A multiscale dynamic mass and energy process model was developed for an industrial rotary dryer with both unflighted and flighted sections. This paper focuses on the development and integration of energy balances into a validated solid transport model published by the authors in an earlier paper. In order to facilitate the drying process, a gas phase model is introduced. The gas phase in both the unflighted and flighted sections was modeled as a plug flow system. Simulations and parameter estimation were undertaken using gPROMS (process modeling software). Parameter estimation and model validation were carried out using the experimental moisture content profile, residence time distribution data, and gas and solid internal temperature profiles. The developed model was utilized to gain better understanding of the interactions between solids transport, operational parameters, and internal solids distribution on heat and mass transfer that occur in flighted rotary dryers. The model provides a means to quantify and solve dryer operational challenges in a real industry example.