Abstract: A mathematical model was developed for a 60 t·h^-1 alumina clinker rotary kiln on the comprehensive consideration of the effects of heat transfer and mass transport processes.The model was utilized to study the impact of the moisture content of feeding slurry on the thermal process in the rotary kiln, and to analyze the clinker sintering method by the substitution of dry clinker sintering for wet-sintering so as to increase production and reduce consumption.The results show that when the moisture content of feeding slurry reduces to 20%, the production capacity of the rotary kiln improves by 24% compared with the actual working conditions, correspondingly the coal-fired unit consumption declines up to 18%;with the water content of feeding slurry further decreasing, the variation tendency of production capacity and coal-fired unit consumption slows down.