Preparation device and preparation method of red ceramsite for orchid planting

Abstract

The invention relates to the technical field of ceramsite production, and discloses a red ceramsite preparation device for orchid planting and a preparation method.The device comprises a combustion kiln, a top cover, a discharging mechanism, an oxygen distribution assembly and a base, the combustion kiln is of a parallel two-way kiln channel design, and the two kiln channels are symmetrically arranged in the reverse direction and are divided into a plurality of kiln chambers; air holes are formed between the kiln chambers to form airflow channels. Independent operation of a single kiln channel or closed-loop combustion of double kiln channels can be realized through opening and closing control of the ignition port and the ignition gate. Through the segmented oxygen supply system and the independently-controlled kiln chamber structure, precise regulation and control of the combustion process are achieved, and the system has the advantages of being high in heat energy utilization rate, high in production flexibility, stable in product quality and the like and is particularly suitable for batch production of ceramsite for orchid planting. The method is implemented based on the device and comprises the steps of burdening, segmented feeding, controllable combustion, discharged material recycling and the like, and the production efficiency and the product percent of pass can be remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of expanded clay production technology, specifically to a device and method for preparing red expanded clay for orchid cultivation. Background Technology

[0002] Orchid cultivation requires high levels of aeration, water retention, and stability in the growing medium, and red ceramsite, due to its porous structure, good drainage, and chemical inertness, has become one of the ideal cultivation media. However, the traditional preparation process of red ceramsite still faces many technical bottlenecks, restricting its large-scale production and quality improvement, specifically as follows:

[0003] In traditional ceramsite preparation processes, such as the single-kiln combustion design described in patent 201620231760.8 (an industrial sludge ceramsite preparation device), significant energy efficiency issues exist. While this technology achieves resource utilization of industrial sludge, the single-kiln structure necessitates preheating and ignition of the entire kiln for each production start-up, resulting in initial energy consumption reaching 25%-30% of total energy consumption. This design cannot flexibly adjust the kiln capacity according to actual production needs; even for small-batch production, the entire kiln must maintain a high-temperature operating state, leading to substantial waste of thermal energy.

[0004] Patent 201922375247.2 describes a system for preparing steel slag ceramsite, but its integrated roasting kiln system suffers from significant limitations in production flexibility. While this technical solution achieves continuous production of steel slag ceramsite through a combination of equipment such as a steel slag mill, auxiliary material mill, and granulator, its core roasting process still employs a single rotary kiln design, requiring whole-kiln feeding and overall firing. This rigid production model prevents companies from flexibly adjusting production scale according to market demand. Even when only a small quantity of specific ceramsite is needed, the entire roasting system must be activated, resulting in severe waste of energy and raw materials. Furthermore, the lack of zoned temperature control leads to uneven temperature distribution within the kiln, making it difficult to guarantee product performance consistency and further hindering quality improvement. This technological limitation sharply contradicts the current market demand for small-batch, multi-variety specialty ceramsite, necessitating the development of a new modular preparation system to achieve flexible production through improvements in kiln structure and control methods. Summary of the Invention

[0005] The purpose of this invention is to provide a device and method for preparing red ceramsite for orchid cultivation. Through the reverse symmetrical design of parallel bidirectional kiln channels and an independently controllable oxygen supply system, the combustion process can be precisely controlled by zone. At the same time, the closed-loop combustion mode is used to improve thermal efficiency, solving the technical problems of high energy consumption, inaccurate temperature control and poor production flexibility in traditional preparation processes, and providing high-quality and low-cost ceramsite matrix for orchid cultivation.

[0006] To achieve the above-mentioned technical objectives and effects, this invention discloses a red ceramsite preparation device for orchid cultivation, including a combustion kiln, a top cover, a discharge mechanism, an oxygen supply component, and a base. The combustion kiln is installed on the base, the top of the combustion kiln is provided with a top cover for feeding, the bottom of the combustion kiln is provided with a discharge mechanism for discharging, and the oxygen supply component is installed on both sides of the combustion kiln.

