A novel form of rotary kiln has been developed which confers advantages over conventional designs. Details are given of the main features of the kiln, along with an approach used to study its heat transfer characteristics when hot processing waste products into a lightweight synthetic aggregate for recycling in building materials. Computer aided finite element modelling was used to predict temperature profiles and heat fluxes involving non-linear properties of the exterior insulation materials and internal radiation effects. Observations are given comparing predicted temperatures for two different cross sectional shapes and with those measured in practice on a prototype novel kiln. Observations are also given on the methods of approach to the modelling
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