Sludge ceramsite production line

Liyang Sucai Mechanical Engineering Co., Ltd. has been manufacturing equipment using lightweight expanded clay and sludge as raw materials (LECA) since 2007. We have been committed to the development of new technologies for ceramsite 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.

Light Expanded Light weight aggregate (LECA) (LECA) is made of sludge and clay as the main raw materials through treatment, granulation, calcination and other processes. Clay is the most widely used material in LECA. The advantages are as follows:

1. Rich resources and easy to obtain.

2. The production process is plastic, the production line is simple, the equipment is few, and the total investment is low.

3. LECA has excellent performance, easy strength and intensity adjustment, and can produce lightweight LECA and porous core ceramic shells.

Since the establishment of the company, we have started the manufacturing of lightweight expanded clay, sludge (LECA) equipment. We have been committed to the development of new technologies for LECA equipment manufacturing, and have cooperated with colleges and R&D institutions to improve the performance and functions of the equipment. Our LECA equipment has been widely used by LECA manufacturers in China and has won a good reputation from customers. We started export business in 2010 and created good economic benefits. We adopted energy-saving technology and achieved good economic benefits.

Light expanded clay aggregate production line: When the raw material is clay or mud, the production flow chart should include raw material process, mixing, granulation, plug-in rotary kiln combustion process, cooling process, screening and bagging; when the raw material is shale, the production flow chart should include crushing, screening, single rotary kiln combustion process, cooling process, screening and bagging. The fuel can be coal, natural gas, biomass fuel, etc.

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 and 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 becomes a spherical material of 5-10mm. Then it is fed into the inserted rotary kiln through a belt conveyor.

3. Preheating and combustion.

When the formed balls enter the preheating kiln through the chute, the moisture is dried and sent to the firing kiln to produce lightweight expanded clay aggregate (LECA) with a bulk density of 500kg/m3.

4. Cooling

The Lightweight Expanded Light weight aggregate (LECA) (LECA) outlet from the kiln will be fed into the cooler. The cooler adopts a single drum cooler.

5. Fuel Burning

Coal, natural gas and biomass fuels are good choices.

6. Dust removal at kiln mouth

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 Light weight aggregate (LECA) (LECA) is exported from the rotary cooler and then sent to the vibrating screen (or rotary screen). The screening size is 5mm, 15mm and 25mm. 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.

No	Indicator	unit	Numeric
1	Yield	m3/a	15,000	25,000	35,000	50,000	100,000
2	product
①	Light expanded clay aggregate	m3/a	15,000	25,000	35,000	50,000	100,000
3	Main fuel and raw material consumption
①	Clay and sludge	t/a	8,800	14,700	20,500	29,400	58,800
②	shale	t/a	8,300	13,900	19,400	27,800	55,600
③	coal	t/a	1,360	2,270	3,180	4,540	9,080
4	power consumption
①	freshwater	t/a	1,000	1,500	2,500	3,000	6,000
②	energy	kWh/a	187,500	312,500	875,000	1,250,000	2,500,000
5	Number of employees required	a	9	10	12	15	18