[0007] The combustion kiln adopts a parallel bidirectional kiln channel design, with two sets of kiln channels arranged in opposite directions and symmetrically. Each kiln channel has an ignition port at the beginning and a flue gas outlet at the end, which is connected to the exhaust gas purification component.

[0008] The kiln passage is divided into several kiln chambers, and each kiln chamber is provided with several air holes at intervals to form airflow channels for combustion.

[0009] An ignition port is provided between the kiln chamber at the beginning of the kiln tunnel and the kiln chamber at the end of another kiln tunnel, and an ignition gate is provided for opening and closing. When the ignition ports of both kiln tunnels are opened, the two kiln tunnels form a closed-loop combustion.

[0010] Preferably, the combustion kiln is constructed of refractory bricks, and the unloading mechanism and the top cover are covered with refractory material.

[0011] The top cover includes a cover body and a feed inlet, and each kiln chamber of the kiln channel is independently equipped with a top cover.

[0012] The unloading mechanism includes an unloading gate and an unloading gate opening and closing cylinder. The unloading gate is opened and closed by the unloading gate opening and closing cylinder. Each kiln chamber in the kiln is independently equipped with an unloading mechanism.

[0013] The oxygen distribution assembly includes a main oxygen distribution pipe connected to the pre-supply end and several branch oxygen distribution pipes. The oxygen supply between the main oxygen distribution pipe and the branch oxygen distribution pipes is controlled by an air volume control valve. Each kiln chamber in the kiln is independently equipped with a branch oxygen distribution pipe.

[0014] Preferably, it also includes a conveying component, which is disposed on the base. When the unloading mechanism starts unloading, the material is conveyed by the conveying component to the next section.

[0015] This invention also discloses a method for preparing red ceramsite for orchid cultivation. The preparation method is based on the above-mentioned preparation apparatus and includes at least the following steps:

[0016] S1. The workshop overhead crane hoists the prepared red ceramsite raw materials to the top of the combustion kiln and opens the kiln channel with the corresponding output according to production needs;

[0017] S2. The overhead crane feeds material through the feed inlet on the top cover of the combustion kiln, with the feeding depth being 1 / 2 to 2 / 3 of the kiln height;

[0018] S3. The kiln duct starter is opened for ignition, the oxygen supply component is activated to supply oxygen to the kiln chamber, and the ceramsite is prepared according to the combustion process.

[0019] S4. After the ceramsite is prepared, start the unloading mechanism to recover the granules.

[0020] In the step of "opening the igniter at the beginning of the kiln", when production needs require the opening of two sets of kilns, the ignition ports of the two sets of kilns are opened, and the igniter of one set of kilns is turned on to form a closed-loop combustion.

[0021] In the step of “opening the kiln chamber to supply oxygen”, the oxygen supply is controlled by the air volume control valve according to the different oxygen consumption at each stage of the combustion process.

[0022] The red ceramic aggregate raw materials include at least: municipal sludge, wood chips and / or bamboo chips after impurity removal, high-pressure filtration and dewatering.

[0023] The present invention has the following beneficial effects:

[0024] 1. Through the reverse symmetrical design of parallel bidirectional kiln channels and closed-loop combustion mode, the efficient recycling of thermal energy is achieved, significantly reducing fuel consumption, while improving combustion uniformity and ensuring stable sintering quality of ceramsite.

[0025] 2. It adopts an independently configured kiln chamber top cover, unloading mechanism and segmented oxygen supply system, which supports differentiated combustion control of different kiln chambers. It can flexibly select the single kiln independent operation mode or the dual kiln linkage mode according to production needs, thereby improving the flexibility of production scheduling.

[0026] 3. By using the staggered pore structure between kiln chambers and intelligent oxygen distribution control, the combustion transfer efficiency is optimized, avoiding local over-burning or under-burning, and ensuring the consistency of physical properties such as porosity and strength of the finished ceramsite.

