A device and method for preparing silt-free baking-free ceramic particles

Abstract

The application discloses a kind of sludge baking-free ceramic granule preparation device and method, belong to hydraulic engineering technical field, device includes stirring mechanism, feeding mechanism, granulating mechanism, screening mechanism and return mechanism;Stirring mechanism stores dry powder and stirs uniformly;Feeding mechanism is correspondingly arranged at the discharge port of stirring mechanism, dry powder and water are added to granulating mechanism;Granulating mechanism is correspondingly arranged at the discharge port of feeding mechanism, receives dry powder and water mixed uniformly and rotates so that mixture material rolls and forms ceramic granule;Screening mechanism is correspondingly arranged at the discharge port of granulating mechanism, ceramic granule meeting target size is transferred to collection box, and ceramic granule not meeting target size is transferred to return mechanism;Return mechanism is arranged between screening mechanism and granulating mechanism, and ceramic granule not meeting target size is returned to granulating mechanism for regranulation.The application can solve the problem that there is no special ceramic granule preparation device, which affects the industrialization of baking-free ceramic granule.

Description

Technical Field

[0001] This invention relates to an apparatus and method for preparing non-fired ceramsite from silt, belonging to the field of water conservancy engineering technology. Background Technology

[0002] Every year, due to the massive accumulation of silt, riverbeds rise continuously, leading to a weakening of lakes' ability to regulate water flow, reduced water supply and drought resistance, shrinking navigation, water pollution, and a declining aquatic environment. Therefore, periodic dredging of river channels is necessary. If massive amounts of silt are not effectively treated and are discharged indiscriminately, they will not only encroach on large amounts of farmland but also pollute surrounding water bodies and soil, causing serious environmental problems. Therefore, the scientific treatment and resource utilization of silt is of significant practical importance.

[0003] Currently, silt resources can be utilized as raw materials for ceramsite production. The main technologies for preparing ceramsite from river and lake silt both domestically and internationally are high-temperature sintering and non-sintering methods. The sintering method requires the river and lake silt to be dried and dehydrated first; some studies even require pre-incineration of the silt into silt ash to be combined with other additives to prepare ceramsite. This method is complex, energy-intensive, and causes significant pollution. The non-sintering method overcomes these drawbacks, but current traditional non-sintering methods produce ceramsite with inconsistent particle sizes and lack stable equipment for producing non-sintered ceramsite, making industrialization difficult.

[0004] Current research on non-fired ceramsite preparation methods largely remains at the laboratory granulation stage. Existing methods face difficulties in particle size control, easily resulting in inconsistent particle sizes. Ceramsite with excessively small particle sizes reduces the compressive strength of the ceramsite aggregate and negates its lightweight and heat-insulating advantages. Therefore, there is an urgent need for a dedicated preparation device capable of continuous and efficient granulation with controllable particle size. However, the current lack of mature and suitable ceramsite preparation equipment hinders the industrial-scale promotion of non-fired ceramsite. Summary of the Invention

[0005] The purpose of this invention is to provide a device and method for preparing non-fired ceramsite from sludge. This invention can perform continuous and efficient granulation, control the particle size, avoid raw material waste, and improve the yield of ceramsite that meets the target size. It solves the problem of lacking a dedicated ceramsite preparation device, which has affected the industrialization and promotion of non-fired ceramsite.

[0006] To solve the above problems, the technical solution adopted by the present invention is as follows:

[0007] In a first aspect, the present invention provides a device for preparing non-fired ceramsite from sludge, comprising a stirring mechanism, a feeding mechanism, a granulation mechanism, a screening mechanism, and a return mechanism; the stirring mechanism stores and mixes dry powder, the dry powder comprising dehydrated sludge; the feeding mechanism is located at the outlet of the stirring mechanism and adds the mixed dry powder and water to the granulation mechanism; the granulation mechanism is located at the outlet of the feeding mechanism and receives the mixed dry powder and water and rotates it to form ceramsite; the screening mechanism is located at the outlet of the granulation mechanism and transfers ceramsite that meets the target size to a collection box and transfers ceramsite that does not meet the target size to the return mechanism; the return mechanism is located between the screening mechanism and the granulation mechanism and returns ceramsite that does not meet the target size to the granulation mechanism for re-granulation.

