Project Overview

1)Introduction to the Gangue Ceramic Granule Line Project
This project is an investment by Anhui customers to build an annual production of 20×20,000 cubic meters of gangue ceramsite. The project uses coal-based solid waste-gangue as the main raw material. The main equipment includes a double-roll granulator, a disc ball forming machine, a rotary kiln, a cooler, and conveying equipment. Aiming at the comprehensive utilization of coal-based solid waste-gangue, the added value of gangue products is improved.

2)Overview of the Gangue Ceramic Granule Line Project
The production line mainly consists of a raw material processing system, a drying system, a grinding system, a stirring and aging system, a granulation system, a roasting system, a finished product packaging system, and an exhaust gas treatment system.

3)Equipment for the Gangue Ceramic Granule Line Project:
Gangue granulation equipment: GL10090 double-roller granulator, PQ42 disc granulator
Gangue calcining equipment: plug-in rotary kiln, rotary cooler
 
Solution

1. Raw material pretreatment and aging
Raw material collection and storage: Establish a special raw material receiving station, equipped with necessary conveying equipment, such as belt conveyors, bucket elevators, etc., to collect and store waste soil, sludge, and industrial waste residues. Ensure a stable source of raw materials, controllable quality, and reduce environmental pollution.
Raw material screening and homogenization: Preliminary screening of collected raw materials to remove oversized or undersized particles and impurities to ensure the quality of subsequent granulation. Homogenization treatment is carried out through the raw material homogenization warehouse to ensure the stability of raw material components and facilitate the stable operation of subsequent production processes.
Aging treatment: Set up an aging yard or warehouse to age the screened and homogenized raw materials for several days to several weeks. During the aging process, physical and chemical changes occur in the moisture and organic matter inside the raw materials, improving their plasticity and conducive to the subsequent granulation process.
 
2. Ceramic granulation
Raw material pulping: Add the aged raw materials to the pulping equipment (such as a mixer), add water, and stir to form a slurry with a certain viscosity, which is convenient for subsequent granulation.
Granulation molding: Use a wet granulator (such as a disc granulator, a drum granulator, etc.) to make the slurry into raw ceramsite with uniform particle size and regular shape. Appropriate additives (such as binders, curing agents, etc.) can be added during the granulation process to improve the performance of ceramsite.
Drying of raw ceramsite: Use a chain plate, belt or fluidized bed dryer to efficiently dehydrate and dry the wet ceramsite so that its moisture content meets the requirements for suitable calcination, while improving the strength of the ceramsite.
 
3. Ceramic rotary kiln calcination
Design and manufacture of ceramsite rotary kiln: Design and manufacture one or more ceramsite rotary kilns suitable for production capacity, using high-temperature resistant and wear-resistant high-quality materials to ensure the long-term stable operation of the kiln body. The internal structure of the kiln body should optimize the airflow distribution to ensure uniform heating of the material and improve the calcination efficiency.
Calcination process: The raw ceramsite is evenly fed into the rotary kiln by the kiln head feeding device, and is preheated, calcined at high temperature and cooled in the preheating zone, calcining zone, and cooling zone in turn. By precisely controlling parameters such as kiln temperature, kiln speed, and air supply, the ceramsite can complete the sintering reaction at an appropriate temperature to form finished ceramsite with high strength, low water absorption, and excellent thermal insulation performance.
Waste heat recovery and environmental protection measures: The kiln tail is equipped with a waste heat boiler or heat exchanger to recover the heat of high-temperature flue gas for drying, heating or power generation to improve energy utilization. At the same time, high-efficiency smoke treatment equipment (such as bag dust collectors, wet electrostatic precipitators, etc.) and desulfurization and denitrification devices are configured to ensure that flue gas emissions meet standards.
 
4. Cooling and screening packaging
Ceramic pellet cooling: Use countercurrent or crossflow coolers to quickly cool high-temperature ceramsite to prevent cracks in the ceramsite due to sudden cooling and ensure product quality. The hot air generated during the cooling process can be recycled in the drying process to save energy.
Ceramic sieving and grading: The cooled ceramsite is graded by particle size through vibrating screens, drum screens, and other equipment to meet the needs of products of different specifications.
Ceramic slurry packaging and storage: Automatic quantitative packaging machines are used for precise packaging to improve production efficiency. Finished ceramsite is stored in a moisture-proof and well-ventilated warehouse to ensure product quality.
 
5. Installation and commissioning
Equipment installation: Equipment installation is carried out strictly following design drawings and technical specifications to ensure that the equipment is tightly connected and reasonably laid out to meet the requirements of the production process.
System commissioning: Single machine commissioning, linkage commissioning, and trial operation with materials are carried out to adjust equipment parameters to the working state to ensure that the entire production line runs smoothly and that various performance indicators meet the design requirements.