subject: Proppant Ceramsite Production Line [print this page] Ceramsite sand is a product of ceramic granule with great harness. It is mainly used as proppant ceramsite to increase the capacity of gas and oil, besides it is environmentally friendly. It is made from bauxite, coal and many other materials by the means of ceramic sintering. ceramsite sand is an excellent substitute for natural zicon sand, glass ball, metal ball or any other low intensity sustainer, helping improve yield.
Simply speaking, production of Proppant ceramsite includes curshing, batching, pulverizing, pelleting, calcination, coal powder making, cooling, sieving,packing and so on. Main material is bauxite with high grade.
Proppant ceramsite production progress
1 Crushing
Size of Raw bauxite chunk is between 300mm-500mm with small amount water. After processed by secondary crush system consisting of jaw crusher and hammer crusher, its granularity is smaller than 8mm.
Process bauxite should be kept separate according to the grade, so that one could be used with others.
Manganese is usually put into the production of ceramsite sand to lower the sintering temperature and dye the product dark color. Nowadays domestic companies use Manganese ore or Manganese dust of low grade (Mn less than 50%).
2 batching
bauxite, manganese powder, feedback material are sent to silo separately. there is electronic loadcell scale under the belt conveyor to balance materials automaticall.
3 pulverizing
It is highly efficient that ball which can both pulverize and dry and powder separator form a close circle.
4 pelleting
raw material powder is stored in 2 or 3 bunks, which can either be used solo or multiple.
there is a small silo storing raw material powder under which there is spiral balance or belt scale weighing the raw material.meanwhile, flowmeter will control the amount of water in the plate pelleting machine when the raw material is becoming pellet of different size.
pellets coming from plate pelleting machine will go to seive by belt conveyor, in where qualified is sent to rotary kiln, others go back to break.
quantity of plate pelleting machine depends on capacity.
This pelleting system is highly automatic and consistent. The air is purified when bag filter is equipped.
5 sintering
Pellets are sintered in the rotary kiln with a certain inclination. while the kiln is rotating, pellets roll to the lower end in which pellets are sintered by the fire inflamed by coal powder.
single channel coal nozzle is simple, reliable and strong wind power; multi channel can reduce air quantity the coal need by 8%, increase the secondary wind in the kiln, saving energy.the latter is divided into outer axial flow, coal air and inner axial flow, shape of flame is easy to adjust.
6 coal powdering machine
Rotor balance or Kiln's blance can be adopted to control precisely the amount of coal, stablize temperature in the kiln
ball mill or vertical mill can produce the coal powder and the hot air from kiln can be used to dry the powder. the dynamic powder separator is able to adjust finess of powder in one's direction, helping coal burn fully.
7 cooling
pellets are chilled by rotary cooler, which is simple and reliable. the combination of secondary of cooler and multi channel burner will save a great deal of energy. the temperature of chilled pellets are very low, you can grad them by the hand.
8 sieving
the chilled pellets are taken to multi seive, classified to several specification.
ceramsite sand specification
0.45-0.9mm(20mesh-40mesh)high intensity medium density
0.9-1.25mm(16mesh-20mesh)high intensity medium density
1.0-1.70mm(12mesh-18mesh)high intensity medium density
0.224-0.65mm(40mesh-60mesh)high intensity medium density
big chunks return to break stage
9 packing
the sieved ceramsite sand, according to different size, go to several silo. there is electronic loadcell scale at the bottom of the silo. the ceramsite is weighed and packed, stacked in the finished product garage, waiting to be delivered. all the dust site will be installed bag filter to purify air.
