Malaysia Annual Output of 60,000 Square Expanded Light Aggregate Production Line Project

I. Project overview

Date of signing: 2019-01-12

Processing materials: shale, sludge

Processing capacity: 60,000 m3/a

Equipment configuration: 2.5x40 rotary kiln, 4 push-head vertical preheater, vertical cooling machine, hammer crusher PC400x300, wet ball mill with 1200x3000, high efficiency frequency conversion main motor (55KW), roll granulator, double shaft mixer, electric starting kerosene machine (auxiliary transmission), 3 bulk machines, cyclone preheater, box feeder, cloth bag dust collector, electrical Control system

Lightweight ceramic has the characteristics of low density, high strength, high water absorption, heat preservation, heat insulation, fire resistance, earthquake resistance, etc. It can be used as a kind of light aggregate to replace ordinary sand and stone in the preparation of light aggregate wallboard material. In 2018, Malaysia JOE Company's wallboard material project built a light ceramite production line, which was used as a light wallboard raw material for personal use. In view of the high-quality equipment manufacturing quality and after-sales service of our products in the industry, the technical solution was quickly recognized by customers. In January 2019, the two sides signed a supply contract for all the equipment of the entire production line. The equipment will be manufactured and shipped in January 2021.

The production line adopts the current new production process and equipment for the production of lightweight ceramic particles, equipped with vertical preheater and vertical cooling machine, to ensure the stable operation of the system, reliable, energy saving and environmental protection.

II. Solution

Based on the traditional construction ceramic preparation, this ceramic production line adopts the following solutions to meet the technical needs of customers:

1) Adopt a straight cylindrical 2.5x40 rotary kiln and vertical preheater supporting scheme, the scheme of material drying and preheating is carried out in the vertical preheater, the materials in the kiln are heated to more than 600℃, and the waste heat in the exhaust gas of the kiln is recovered and utilized, which greatly saves fuel cost and avoids the disadvantages of high manufacturing and installation cost of ceramic plug kiln.

2) The roller bearing of rotary kiln adopts aligning rolling bearing. Compared with traditional sliding bearings, the sliding friction between shaft and bearing becomes rolling friction, which reduces power consumption and is convenient for installation and maintenance; The main motor adopts frequency conversion speed regulation mode, which can adjust the rotary kiln speed in real time according to the production needs, and the production control is simple and convenient and saves power consumption.

3) Compared with the single cylinder rotary cooler, the vertical cooler has fewer rotating parts, easy maintenance and saving land occupation area. At the same time, during the cooling process of ceramic particles out of the kiln, the cold air pumped into the kiln by the blower is heated to more than 700℃, and the waste heat is recycled to save energy and reduce consumption.

4) The rotary kiln auxiliary drive adopts electric starting kerosene machine, which can continue to pan the kiln after the whole system is powered off to ensure that the kiln cylinder body will not bend and deform under hot state, and also avoid the high investment in the emergency backup power supply part of the ordinary motor auxiliary drive.

5) Wet grinding of raw materials after crushing by hammer crusher to ensure homogeneous mixing of materials and avoid systematic dust discharge; The filter bag of the cloth bag filter at the end of the kiln is made of film material, which reduces the resistance of the system and ensures the efficiency of dust collection, environmental protection and energy saving.

III. Project site