STCrushers Is A Professional Minging Equipment Manufacturer since 2004, Providing High Quality Crushers, Sand Making Machines, Drying Equipment and more.
STCrushers Is A Professional Minging Equipment Manufacturer since 2004, Providing High Quality Crushers, Sand Making Machines, Drying Equipment and more.
The Sentai Ceramsite Rotary Kiln Production Line serves to manufacture clay granules (artificial lightweight aggregate), functioning as a specialized industrial system.
The core principle of the Sentai Ceramsite Rotary Kiln Production Line involves utilising a rotary kiln—a high-temperature calcination apparatus—to transform raw materials such as various clays, shales, fly ash, sludge, and tailings.
The production process converts these materials, through a series of steps including preheating, calcination, and cooling, into spherical or elliptical clay granule products that feature a porous structure, lightweight properties, and high strength.
| Category | Equipment | Model (Example) | Quantity | Function |
|---|---|---|---|---|
| Crushing System | Jaw Crusher | PE500×750 | 1 set | Primary coarse crushing of auxiliary materials |
| Hammer Crusher | PC800×600 | 1 set | Secondary fine crushing to ≤8mm | |
| Batching System | Storage Silos | Customized | 3+ sets | Store sludge, auxiliary materials, recycled fines |
| Belt Scale Batching System | Customized | 1 set | Automatic metering and batching | |
| Grinding System | Ball Mill (with drying) | Φ1830×6400 | 1–2 sets | Integrated drying and grinding of mixed materials |
| High-Efficiency Classifier | Cyclone Classifier | 1 set | Closed-circuit classification | |
| Pelletising System | Disc Pelletiser | Φ3200/Φ4500 | 1 set | Form spherical sludge ceramsite pellets |
| Vibrating Screen | 3YK1548 | 1 set | Screen qualified pellets | |
| Calcination System | Rotary Kiln | Φ2.5×40m / Φ3.2×50m | 1 set | High-temperature calcination & heavy metal stabilization |
| Multi-Channel Burner | Customized | 1 set | Efficient fuel combustion | |
| Cooling System | Rotary Cooler | Φ2.0×20m | 1 set | Cool finished ceramsite & recover heat |
| Screening System | Multi-Stage Vibrating Screen | 4YK1860 | 1 set | Grade ceramsite into particle size fractions |
| Auxiliary System | PLC Control Cabinet | Customized | 1 set | Centralized process control |
| Flue Gas Treatment System | Bag Filter + Desulfurization | 1 set | Control dust & SO₂ emissions |
Converts hazardous sludge and solid waste into high-value lightweight ceramsite, achieving harmless disposal and resource recycling.
Rotary kiln with heat recovery and multi-channel burners reduces fuel consumption by up to 20% while stabilizing heavy metals in sludge.
Configurable for various sludge types (sewage sludge, industrial sludge) and production capacities (5–200 TPH) to suit different project scales.
Equipped with flue gas desulfurization and dust removal systems, meeting strict environmental emission standards for solid waste treatment.
Mined auxiliary materials and dewatered sludge lumps (300–500mm) are reduced to ≤8mm via a two-stage crushing system (jaw crusher + hammer crusher), preparing for uniform mixing and grinding.
Sludge, auxiliary materials (bauxite, clay), and recycled ceramsite fines are stored in silos, with variable-speed belt scales enabling automatic, precise metering and batching.
A drying-integrated ball mill and high-efficiency classifier form a closed-circuit system, grinding mixed materials into fine powder with consistent particle size distribution.
Powder is fed into a disc pelletiser, where water is sprayed to form spherical pellets. Screening separates qualified pellets (for kiln feeding) from oversize pellets (returned to grinding).
Pellets enter an inclined rotary kiln, where high-temperature calcination (1100–1300°C) transforms them into lightweight, high-strength ceramsite granules while stabilizing heavy metals in sludge.
Finished ceramsite is cooled in a rotary cooler, with secondary air recycled back to the kiln to reduce energy consumption and improve thermal efficiency.
Cooled ceramsite is graded into multiple particle size fractions via multi-stage vibrating screens, meeting specific application requirements.
Note: Stcrushers can customize a set of Ceramsite rotary kiln production plant according to customer's needs.
STCrushers provides high quality and reliable mining equipment customize manufacturing service for global customers, we design the production line according to the needs of the customer's processed materials and output, and realize fully automatic production from feed to discharge.
We have more than 20 years of experience in the production of large mining equipment.
We have an experienced production line design team to meet the processing needs of different materials.
We have two large workshops, a variety of processing equipment and machine tools.
The company strives to provide customers with preferential prices and payment methods to meet customer needs.
If you are looking for mining equipment such as stone crushers, ball mills, rotary dryer, rotary kiln and other equipment, feel free to contact us and our team will reply within 48 hours.
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