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1. System Overview
LECA (Lightweight Expanded Clay Aggregate) is a porous lightweight building material made by high-temperature sintering process, which is widely used in green buildings, hydroponic gardening, water treatment and other fields. This production line has a designed capacity of 1.9-76 t/h, suitable for raw materials such as clay, shale, industrial waste, etc., and produces aggregates with a density of 300-900 kg/m³ and a particle size of 0.1-25 mm to meet the needs of different scenarios. The finished product has the characteristics of high strength, heat insulation and sound insulation, environmental protection and non-toxicity, and complies with the EN 13055-1 international standard.
2. Core Process System
Raw material pretreatment module
Coarse crushing: jaw crusher (feed ≤ 1200mm → discharge 10-350mm)
Fine grinding: ball mill (particle size ≤ 0.075mm, accounting for ≥ 90%)
Mixing and tempering: double-shaft mixer (clay: shale = 1:1, moisture content 15-20%)
Forming and drying modules
| Equipment | Function | Key parameters |
|---|---|---|
| Disk granulator | Prepare spherical particles (particle size 5-25mm) | Ball formation rate ≥93%, production capacity 4-24t/h |
| Drum dryer | Pre-dry to moisture content ≤8% | Hot air temperature 850℃, processing capacity 76t/h |
High temperature sintering module
Rotary kiln system:
Sintering temperature: 1100-1250℃ (precise temperature control ±10℃)
Residence time: 45-60 minutes (expansion rate control ±5%)
Fuel: natural gas/biomass pellets (heat consumption ≤850kcal/kg)
Cooling system:
High-efficiency cooler (discharge temperature ≤ 200 ℃, recycled heat utilization rate ≥ 30%)
Finished product processing module
Grading and screening: multi-stage trommel screen (grading accuracy ±1mm)
Intelligent packaging: ton bag/25kg bag dual mode packaging line (speed 40 bags/minute)
3.Equipment configuration and technical parameters
| Equipment module | Technical indicators |
|---|---|
| Jaw crusher | Processing capacity 435t/h，power 160kW |
| Ball mill | Cylinder speed 19r/min，installed power 1250kW |
| Rotary kiln | Production capacity 10000t/d, Slope 3.5% |
| Trommel screen | Screening efficiency ≥95%, processing capacity 280t/h |
| Dust removal system | Emission concentration ≤10mg/m³, filtration area 1280㎡ |
4.Performance Indicators and Grading Applications of LECA
| Particle size (mm) | Density (kg/m³) | Compressive strength (MPa) | Typical applications |
|---|---|---|---|
| 0-4 | ≤710 | 3.0-7.0 | Lightweight concrete, water filtration |
| 4-10 | ≤480 | 2.5-5.0 | Green roof, noise barrier |
| 10-20 | ≤380 | 1.5-3.0 | Horticultural substrate, road filling |
| 0-25 | ≤430 | 2.0-4.0 | Building decoration, aquaculture |
5. Technical Advantages
Highly efficient energy saving
Waste heat recovery system: reduce energy consumption by 25% (compared with traditional process)
Intelligent temperature control technology: rotary kiln thermal efficiency is increased to 85%.
Environmental innovation
Zero wastewater discharge: Dry condensate water recycling
Low-carbon process: Support biomass fuel substitution, CO₂ emission reduction by 30%
Intelligent control
DCS central control system: real-time monitoring of 200+ process parameters
AI quality prediction: prejudge the expansion rate through the kiln temperature curve, accuracy ≥95%.
Raw material adaptability
Can handle gangue, tailings and other industrial solid wastes (substitution rate ≤50%)
Clay moisture content tolerance up to 25% (pre-drying system adjustment)
6.Typical Customer Cases
Case 1: European Green Building LECA Project
Production capacity: 50t/h
Raw material: shale + construction waste soil (1:1 mix)
Achievements:
Aggregate density 420kg/m³, thermal conductivity 0.12W/(m·K)
Applied to passive buildings, energy saving rate increased by 40%
Case 2: Southeast Asia hydroponic gardening substrate line
Configuration:
Disk granulator (particle size 4-8mm)
Low-temperature sintering process (1050℃)
Indicator:
pH neutral (6.8-7.2), porosity ≥65
Annual supply of horticultural substrate 200,000 tons
7. Core Services
Full-cycle support
EPC general contracting service: including process design-equipment installation-worker training
Intelligent operation and maintenance system: equipment health monitoring + remote fault diagnosis