[0008] The aforementioned sludge-free ceramsite preparation device also includes a control system; the stirring mechanism, feeding mechanism, granulation mechanism, screening mechanism, and return mechanism are each signal-connected to the control system; or, the stirring mechanism, feeding mechanism, granulation mechanism, screening mechanism, and return mechanism are each signal-connected to the control system; the control system is equipped with three buttons: start, stop, and alarm. The start and stop buttons serve as on-site start and stop buttons for the preset preparation program of the control system, and the alarm button is used to send a signal to an external monitoring terminal on-site to remind staff to remotely control the control system; it also includes a monitoring mechanism, which is installed on the top of the sludge-free ceramsite preparation device for real-time monitoring and recording of the entire ceramsite preparation process; the video signals collected by the monitoring mechanism are transmitted to an external monitoring terminal for staff to observe the device's operating status and ceramsite preparation, and manually adjust the control parameters of the preparation program based on the feedback from the monitoring screen.

[0009] The aforementioned sludge-free ceramsite preparation device includes a mixing mechanism comprising: a mixing chamber, a mixing drive motor, a mixing shaft, mixing blades, a slide rail, and an electric cover plate; the mixing chamber stores dry powder and has an opening at the top; the output shaft of the mixing drive motor is connected to the mixing shaft extending into the mixing chamber, and the mixing drive motor signal is connected to the control system; the mixing shaft inside the mixing chamber is circumferentially equipped with mixing blades; two electric cover plates are installed on the slide rail at the top opening of the mixing chamber, driven by the control system, and slide in opposite directions along the slide rail to open or close the top opening of the mixing chamber; the bottom of the mixing chamber is equipped with a feeding solenoid valve for controlling the opening and closing of the bottom of the mixing chamber and a weight sensor for collecting the weight data of the mixing chamber; the feeding mechanism includes an electric... The system comprises a turntable, a screw conveyor, and a spraying unit. The screw conveyor's inlet is connected to the feeding solenoid valve of the mixing chamber. The feeding solenoid valve's signal is connected to the control system, which opens the solenoid valve to feed material into the screw conveyor or closes it to stop feeding material into the screw conveyor. The screw conveyor is connected to the rotating end of the electric turntable, which in turn is connected to the control system. The turntable's signal is connected to the control system, which rotates the screw conveyor to adjust its output angle so that it is aligned with or away from the feeding end of the granulation mechanism. The screw conveyor's drive unit is connected to the control system to add the mixed dry powder to the granulation mechanism. The spraying unit's drive unit is connected to the control system to add water to the granulation mechanism.

[0010] The aforementioned sludge-free ceramsite preparation device includes a spraying unit comprising a telescopic support, a spray pipe, and a brush. The telescopic support comprises a fixed frame, a telescopic component, and a rotary drive component connected in sequence. The fixed end of the fixed frame is connected to the fixed end of the telescopic component, and the telescopic end of the telescopic component is connected to the rotary drive component. The telescopic component is connected to the control system via a signal, and its extension or retraction according to the control system signal drives the rotary drive component to enter or exit the feed end of the granulation mechanism. A rotating rod extends from the end opening of the rotary drive component. One end of the rotating rod is rotatably connected to the inside of the rotary drive component, and the other end of the rotating rod outside the rotary drive component is symmetrically connected to the spray pipe and the brush. The rotary drive component is provided with a water inlet connected to an external water supply. The water inlet is connected to the rotating rod and the spray pipe via a pipeline, and the spray pipe is evenly distributed with atomizing nozzles. The rotary drive component is connected to the control system via a signal, and its rotation is driven by the control system signal. The granulation mechanism is provided with an electric gate as a discharge port. The electric gate is connected to the control system via a signal. A waste trough is provided outside the discharge port of the granulation mechanism to receive and discharge waste generated by cleaning the granulation mechanism.

