High Density Ceramsite

Types of High Density Ceramsite

The Production Process of High Density Ceramsite

1. Raw material preparation
The first step in the ceramsite sand production line is raw material preparation. The primary materials used are clay, shale, or other aggregates.
Common raw materials include:

Clay aggregate: The primary component for ceramsite production.

Shale: The material expands when heated to increase the strength and durability of the final product.

Slate and fly ash: Often used as supplementary materials to improve properties.

Preparation steps are as follows:
Crushing: Raw materials are crushed and ground to achieve a uniform size suitable for further processing. It is recommended to use a jaw crusher andball mill to crush the raw materials to within 25 mm.

Mixing/Blending: Mix the crushed materials (a 1:1 volume ratio is good) to form a paste to ensure the consistency of the mixture quality. This can lay the foundation for the subsequent granulation (clay aggregate balls).

2. Granulation

• Once the raw materials are prepared, they undergo a granulation process. The granulation process is crucial, as it directly affects the size and density of the final ceramsite sand product.
• The mixture is formed into high-strength balls of the desired size in a short time (within 15 minutes) using a granulator. The ball-forming rate can reach 93% and above. The size ranges from a few millimeters to several centimeters, depending on the application.

3. Rotary kiln sintering

• The granulated material is then transferred to a rotary kiln. The rotary kiln is the heart of the ceramsite sand production line. This large cylindrical furnace is designed to heat the granulated material to high temperatures (usually between 1000°C and 1400°C).
• Precise temperature control is essential to achieve the desired expansion and properties of ceramsite sand. The rotation of the kiln ensures even heating and prevents the material from sticking to the walls.
• The sintering process causes the particles to fuse, creating a porous structure that contributes to the lightweight and insulating properties of ceramsite sand.

4. Cooling
After sintering, the ceramsite sand needs to be gradually cooled to below 200°C. A rotary coolerhelps stabilize the ceramic sand, prevents it from deforming, and enhances its mechanical properties. Proper cooling also prevents thermal shock, which can lead to cracking or deformation.
Some tips for cooling you should know.

• Air cooling: Utilizing ambient air to gradually lower the temperature of the ceramsite sand.
• Water cooling: In some cases, water sprays are adopted to speed up the cooling process.

5. Screening and grading
Once cooled, the ceramsite sand is screened to separate fine particles from large particles by size.

This step is important because it ensures that the final product meets the specific grading requirements of different applications.

Quality control: Ensures uniform particle size, which is critical for applications such as lightweight concrete.

Product diversification: Allows for the production of various grades of ceramsite sand to meet different market needs.

Unlike traditional vibrating screens, we recommend usinga drum screen. This screen can screen clay materials more efficiently and prevent clogging.

Generally, the output of a 2 mm screen is 19.2–56 t/h, and the output of a 30 mm screen is 280 t/h.

6. Packaging and storage
The final stage involves packaging the ceramsite sand for distribution. Proper packaging is essential to maintain product quality during transportation.

Packaging options

• Bulk Bags: Ideal for large-scale customers requiring significant quantities.
• Small Bags: Convenient for retail and smaller projects.