Lightweight aggregate(LECA) Production Line

Liyang Sucai Mechanical Engineering Co., Ltd. has been manufacturing equipment using clay and sludge as raw materials for Light weight aggregate(LECA) since 2007. We have been committed to the development of new technologies for LECA equipment manufacturing and have cooperated with R&D institutions to improve the performance and function of equipment. We provide equipment design, manufacturing and installation services. We also provide customers with general contracting services, including preliminary research and consulting, engineering design, bidding consulting, equipment supply, installation, commissioning, etc. We started export business in 2010 and have provided products or services to more than 1,000 customers at home and abroad, creating good economic benefits for customers.

•  The preheating and calcining process is controlled by a single-drum or double-drum inserted rotary kiln. The process is advanced, the energy consumption is 30% lower than that of ordinary ceramsite kilns, the production capacity is increased by more than 50%, energy is recycled, the process design is reasonable, and the overall technical level is at the world's leading level.
•  According to the different product requirements of customers (particle shape, size and production scale), we provide customers with personalized equipment customization solutions. From equipment process selection and design to the entire plant layout design, we fully meet the special requirements of customers and ensure the practicality and economy of the production line.
• The single production line has large production capacity and low heat loss. The LECA unit uses advanced bag dust collectors to keep the flue gas concentration below 20mg/Nm3.
• The production line is equipped with temperature and pressure monitoring instruments, the operating parameters are displayed by computers, and advanced computer control can be used to achieve automatic operation of the entire system, saving 60% of labor costs for customer factories.

• Clay light weight aggregate is made of clay with suitable ingredients as raw material. When the ingredients are not suitable, some other materials need to be added. It is processed into granules and then expanded at high temperature in a rotary kiln to form artificial lightweight aggregate. After years of research, Sucai has developed energy-saving and environmentally friendly equipment suitable for ceramsite production lines, opening up a new process route for the construction of new environmentally friendly and energy-saving ceramsite.

In terms of environmental protection, our company is committed to the research of process technology and complete process equipment for solid and hazardous waste treatment, so as to achieve the four goals of solid and hazardous waste treatment: reduction, harmlessness, resource utilization and stabilization.

Experimental analysis: The company's pilot test line can conduct raw material analysis, formula design, sample preparation, roasting, small-scale and pilot tests of various clay ceramsite

Energy-saving and environmentally friendly: The clay ceramsite produced by our equipment has the properties of light bulk density, high strength, thermal insulation, high seismic and compressive strength, non-toxicity, no radioactive side effects, environmental protection and energy saving, and strong construction adaptability.

Advanced process equipment: We provide complete services for the entire industry chain, from overall project planning to detailed process formula, process design, equipment design and manufacturing, engineering installation, commissioning, etc., and have complete solid and hazardous waste treatment system solutions

The clay is stored in the pile shed for about 30 days. The clay with a particle size of 10-30mm is sent to the silo by a forklift, and then sent to the double-shaft mixer by a box feeder via a belt conveyor for forced mixing and stirring to reduce the particle size and make the composition uniform, and then enter the roller granulator for extrusion granulation. The granular balls from the granulator are sent to the dryer by a belt conveyor, and after drying, they are sent to the ceramsite rotary kiln for preheating and roasting. The fired ceramsite products fall into the cooler for cooling, and then are screened by the rotary screen into finished products of different particle sizes, which are stored in the yard and shipped after bagging. The natural air that cools the ceramsite in the cooler is heated to form high-temperature secondary air, which enters the rotary kiln for auxiliary combustion, which can save fuel. The fuel is sent to the rotary kiln for combustion by a high-pressure fan through a multi-channel burner. The dusty high-temperature flue gas at the end of the kiln enters the air cooler for cooling, and then enters the bag dust collector for purification and emptying.

1.Raw material process

The main raw material is clay or mud. Build clay (or mud) storage silos and fly ash storage silos, use loaders to take materials, and make appropriate mix ratios. When the clay particle size is too large, a roller crusher should be used to crush it to obtain a smaller particle size.

2.Mixing granulation

A plate feeder is set under the hopper. The material is fed into the double-shaft mixer. Then the material falls into the double-roll granulator and becomes5-10mmThe spherical materials are then sent to the inserted rotary kiln through a belt conveyor.

3.Preheat and burn.

When the shaped ball material enters the preheating kiln through the chute, the moisture is dried and sent to the firing kiln to make a bulk density500kg/m3Lightweight expanded clay aggregate (LECA）。

4.cool down

Lightweight expanded clay aggregate from the kiln (LECA）The outlet will be sent to the cooler. The cooler adopts a single-cylinder cooler.

5.Fuel Burning

Coal, natural gas and biomass fuels are good choices.

6.Kiln mouth dust removal

The air from the kiln is treated by the air cooler and then sent to the bag filter for dust removal. Then it will be sent to the sky.

7.Final product screening and packaging.

Light expanded clay aggregate (LECA) from the outlet of the rotary cooler and then sent to the vibrating screen (or rotary screen). The screening size is5mm、15mmand25mm. Different sizes will be packed in different bags for sale.

1. Energy saving and environmental protection

The production process is advanced, the single production line has large production capacity and low heat loss. The LECA device uses advanced bag dust collectors to keep the flue gas concentration below 20mg/Nm3.

2. High degree of automation

The Leca production line is equipped with temperature and pressure monitoring instruments, the operating parameters are displayed by computers, and advanced computer control can be used to achieve automatic operation of the entire system.

3. Investment losses

According to the characteristics of lightweight expanded clay aggregate, a double-drum inserted rotary kiln is used to control the preheating and calcining process. The LECA production line adopts energy-saving preheater with advanced technology, reasonable design and high technical level.