Use of ceramsite sand

Ceramsite sand production line equipment is one of the best-selling brand equipment of our company at home and abroad for many years. It has won many honors for its perfect performance, advanced technology and superior cost performance, and has been widely praised and affirmed by customers at home and abroad.

Use of ceramsite sand

At the beginning of the invention and production of ceramsite sand, it was mainly used in the field of building materials. Due to the continuous development of technology and people's deeper understanding of the properties of ceramsite, the application of ceramsite sand has already exceeded the traditional range of building materials, and its new application fields have been constantly expanded. At present, the application of ceramsite sand in building materials has dropped from 100% to 80%, and the application in other fields has accounted for 20%. With the continuous development of new uses of ceramsite sand, its proportion in other aspects will gradually increase.

Ceramsite sand has excellent properties, such as low density, high compressive strength, high porosity, high softening coefficient, good frost resistance, excellent alkali-aggregate reactivity, etc. Especially because ceramsite sand has small density, porous inside, uniform shape and composition, and has certain strength and firmness, it has many features such as light weight, corrosion resistance, frost resistance, seismic resistance and good insulation. With these excellent properties, ceramsite can be widely used in building materials, horticulture, food and beverage, fire-resistant and thermal insulation materials, chemical industry, petroleum and other sectors. The application field is increasingly wide and continues to expand.

Ceramsite sand is also used for downhole support in oil fields to increase the production of oil and gas, which is an environmental protection product. This product is made of high-quality bauxite, coal and other raw materials and sintered with ceramics. It is a substitute for natural quartz sand, glass ball, metal ball and other medium-low strength proppants, and has a good effect on increasing oil and gas production.

Production process of ceramsite sand production line

In short, the production of petroleum proppant ceramsite sand can be summarized as crushing, batching, grinding, ball-making, calcination, pulverized coal preparation, finished product cooling, screening, packaging and other processes. The main raw material is high-grade bauxite.

1. Crushing:

The mined bauxite is generally about 300~500mm in size and contains a small amount of water. Generally, the secondary crushing system composed of jaw crusher and hammer crusher is adopted, and its particle size is controlled at ≤ 8mm. The bauxite after entering the plant can be stacked separately according to different grades. Use according to indicators.

In the process of producing ceramsite sand, manganese (Mn) is usually added to reduce the sintering temperature and dye the product into dark color. At present, most domestic manufacturers use low-grade (~50%) manganese ore or manganese ash as the source of manganese.

2. Ingredients:

Bauxite, manganese powder, recycled materials and other materials are respectively transported to their respective material warehouses, under which a speed-regulating belt scale is set to realize automatic material batching and metering.

3. Grinding:

Generally, the ball mill for drying and grinding is used, and the high efficiency powder concentrator is equipped to form a closed circuit system. This grinding is efficient. The hot air for drying materials can come from the waste gas of the rotary kiln, so as to achieve waste heat utilization; Special hot-blast stove can also be set.

4. Ball making:

The raw meal powder from the mill is stored in the raw meal silo. Generally, 2~3 warehouses are set, which can be discharged separately or in combination with multiple warehouses.

The raw meal powder is sent to a small silo, under which a screw metering device or a speed-regulating belt scale device is set to measure the raw meal quantity. The raw material enters the disc pelletizer. At the same time, the flow meter can be used to measure the amount of water, and the pipe pump will spray the water into the disc pelletizer. During the rotation of the ball-making machine, it can be made into balls of various particle sizes.

After the pellets are discharged from the tray, they are sent to the screening device by the belt conveyor, and the qualified ones enter the rotary kiln, and the oversized ones return to the raw material grinding flow. According to the output of different kilns, different number of disc pelletizers can be equipped.

The pelletizing system has a high degree of automation and continuous process. After the bag dust collector is equipped, the dust at the post can reach the standard and the working environment at the post can be purified.

5. Calcination:

The feed ball enters the rotary kiln with a certain slope for calcination. With the rotation of the rotary kiln, the feed ball rolls towards the kiln head. At the same time, the pulverized coal is sprayed into the kiln from the kiln head for combustion. The feed ball is calcined into ceramsite sand with high strength in the rotary kiln.

The pulverized coal burner can adopt a single-channel coal injection pipe, which is simple and reliable and has high primary air volume; Multi-channel burners can also be used. The primary air volume can be reduced to 8% of the air volume required for pulverized coal combustion, and the secondary air volume into the kiln can be increased. The energy-saving effect is remarkable. Multi-channel burner is divided into external axial flow air, coal air, internal axial flow air, etc. The flame shape is very easy to adjust.

The measurement of pulverized coal can be carried out by using a rotor-type measuring scale or a Coriolis force scale to accurately control the coal quantity and stabilize the thermal system in the kiln.

6. Pulverized coal preparation:

Pulverized coal can be prepared by ball mill or vertical mill, and hot air can be extracted from the kiln head cover to dry the pulverized coal. The fineness of pulverized coal can be adjusted arbitrarily by using the dynamic separator, which provides conditions for the full combustion of pulverized coal.

7. Finished product cooling:

Rotary cooler is generally used for cooling ceramsite sand, which is simple and reliable. The secondary air of the cooler is completely fed into the kiln, and the use of multi-channel burner can save a lot of energy consumption. The temperature of ceramsite sand coming out of the cooler is very low and can be grasped by hand.

8. Screening:

The ceramsite sand from the cooler can be directly transported to the multi-stage vibrating screen and divided into multiple particle size grades as required.

Product specification of ceramsite sand

Type I 0.45-0.9mm (20-40 mesh) high strength medium density

Type II 0.9-1.25mm (16-20 mesh) high strength medium density

Type III 1.0-1.70mm (12-18 mesh) high strength medium density

Type IV 0.224-0.65mm (40-60 mesh) high strength medium density

Crushing process of bulk returned raw materials.

9. Packaging

The screened ceramsite sand enters into different round silos, and electronic weighing scales are set under the silos. The qualified finished products in bags are sealed by the sewing machine and stacked in the finished product warehouse for shipment.

Bag dust collectors are set at all dust points in the process to achieve clean production.

The production process of ceramsite sand (1) takes clay and clay as raw materials and adopts the plastic method production process. The process is: clay ->plasticization, homogenization ->roller granulation ->roasting ->cooling ->finished ceramsite.

(2) Fly ash or other powdery materials are used as raw materials and slurry balling process is adopted. The process is as follows: fly ash ->mixing and homogenization ->pelletizing in ceramsite pot ->roasting ->cooling ->finished products.

(3) With shale, argillaceous shale and coal gangue as raw materials, the grinding process is adopted. The process is as follows: shale ->drying ->grinding ->pre-wetting ->ceramsite pot granulation ->roasting ->cooling ->ceramsite finished products.

(4) With shale as raw material, the crushing (dry process) process is adopted, and its process is: shale ->crushing and grading ->roasting ->cooling ->ceramsite finished product.

To sum up, no matter what raw materials are used, the production process of ceramsite sand is generally inseparable from the processes of homogenization, granulation, roasting and cooling.