Ceramsite Rotary Kiln Production Line

Process Introduction

The Zhongya Ceramsite Rotary Kiln Production Line serves to manufacture clay granules (artificial lightweight aggregate), functioning as a specialized industrial system. The core principle of the Zhongya Ceramsite Rotary Kiln Production Line involves utilising a rotary kiln—a high-temperature calcination apparatus—to transform raw materials such as various clays, shales, fly ash, sludge, and tailings. The production process converts these materials, through a series of steps including preheating, calcination, and cooling, into spherical or elliptical clay granule products that feature a porous structure, lightweight properties, and high strength.

Production Process

1.Crushing:
Mined bauxite typically measures 300–500mm in size and contains minimal moisture. A two-stage crushing system comprising jaw crushers and hammer crushers is generally employed to reduce particle size to ≤8mm.

2.Batching:
The process transfers bauxite, manganese powder, and recycled materials to their respective storage silos. Variable-speed belt scales beneath the silos enable automatic batching and metering of materials.

3.Grinding:
The process typically employs a ball mill with integrated drying and grinding functions, pairing it with a high-efficiency classifier to form a closed-circuit system. This configuration ensures high grinding efficiency.

4.Pelletising:
The process stores the raw material powder discharged from the mill in a raw material silo. The powder enters a disc pelletiser, with a pipeline pump spraying water into the disc. As the pelletiser rotates, the process generates pellets of various particle sizes. After exiting the disc, a belt conveyor transports the pellets to a screening device. Qualified pellets enter the rotary kiln, while oversized pellets are returned to the raw material grinding process.

5.Calcination:
The pellets enter a rotary kiln with a specific inclination for calcination. As the kiln rotates, the pellets roll towards the kiln head. The kiln transforms them into high-strength ceramic granules through calcination.

6.Product Cooling:
Expanded clay aggregate typically goes through a rotary cooler for cooling, which operates simply and reliably. The system fully introduces the cooler's secondary air into the kiln. Combined with the use of multi-channel burners, this significantly reduces energy consumption.

7.Screening:
Expanded clay aggregate exiting the cooler can be directly conveyed to multi-stage vibrating screens, where it is graded into multiple particle size fractions according to requirements.

Process Advantages

• Product quality is consistently superior:
  Expanded clay aggregates feature uniform particle size, outstanding performance and excellent consistency.
• Production efficiency is exceptionally high:
  Continuous automated manufacturing enables large-scale operations with low costs.
• Waste utilisation promotes environmental sustainability:
  Capable of processing substantial quantities of fly ash, sludge and other waste materials to achieve green production.
• Raw material adaptability is extensive:
  Suitable for diverse feedstocks, enabling flexible production of various product specifications.