LECA Rotary Kiln

Introduction

The LECA rotary kiln is mainly used for calcining semi-finished ceramsite particles. There are two types: single-cylinder rotary kiln and double cylinder rotary kiln. The double-cylinder kiln is further divided into a preheating kiln and a calcination kiln. The preheating kiln is used for drying and preheating, and the calcination kiln is used for sintering. It is widely suitable for the calcination and production of LECA of various materials such as sludge, clay, yellow mud, river bottom sludge, fly ash, shale, slag, etc.

LECA rotary kiln is also the key equipment in the ceramsite production line, with advantages of high unit volume, long kiln life, high operation rate, stable operation, high heat transfer efficiency, low heat consumption, etc. It is an ideal ceramsite calcining equipment.

Application

LECA uses clay, fly ash and biological sludge as the main raw materials, and is made by high temperature calcination and expanded. It has the characteristics of low density, high strength, high water absorption, heat preservation, heat insulation, fire resistance, shock resistance, etc. It is widely used in different industries. It can replace ordinary sand and gravel to prepare light aggregate concrete, which can be used as water treatment filter material, adsorbent, permeable pavement material, and can also be used for soilless cultivation in agriculture and gardens, as well as building materials such as bridge decks and hollow blocks.

Working Principle

The semi-finished particles are fed into the kiln through the chute at the kiln tail of the preheating kiln. Due to the inclination and slow rotation of the cylinder, the semi-finished particles roll along the circumference and move from the end of the preheating kiln to the kiln head of the calciantion kiln along the axial direction. The fuel is injected into the kiln from the kiln head of the calciantion kiln through the burner for combustion, and the heat is transferred to the semi-finished particles in various ways such as radiation, convection, and conduction. During the movement of the semi-finished particles, after drying and preheating, they enter the calcination kiln for sintering, and complete various physical changes and chemical reactions to form ceramsite. Then they are discharged from the head end of the calcination kiln and enter the cooler. The high-temperature flue gas enters the kiln tail dust removal system from the kiln tail end of the preheating kiln.

Process Description

To produce LECA, the production process generally includes: raw material pre-treatment, batching, granulating, pre-heating, calcination, cooling, fuel combustion, dust collection system, and final products screening and packing, etc.

Raw materials pre-treatment: main raw material is clay or slurry. Clay (or slurry) is stored in the storage yard, we get the materials by loader and do the proper mixing ration. Then the materials will be fed into silo.When the clay size is too big, it should be crushed by roller crusher to get small size.

Mixing and Granulating: set up an apron feeder under the hopper. Feed the materials into a double shaft mixed and the materials fall into a double roller granulator to become 5-10mm sphere shape material. And then they are fed to an insert type rotary kiln by belt conveyor.

Preheating and Calcination: when the sphere shape materials enter into the preheating kiln by chute. They will be dried and then the material will be fed into the calcianation kiln to become the Light Expanded Clay Aggregate (LECA) with bulk density of 500kg/m3.

Cooling: Light Expanded Clay Aggregate (LECA) discharging from the kiln will be fed into the cooler.

Fuel Combustion: Coal, natural gas and biomass fuel are all good choices as fuel.

Kiln inlet Dust Collection: Exhaust Gas from kiln inlet will be processed by air cooler machine and then sent to the bag filter for de-dusting. And then it will be exhausted in the air.

Final Product Screening and Packing: The Light Expanded Clay Aggregate (LECA) discharging from rotary cooler are fed into a vibration screen (or rotary screen). They will be screened into different size They will be packed in different bags, which will be loaded for sales.

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