The influence of operational variables on the mean residence time (MRT) and hold-up of the solids in rotary kilns has been investigated by many researchers. However, their reports on the influence of the feed rate on MRT, for example, are not consistent with one another. In this study, experiments are conducted on a 400 mm, ID pilot kiln with a cylindrical discharge dam. Sand is used as the testing solids. MRT and the hold-up are measured under various feed rates and rotation speeds. Experimental results indicate that MRT increases slightly with the feed rate, and that the gradient is smaller at high rotation speeds. The hold-up shows a near-linear increase with the mass of feed per kiln rotation. The experimental data are then used to test equations provided by different researchers for the prediction of MRT. Comparisons show that, results of the empirical equation from Sullivan, J.D., Maier, C.G., Ralson, O.C. [1927. Passage of solid particles through rotary cylindrical kilns. U.S. Bureau of Mines Technical Paper No. 384.] agree well with measurements for the cases of low kiln loadings, while the numerical model of Saeman, W.C. [1951. Passage of solids through rotary kilns: factors affecting time of passage. Chemical Engineering Progress 47, 508-514.] gives good predictions over the entire range of parameters considered. (c) 2006 Elsevier Ltd. All rights reserved.