[0027] 4. By using municipal sludge as the main raw material and combining it with auxiliary materials such as wood chips / bamboo chips, the resource utilization of urban solid waste is realized. After impurity removal and filter press pretreatment, the municipal sludge is efficiently converted into high-quality ceramsite in a closed-loop combustion system. This not only solves the problem of sludge disposal but also reduces raw material costs. At the same time, it ensures that the final product meets environmental protection standards, providing an innovative solution for urban solid waste treatment and resource recycling. Attached Figure Description

[0028] Figure 1 This is a perspective view of the preparation apparatus of the present invention.

[0029] Figure 2This is a perspective view of the preparation device of the present invention from another angle.

[0030] Figure 3 This is a structural diagram of the kiln chamber of the preparation apparatus of the present invention.

[0031] Symbol explanation:

[0032] 1. Combustion kiln; 2. Cover; 3. Feed inlet; 4. Discharge gate; 5. Discharge gate opening and closing cylinder; 6. Oxygen supply main pipe; 7. Oxygen supply branch pipe; 8. Air volume control valve; 9. Base; 10. Ignition port; 11. Ignition port; 12. Flue gas outlet; 13. Ignition gate. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments.

[0034] Example 1

[0035] like Figure 1-3 As shown, the present invention discloses a red ceramsite preparation device for orchid cultivation, including a combustion kiln 1, and also including a top cover, a discharge mechanism, an oxygen distribution component and a base 9. The combustion kiln 1 is installed on the base 9. The top of the combustion kiln 1 is provided with a top cover for feeding, and the bottom of the combustion kiln 1 is provided with a discharge mechanism for discharging. The oxygen distribution component is installed on both sides of the combustion kiln 1.

[0036] Kiln design:

[0037] The combustion kiln 1 adopts a parallel bidirectional kiln channel design, with two sets of kiln channels arranged in opposite directions and symmetrically. Each kiln channel has an ignition port 10 for ignition at the beginning and a flue gas outlet 12 at the end. The flue gas outlet 12 is connected to the exhaust gas purification component.

[0038] An ignition port 11 is provided between the kiln chamber at the beginning of the kiln channel and the kiln chamber at the end of another kiln channel, and an ignition gate 13 is provided for opening and closing. When the ignition ports 11 of both kiln channels are opened, the two kiln channels form a closed-loop combustion.

[0039] The combustion kiln 1 is constructed of refractory bricks, and the unloading mechanism and the top cover are covered with refractory materials. The refractory bricks used in the combustion kiln have a refractoriness of not less than 1580℃. The refractory material covering the unloading mechanism and the top cover is a high-alumina refractory castable, which can withstand a high temperature environment of 800℃ for a long time. The design length of the combustion kiln 1 and the spatial layout of each kiln chamber are optimized and adjusted according to the production capacity.

[0040] Kiln chamber design:

[0041] The kiln passage is divided into several kiln chambers, each of which is a smallest independent repeating unit.

[0042] The kiln chamber is provided with several air holes at intervals to form airflow channels for combustion. The top of the kiln chamber is provided with a top cover, which includes a cover body 2 and a feed inlet 3. The bottom of the kiln chamber is provided with a discharge mechanism, which includes a discharge gate 4 and a discharge gate opening and closing cylinder 5. The discharge gate 4 is opened and closed by the discharge gate opening and closing cylinder 5. An oxygen distribution branch pipe 7 connected to the oxygen distribution assembly is arranged inside the kiln chamber.

[0043] The oxygen distribution assembly includes a main oxygen distribution pipe 6 connected to the pre-supply end and branch oxygen distribution pipes 7 branching to each kiln chamber. The main oxygen distribution pipe 6 and the branch oxygen distribution pipes 7 are connected by an air volume control valve 8 to achieve precise oxygen distribution. The branch oxygen distribution pipes 7 of each kiln chamber are independently controlled, forming a combustion control system with zoned oxygen supply.