[0011] The aforementioned sludge-free ceramsite preparation device includes a rotary drive unit with a built-in rotary joint, a driven gear, a driving gear, a rotary rod motor, and a positioning bearing. The inlet pipe connects to the fixed end of the rotary joint; the rotating end pipe of the rotary joint connects to the rotating rod; driven gears and positioning bearings are fixed at different heights on the outer circumference of the rotating rod within the rotary drive unit; the driven gear meshes with the driving gear ring; the driving gear is connected to the output end of the rotary rod motor; the rotary rod motor drive unit's signal is connected to the control system; the inner ring of the positioning bearing connects to the outer circumference of the rotating rod, and the outer ring is fixed inside the rotary drive unit.

[0012] The aforementioned sludge-free ceramsite preparation device includes a telescopic component comprising a first rotating block, a first telescopic rod, a second rotating block, and a second telescopic rod connected in sequence; the first rotating block and the second rotating block are each equipped with a servo motor; the end of the fixed frame is connected to the fixed end of the first telescopic rod via the first rotating block, and the telescopic end of the first telescopic rod is connected to the fixed end of the second telescopic rod via the second rotating block; the first rotating block drives the first telescopic rod to rotate around the axis of the end of the fixed frame; the second rotating block drives the second telescopic rod to rotate around the axis of the telescopic end of the first telescopic rod; the first telescopic rod drive unit and the second telescopic rod drive unit respectively drive the telescopic ends of the first and second telescopic rods to extend and retract; the servo motors, the first telescopic rod drive unit, and the second telescopic rod drive unit are respectively signal-connected to the control system.

[0013] The aforementioned sludge-free ceramsite preparation device includes a granulation mechanism comprising a circular pot, a circular pot rotary motor, a bottom plate, and an inclination adjustment unit. The circular pot opening serves as the feed end, and a weight sensor is mounted on the bottom of the pot and rotatably connected to the bottom plate via a slewing bearing. The circular pot rotary motor is fixed to the lower surface of the bottom plate, and its output end passes through the bottom plate surface to connect to a drive gear located on the upper plate surface. The drive gear meshes with the outer ring gear of the slewing bearing. The inner ring of the slewing bearing is fixedly connected to the bottom plate, and its outer ring is fixedly connected to the bottom of the circular pot. The circular pot rotary motor drive unit drives the circular pot rotary motor, rotating the outer ring of the slewing bearing and the circular pot through gear meshing. The circular pot rotary motor drive unit is connected to the control system. The inclination adjustment unit is connected to the bottom plate and is connected to the control system to adjust the tilt angle of the circular pot. The inclination adjustment unit includes a frame, a tilting linkage, a slider, a lead screw, a bottom plate rotary motor, and... The system includes a support with a slide rail; a frame hinged to one end of the base plate; the support is fixed to the frame under the base plate; a base plate rotary motor is fixed to the support, and the output end of the base plate rotary motor is connected to a lead screw; the drive motor signal of the base plate rotary motor is connected to the control system; a slider meshing with the lead screw is fitted around the lead screw; the slider has a groove that engages with the slide rail; the base plate rotary motor drives the lead screw to rotate, converting the rotational motion of the lead screw into the linear motion of the slider along the base plate slide rail; one end of an inclined connecting rod is rotatably connected to a fixed point on the base plate, and the other end is rotatably connected to the slider; the slider slides along the base plate slide rail to adjust the inclination angle between the base plate and the frame hinge point; the side wall of the round pot is equipped with an electric gate connected to the control system; the lower end of the base plate is equipped with a proximity switch receiver, and the electric gate is equipped with a corresponding proximity switch transmitter; the proximity switch receiver and transmitter are respectively connected to the control system, so that when the electric gate is aligned with the lower end of the base plate, the electric gate serves as the discharge port of the granulation mechanism.

