This paper presents a dynamic simulation system (DSS) and a simulation study of a pilot scale rotary kiln for activated carbon manufacture. DSS has been developed by using the Simulink-Matlab framework, based on a dynamic mathematical model. The model consists of a set of nonlinear partial differential equations, and represents the mass and energy balances in the kiln. The space dimension is approximated by a backward finite difference scheme and the set of ordinary differential equation obtained is solved with a stiff solver. The changes in temperature and mass flow rate with time and space are obtained for solid, gas and wall. Several disturbances in the operating variables are tested with the DSS, and the dynamic response is analyzed. Furthermore, the performance in the start up and shut down operation mode are analyzed. The good performance exhibited by the DSS makes it suitable for controller's design and synthesis purposes. (c) 2005 Elsevier Ltd. All rights reserved.