[0044] In terms of overall structural design, this invention can be well integrated with production lines without the need for excessive design such as oxygen supply and exhaust treatment equipment. The complete operation function of the equipment can be achieved by connecting it in series with existing oxygen supply terminals (such as air compressors or oxygen generators) and exhaust gas purification systems (including cyclone dust collectors, SCR denitrification devices, etc.).

[0045] Furthermore, based on the design of this invention, a conveying component can be added. The conveying component is set on the base 9. When the unloading mechanism starts unloading, the material is conveyed by the conveying component to the next section, achieving seamless connection with the grading and screening or packaging section.

[0046] Example 2

[0047] This embodiment is based on the red ceramsite preparation device for orchid cultivation proposed in Embodiment 1, and describes the corresponding production process.

[0048] This invention discloses a method for preparing red ceramsite for orchid cultivation, comprising the following steps:

[0049] S1. The workshop overhead crane hoists the prepared red ceramsite raw materials to the top of the combustion kiln and opens the kiln channel with the corresponding output according to production needs;

[0050] S2. The overhead crane feeds material through the feed inlet on the top cover of the combustion kiln, with the feeding depth being 1 / 2 to 2 / 3 of the kiln height;

[0051] S3. The kiln duct starter is opened for ignition, the oxygen supply component is activated to supply oxygen to the kiln chamber, and the ceramsite is prepared according to the combustion process.

[0052] S4. After the ceramsite is prepared, start the unloading mechanism to recover the granules.

[0053] In the step of "opening the igniter at the beginning of the kiln", when production needs require the opening of two sets of kilns, the ignition ports of the two sets of kilns are opened, and the igniter of one set of kilns is turned on to form a closed-loop combustion.

[0054] In the step of “opening the kiln chamber to supply oxygen”, the oxygen supply is controlled by the air volume control valve according to the different oxygen consumption at each stage of the combustion process.

[0055] Furthermore, considering the management of municipal sludge disposal, this embodiment proposes to use municipal sludge as the main raw material to replace the clay component in the traditional ceramsite formula. After removing impurities such as stones and plastics through mechanical screening, the moisture content is reduced from 80% to below 40% using high-hydraulic mechanical equipment, and then further reduced to below 30% through natural evaporation to obtain pretreated sludge that meets the process requirements.

[0056] The pretreated sludge is mixed with auxiliary raw materials (including sawdust / bamboo chips, clay, pore-forming materials, etc.) in an optimized ratio. The sawdust / bamboo chips mainly provide some heat, the clay mainly provides plastic components to improve molding performance, and the pore-forming materials are used to precisely control the pore structure of the product. This scientific batching scheme not only realizes the efficient resource utilization of municipal sludge, but also reduces the proportion of clay added by 40-60% compared with traditional processes, significantly reducing the cost of using high-value raw materials, while ensuring that the final ceramsite product has both good air permeability and water retention, providing an innovative solution for urban solid waste treatment and ceramsite production.

[0057] This invention discloses a method for preparing red expanded clay aggregate for orchid cultivation, which achieves a highly efficient and precise process through modular kiln design and an intelligent control system. The method combines automatic feeding by a traveling crane with staged oxygen supply, flexibly selecting either single-kiln independent operation or dual-kiln closed-loop combustion mode according to production needs. The oxygen supply to each kiln chamber is adjusted in real-time via air volume control valves to adapt to the oxygen consumption characteristics of different combustion stages. The entire process, from raw material feeding and ignition to finished product unloading, forms a complete automated production flow. The innovative closed-loop combustion design significantly improves thermal energy utilization efficiency, while precise oxygen supply control ensures the quality stability of the expanded clay aggregate product. This method is particularly suitable for the mass production of high-quality expanded clay aggregate for orchid cultivation, offering advantages such as simple operation, low energy consumption, and good product consistency.

