Henan Hongke Heavy Machinery Co., Ltd. successfully designed, manufactured, and delivered a complete 10,000-ton-per-year shale ceramsite sand rotary kiln production line for a customer in Mianchi County, Henan Province, China. This project stands as a testament to Hongke’s engineering excellence and deep expertise in the field of lightweight aggregate and proppant production equipment.
The production line was engineered to process local shale resources into high-quality ceramsite sand—a lightweight, high-strength artificial aggregate widely used in building materials, oil fracturing proppants, refractory insulation, and water treatment applications .
Production Process & Technical Highlights
The Mianchi project employs a complete shale ceramsite production workflow, following the industry-standard process of raw material homogenization, granulation, calcination, and cooling .
Raw Material Preparation
The production line begins with a dry-method crushing process for shale: raw shale undergoes primary and secondary crushing, followed by screening and classification. This prepares the material for the subsequent granulation stage .
Granulation
For shale-based raw materials, Hongke configured the system with a powder grinding and balling process: crushed shale → drying → grinding → pre-wetting → balling and granulation via disc pelletizer .
Calcination – The Core Technology
The heart of the production line is the shale ceramsite rotary kiln, featuring:
A kiln body set at approximately 3° inclination to ensure smooth material flow from feed end (kiln tail) to discharge end (kiln head)
A calcination temperature range of 950°C to 1050°C, precisely controlled to achieve optimal expansion and product quality
Advanced kiln head and kiln end sealing systems that prevent cold air ingress and dust leakage, ensuring stable thermal performance and reduced energy consumption
A robust supporting device with thrust rollers to control kiln body movement, plus both main and auxiliary drive units that allow slow rotation during power interruptions to prevent kiln deformation
Cooling & Screening
After calcination, the hot ceramsite sand enters a cooling system, followed by screening through a trommel screen to achieve the required particle size grades before final packaging .
Equipment Configuration
The complete production line supplied by Henan Hongke includes:
| Equipment Category | Key Components |
|---|---|
| Crushing & Grinding | Jaw crusher, hammer crusher, ball mill |
| Granulation | Disc pelletizer / granulator |
| Calcination | Shale ceramsite rotary kiln (with preheating section) |
| Cooling | Single-drum cooler |
| Screening & Conveying | Trommel screen, belt conveyors, bucket elevators |
| Dust Collection | Bag filter, dust settling chamber, induced draft fan |
The system is equipped with variable frequency drives for the kiln rotation speed and feeder, allowing precise adjustment of process parameters to achieve optimal output while maintaining product quality .
Project Outcomes & Client Benefits
Since commissioning, the Mianchi 10,000 TPY production line has delivered significant advantages:
Stable Production Capacity: The system consistently meets its annual output target of 10,000 tons of high-grade shale ceramsite sand.
High-Quality Product: The resulting ceramsite sand exhibits excellent properties including low density, high strength, good frost resistance, and superior thermal insulation—meeting standards for both construction aggregates and oilfield proppants .
Energy Efficiency: The kiln design minimizes heat dissipation and maximizes heat transfer efficiency, reducing overall fuel consumption per unit of product .
Operational Reliability: With automated temperature control and robust mechanical design, the line operates with high uptime and low maintenance requirements.
Environmental Compliance: The integrated dust collection system and sealed kiln design ensure that production meets modern environmental standards .
Why Henan Hongke for Your Ceramsite Project?
With extensive experience in rotary kiln manufacturing and complete production line integration, Henan Hongke Heavy Machinery Co., Ltd. offers:
Custom Engineering: Tailored solutions based on specific raw materials, capacities, and site conditions
Full Equipment Supply: From crushers and mills to kilns, coolers, and dust collection systems
Project Management: Design, manufacturing, installation guidance, and commissioning support
Proven Track Record: Successful deliveries of ceramsite production lines across China and internationally
Contact Us
To learn more about our shale ceramsite sand rotary kiln production lines or to discuss your project requirements, please contact Henan Hongke Heavy Machinery Co., Ltd. Our engineering team is ready to provide professional consultation and customized solutions.