Ceramsite rotary kiln is a specialized industrial kiln used to produce ceramsite, which converts raw materials into ceramsite through a high-temperature calcination process. A ceramsite rotary kiln is a specialized industrial kiln used to produce ceramsite. Ceramsite is a lightweight aggregate material made from clay or shale.
During the process, raw materials are fed into the rotary kiln from one end, and the kiln body rotates slowly to evenly distribute heat. As the material moves through the kiln, it undergoes a series of chemical and physical changes, including dehydration, calcination, and sintering. These processes expand the material to form small, porous, lightweight particles.
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Tongli's ceramsite rotary kiln is a highly efficient equipment specially used for ceramsite production. The temperature of Tongli's ceramsite rotary kiln can be precisely controlled between 950°C and 1100°C. The raw materials are converted into lightweight porous particles through high-temperature calcination. During the process, the materials undergo dehydration, calcination and sintering in sequence, and finally expand to form ceramsite to ensure the quality of the ceramsite. The diameter of the kiln is usually 2.5 meters to 4 meters, the length is between 40 meters and 60 meters, and the output can reach 1,000 tons/day, which is suitable for applications in the fields of construction, insulation and horticulture.
Thermal efficiency exceeds 80%, and high-alumina bricks or mullite bricks inside the kiln body reduce energy consumption to 650-750kcal/kg.
dust removal efficiency is more than 99%, emission concentration is less than 30mg/Nm³, and the wet desulfurization system further reduces sulfur dioxide emissions
The equipment is equipped with an advanced PLC control system, with a temperature adjustment accuracy of ±2°C, a friendly operation interface, and support for remote monitoring
xxxxxxx | Capacity (t/h) | Motor Model: | Gearbox Model | Input Moisture (%) | Fuel Coal Calorific Value (kcal) | Output Moisture (%) |
φ1.2x10 | 2.5-3 | M160M-6 → 7.5 | ZQ350Ⅱ-25 | 25±5 | ≥5500 | ≤13 |
φ1.5x14 | 7-9 | Y180L-6 → 15 | ZQ400Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
φ1.5x18 | 9.5-12 | Y180L-6 → 15 | ZQ400Ⅱ-31.5 | 27±5 | ≥5500 | ≤13 |
φ1.8x14 | 12-15 | Y200L-6 → 18.5 | ZQ400Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
φ1.8x18 | 14-18 | Y200L1-6 → 18.5 | ZQ400Ⅱ-31.5 | 27±5 | ≥5500 | ≤13 |
φ2.0x18 | 18-22 | Y200L2-6 → 22 | ZQ50Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
φ2.0x20 | 18-23 | Y200L2-6 → 22 | ZQ50Ⅱ-31.5 | 30±5 | ≥5500 | ≤13 |
φ2.2x18 | 21-25 | Y200L2-6 → 22 | ZQ65Ⅱ-31.5 | 27±5 | ≥5500 | ≤13 |
φ2.2x20 | 22-25 | Y225M-6 → 30 | ZQ65Ⅱ-31.5 | 30±5 | ≥5500 | ≤13 |
φ2.4x20 | 25-29 | Y225M-6 → 30 | ZQ75Ⅱ-31.5 | 27±5 | ≥5500 | ≤13 |
φ2.4x22 | 26-30 | Y225M-6 → 30 | ZQ75Ⅱ-31.5 | 30±5 | ≥5500 | ≤13 |
φ2.6x20 | 28-33 | Y250M-6 → 37 | ZQ85Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
φ2.6x24 | 29-35 | Y250M-6 → 37 | ZQ85Ⅱ-31.5 | 30±5 | ≥5500 | ≤13 |
φ3.0x20 | 45-50 | Y280S-6 → 45 | ZQ100Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
The ceramsite rotary kiln is a specialized industrial kiln used to produce ceramsite. Ceramsite is a lightweight aggregate material made from clay or shale. The rotary kiln is a cylindrical rotating furnace that operates at high temperatures to heat treat the raw materials and eventually make ceramsite.
During the process, the raw materials are fed in from one end of the rotary kiln, and the kiln body rotates slowly to evenly distribute the heat. As the material moves in the kiln, it undergoes a series of chemical and physical changes, including dehydration, calcination, and sintering. These processes expand the material to form small, porous, lightweight particles.
Raw materials such as clay or shale are fed into one end of the rotary kiln, and the kiln body rotates slowly. The raw materials are gradually heated and chemically reacted at high temperatures to form ceramsite. The calcined ceramsite is discharged from the other end of the kiln and cooled.
The cooled ceramsite is transported out and becomes the final building material. The ceramsite rotary kiln processes the raw materials into lightweight ceramsite by rotation and heating, and the whole process is highly automated.
The ceramsite rotary kiln can achieve continuous large-scale production with a high degree of automation, reducing manual operations and improving production efficiency. The design of modern ceramsite rotary kilns focuses on energy consumption optimization, high thermal energy utilization efficiency, low fuel consumption, and is equipped with advanced environmental protection facilities to reduce pollutant emissions.
In addition to producing ceramsite, rotary kilns can also be used to calcine other lightweight aggregates, such as expanded clay, shale, etc., with strong adaptability and able to meet the production needs of different materials.
Common problems of ceramsite rotary kilns include uneven temperature distribution in the kiln, inconsistent ceramsite quality caused by inappropriate kiln speed or uneven raw material feeding amount, and hard rings formed on the inner wall of the kiln due to uneven raw material composition or insufficient combustion.
Adjusting the combustion system, optimizing the kiln speed and feeding system, regularly checking and cleaning the rings, and adjusting the raw material formula and combustion parameters can help solve these problems.
In order to increase the output of ceramsite rotary kiln, the operator can optimize the production process by properly adjusting the parameters of rotary kiln. Ensure that the heating temperature of rotary kiln reaches the appropriate level, not too high or too low.
Optimize the ventilation system in the kiln and improve the oxygen supply in the kiln, which will help improve the combustion efficiency. Regular maintenance and maintenance to ensure that the rotary kiln is always in the best performance.
Regularly check the overall condition of the kiln body, especially the wear of the kiln lining. Regularly check and replenish the lubricating oil of each transmission component to ensure smooth operation of gears, bearings and other components and reduce wear. Lubricate and maintain according to the time and method specified in the equipment manual. Check the cooling water system to ensure that the flow and temperature of cooling water are normal to prevent overheating of the equipment and damage to components.
According to the operating time and status of the equipment, carry out medium or major repairs every year or every two years, including disassembly, cleaning, replacement of parts, reassembly of the equipment, etc., to ensure that the equipment is restored to the best operating condition.
Clay is widely used in ceramsite production due to its abundant availability and ideal plasticity for forming lightweight aggregates.
Shale's low density and high thermal stability make it an excellent choice for ceramsite production in rotary kilns.
Slate, when crushed, provides a good raw material for lightweight aggregate production, helping to maintain product strength and stability.
Coal gangue is a rich, low-cost material ideal for ceramsite manufacturing, with excellent insulation properties when processed.
Fly ash, a byproduct of coal combustion, offers a cost-effective solution for producing ceramsite aggregates with improved durability.
Siltstone is used in ceramsite production for its consistency in particle size and high strength after calcination.
Bauxite, rich in alumina, is employed in ceramsite production to enhance the material's strength and heat resistance.
Industrial sludge, when treated in a rotary kiln, can be transformed into ceramsite, promoting recycling and reducing environmental impact.
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