a-combustion-chamber-
necessary/).
EXHAUST GAS RECYCLING

When using a combustion chamber, the secondary air can
sometimes be provided via recycled exhaust gas from the dryer.
Since this air is already preheated, a savings in fuel can be
achieved if designed properly.
CONCLUSION
Understanding how each dryer configuration works is an important
factor in designing
(https://feeco.com)
the most efficient rotary dryer for the job, with
each configuration offering unique advantages and
disadvantages. FEECO encourages that each material go through
a research and development process at our on-site concept testing
facility (https://feeco.com/lab/), The FEECO Innovation Center. The
information gained through our proven testing procedures allows us
to design the most efficient and beneficial drying system for our
customer’s material requirements. For more information on co-
current or counter-current drying, contact us today!

About the Author . . .
Shane Le Capitaine is a Process Sales Engineer

and thermal processing and fertilizer
production expert.
MORE ABOUT SHANE
(HTTPS://FEECO.COM/SHANE/#CONTACT_ME)
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Home (https://feeco.com) ▶ Rotary Dryers (https://feeco.com/category/thermal-

processing/rotary-dryers/) ▶ Co-Current Vs. Counter Current Drying

This article was authored by:

Shane Le Capitaine (/author/shane/)

Thermal Processing Expert

Many factors are

(https://feeco.com/rotary-dryers/) that can both efficiently and

Rotary dryers are available in two types of air-flow configurations:

Below is an overview on the advantages and disadvantages of

THE CO-CURRENT ROTARY DRYER

Key Advantages: Greater control over solids temperature and

Disadvantages: Slightly less thermally efficient than counter-current

ADVANTAGES OF THE CO-

RAPID REMOVAL OF FREE MOISTURE

IDEAL FOR HEAT-SENSITIVE MATERIALS

CONTROL OVER SOLIDS TEMPERATURE

IMPROVED DRYER LONGEVITY

DISADVANTAGES OF THE CO-

THE COUNTER CURRENT ROTARY

Key Advantage: More efficient

Disadvantages: Less control over solids temperature, greater

Counter-current drying occurs when the gas and material flow in

ADVANTAGES OF THE COUNTER-

GRADUAL REMOVAL OF MOISTURE

HIGH HEAT CAPABILITIES

GREATER THERMAL EFFICIENCY (LOWER

If the inlet gas temperatures need to be lower to avoid overheating

OTHER CONSIDERATIONS WITH AIR

WHETHER OR NOT TO USE A COMBUSTION

EXHAUST GAS RECYCLING

About the Author . . .

Shane Le Capitaine is a Process Sales Engineer

MORE ABOUT SHANE

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