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Drying Drum Lifting Flight
Zone-matched internal steel lifting flights that cascade aggregate through the burner gas stream for efficient drying and heat transfer.
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At a glance
| Material | S355 structural carbon steel, 8 – 16 mm |
|---|---|
| Hard-facing (inlet zone) | 55 – 62 HRC weld overlay, open-arc applied |
| Flight height (radial) | 300 – 800 mm (drum-diameter dependent) |
| Attachment method | M16 bolted or stitch-welded per drum design |
| Drum diameter range covered | 1.2 m – 2.4 m (4 ft – 8 ft) |
| Zone profiles supplied | Inlet / mid-curtain / outlet (3-zone matched sets) |
| Operating temperature (shell) | Up to 600 °C shell surface |
| Flights per drum (typical) | 24 – 60 per full drum (capacity-dependent) |
Overview
Drying drum lifting flights — also termed lifters or flights — are longitudinal steel vanes attached to the interior shell of the rotary drying drum. As the drum rotates at 5–15 RPM, the flights lift aggregate from the tumbling bed and release it as a falling curtain across the full drum cross-section, directly through the hot gas stream from the burner. This curtaining action is the primary mechanism of heat and mass transfer in the drum; the flights are designed in three axial zones — heavy-duty inlet flights handling wet, large-stone aggregate; mid-drum curtain flights providing maximum curtain density; and outlet flights handling dried, heated aggregate near the discharge end.
Flight geometry, height, pitch, and profile are specific to each drum diameter and plant capacity. A typical 2.0 m diameter drum for a 160 TPH plant carries 32–48 flights arranged in two or three longitudinal rows per zone, each flight 400–600 mm in radial height.
Function
The flight geometry controls aggregate curtain density, material dwell time inside the drum, and the proportion of the drum cross-section covered by falling aggregate. A worn or broken flight reduces curtain coverage, creating hot-gas bypass channels that lower thermal efficiency, raise specific fuel consumption, and may leave aggregate under-heated — causing temperature rejection at the hot bins. Conversely, clogged, bent, or reversed flights cause aggregate bed rolling rather than cascading, sharply reducing heat exchange and plant throughput. Maintaining flight geometry is one of the most direct interventions for improving fuel economy and drying capacity.
Construction & quality
Flights are fabricated from 8–16 mm structural carbon steel plate (S355 or equivalent), cut and formed to the zone profile specified for each drum diameter. Inlet-zone flights in contact with wet, angular stone are hard-faced on the leading face with abrasion-resistant weld overlay (55–62 HRC) applied by open-arc or flux-cored wire process. Bolted flights use M16 countersunk bolts into pre-drilled and tapped shell pads. Welded flights are stitch-welded to the drum shell with full-penetration root passes and cap runs to EN ISO 5817 Class B. Flight profiles per zone: straight radial (inlet), angle-shaped L or V (mid-curtain), cellular-pattern or scroll (outlet).
When to replace
- Flight tip or face worn to below 4 mm remaining thickness, reducing curtain projection and material throw
- Fracture or detachment at the shell weld or bolt — visible as missing flight sections on drum inspection
- Severe heat distortion bending flights out of the drum plane, reducing lift angle and curtain effectiveness
- Measurable increase in specific fuel consumption (litres per tonne) without change in feed rate or aggregate moisture
- Aggregate exiting drum consistently below target temperature despite normal burner firing rate and excess-air setting
Compatibility & fitment
Avelta supplies flight sets profiled to the AVL-ABP drum diameters from 1.2 m to 2.4 m across 40 TPH to 320 TPH models, with zone-matched profiles, shell-bolt patterns, and hard-face specifications matched to the customer's drum serial number and plant capacity.
Why buy from Avelta
Avelta drum flights are profile-cut and hard-faced to the original design geometry, restoring thermal efficiency to commissioning specification. Full three-zone flight sets are dispatched together, enabling a complete re-flight during a single planned maintenance shutdown without multiple part orders.
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