In order to evaluate process efficiency of a rotary sintering furnace when sintering bauxite charge, specifics of its thermal performance variation were analyzed using thermal engineering studies. It was found that the main material flows in the rotary sintering furnace are pulp consumption (47.65%), as well as gaseous flows of air (48.90%) and flue products (51.17%) with process gases (18.01%) and entrainment of physical moisture in the form of steam (12.34%). The efficiency of solid charge components participation in the process is characterized by a sinter yield (21.46%), dust blowout from the working space (1.71%), and a flow of recirculated dust particles (0.96%), which is due to limited heat transfer intensity in the furnace working space. A comparative analysis of gas flow parameters at the outlet of the furnace points to a low efficiency of utilizing the existing dust-collecting equipment, such as a dust collection chamber (≤43.66%) and electrostatic precipitators (89.77 – 90.00%). To improve their performance, it is proposed to use acoustic intensification of the dust collection process. Examination of the material flows of the sintering process points to an unsaturated composition of bauxite charge, limiting the development of exothermic reactions. By analyzing the heat balance items of the sintering furnace, it was established that a significant level of heat losses is associated with sinter and flue gases, which limits the overall thermal efficiency of the unit (≤67.16%).