[0058] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A device for preparing red ceramsite for orchid cultivation, comprising a combustion kiln, characterized in that, It also includes a top cover, a discharge mechanism, an oxygen distribution assembly, and a base. The combustion kiln is installed on the base. The top of the combustion kiln is provided with a top cover for feeding, and the bottom of the combustion kiln is provided with a discharge mechanism for discharging. The oxygen distribution assembly is installed on both sides of the combustion kiln. The combustion kiln adopts a parallel bidirectional kiln channel design, with two sets of kiln channels arranged in opposite directions and symmetrically. Each kiln channel has an ignition port at the beginning and a flue gas outlet at the end, which is connected to the exhaust gas purification component. The kiln passage is divided into several kiln chambers, and each kiln chamber is provided with several air holes at intervals to form airflow channels for combustion. An ignition port is provided between the kiln chamber at the beginning of the kiln tunnel and the kiln chamber at the end of another kiln tunnel, and an ignition gate is provided for opening and closing. When the ignition ports of both kiln tunnels are opened, the two kiln tunnels form a closed-loop combustion.

2. The apparatus for preparing red ceramsite for orchid cultivation as described in claim 1, characterized in that, The combustion kiln is constructed of refractory bricks, and the unloading mechanism and the top cover are covered with refractory materials.

3. The apparatus for preparing red ceramsite for orchid cultivation as described in claim 1, characterized in that, The top cover includes a cover body and a feed inlet, and each kiln chamber of the kiln channel is independently equipped with a top cover.

4. The apparatus for preparing red ceramsite for orchid cultivation as described in claim 1, characterized in that, The unloading mechanism includes an unloading gate and an unloading gate opening and closing cylinder. The unloading gate is opened and closed by the unloading gate opening and closing cylinder. Each kiln chamber in the kiln is independently equipped with an unloading mechanism.

5. The apparatus for preparing red ceramsite for orchid cultivation as described in claim 1, characterized in that, The oxygen distribution assembly includes a main oxygen distribution pipe connected to the pre-supply end and several branch oxygen distribution pipes. The oxygen supply between the main oxygen distribution pipe and the branch oxygen distribution pipes is controlled by an air volume control valve. Each kiln chamber in the kiln is independently equipped with a branch oxygen distribution pipe.

6. The apparatus for preparing red ceramsite for orchid cultivation as described in claim 1, characterized in that, It also includes a conveying component, which is mounted on the base. When the unloading mechanism starts unloading, the material is conveyed by the conveying component to the next section.

7. A method for preparing red ceramsite for orchid cultivation, characterized in that, The preparation method described herein is based on the preparation apparatus according to any one of claims 1-6, and includes at least the following steps: S1. The workshop overhead crane hoists the prepared red ceramsite raw materials to the top of the combustion kiln and opens the kiln channel with the corresponding output according to production needs; S2. The overhead crane feeds material through the feed inlet on the top cover of the combustion kiln, with the feeding depth being 1 / 2 to 2 / 3 of the kiln height; S3. The kiln duct starter is opened for ignition, the oxygen supply component is activated to supply oxygen to the kiln chamber, and the ceramsite is prepared according to the combustion process. S4. After the ceramsite is prepared, start the unloading mechanism to recover the granules.

8. The method for preparing red ceramsite for orchid cultivation as described in claim 7, characterized in that, In the step of "opening the igniter at the beginning of the kiln", when production needs require the opening of two sets of kilns, the ignition ports of the two sets of kilns are opened, and the igniter of one set of kilns is turned on to form a closed-loop combustion.

9. The method for preparing red ceramsite for orchid cultivation as described in claim 7, characterized in that, In the step of "opening the kiln chamber to supply oxygen with the oxygen distribution component", the oxygen supply is controlled by the air volume control valve according to the different oxygen consumption at each stage of the combustion process.

10. The method for preparing red ceramsite for orchid cultivation as described in claim 7, characterized in that, The raw materials for the red ceramic aggregates include at least: municipal sludge, wood chips, and / or bamboo chips that have been purified, dehydrated by high-pressure filtration, and treated with impurities.

Images