[0014] The aforementioned sludge-free ceramsite preparation device includes a screening mechanism mounted on a movable support, comprising a screen, a vibrating motor, and a feed guide trough. The screen is evenly distributed with a perforated mesh and is inclined, with the higher end serving as the feed end and the lower end as the discharge end. The screen separates ceramsite of different sizes into oversize and undersize particles. The oversize particles, conforming to the target size, are discharged into a collection box from the discharge end, while the undersize particles, not conforming to the target size, pass through the screen and fall into the feed end of the return mechanism below. The vibrating motor, acting as the excitation source, is mounted on both sides of the screen to drive its vibration. The drive unit of the vibrating motor is connected to the control system. The feed guide trough is connected to the feed end of the screen and receives the ceramsite output from the granulation mechanism, guiding it into the central area of ​​the screen. The movable support is driven by... The unit signal is connected to the control system, which drives the moving bracket to work according to the control system signal, causing the feed guide channel to align with or move away from the discharge port of the granulation mechanism; the moving bracket includes two parallel bracket slide rails and a base slidably connected to the two bracket slide rails; a screening mechanism is installed on the base; each bracket slide rail has a limit plate at both ends, and when the base contacts the limit plate, the feed guide channel aligns with or moves away from the discharge port of the granulation mechanism; the moving bracket drive unit uses a cylinder, the cylinder body is fixed to the bracket slide rail, and the piston rod end is connected to the base; the solenoid valve signal of the cylinder is connected to the control system, and by controlling the cylinder's air intake and exhaust, the base is driven to slide back and forth between the limit positions at both ends of the bracket slide rail, so that the feed guide channel aligns with or moves away from the discharge port of the granulation mechanism.

[0015] The aforementioned sludge-free ceramsite preparation device includes a return mechanism comprising a return guide trough, a conveyor belt with evenly distributed partitions, and a hopper with a solenoid valve and a weight sensor at the bottom, connected in sequence. The conveyor belt drive unit, the solenoid valve and weight sensor of the hopper, and the hopper rotation drive unit are respectively signal-connected to the control system. The return guide trough is located below the screen to receive ceramsite that does not meet the target size and guides it to the feed end of the conveyor belt. The conveyor belt drive unit drives the conveyor belt to move upward at an incline, lifting and transporting the ceramsite through the partitions. The hopper connected to the discharge end of the conveyor belt is driven by the hopper rotation drive unit to rotate around the discharge end of the conveyor belt, so that the hopper closes the discharge end of the conveyor belt before the conveyor belt starts, and rotates to the open horizontally upward after the conveyor belt starts to receive the returned ceramsite. After the hopper reaches the preset weight, the solenoid valve is opened to return the ceramsite to the granulation mechanism.

[0016] In a second aspect, the present invention provides a method for preparing non-fired ceramsite from sludge, comprising preparing ceramsite according to the non-fired ceramsite preparation device for sludge as described in the first aspect, including: storing and mixing dry powder through a stirring mechanism; adding the mixed dry powder and water to the granulation mechanism through a feeding mechanism; receiving the mixed dry powder and water through the granulation mechanism and rotating it to form ceramsite by rolling the mixture; transferring ceramsite that meets the target size to a collection box through a screening mechanism and transferring ceramsite that does not meet the target size to the return mechanism; and returning ceramsite that does not meet the target size to the granulation mechanism for re-granulation through the return mechanism; wherein the dry powder comprises: mineral powder, dehydrated sludge and solid water glass in a mass ratio of 1200:1800:78.1, or sodium perborate, mineral powder, dehydrated sludge and solid water glass in a mass ratio of 450:1000:4000:130.2.

[0017] The beneficial effects achieved by this invention are as follows:

[0018] The sludge-free ceramsite preparation device of the present invention integrates the mixing, feeding, granulation, screening and return processes through the design of a feeding mechanism, a stirring mechanism, a granulation mechanism, a screening mechanism and a return mechanism, so as to achieve continuous and efficient granulation, control the particle size, avoid raw material waste and improve the yield of ceramsite that meets the target size, and solve the problem of lack of mature ceramsite preparation device, which affects the industrialization and promotion of non-fired ceramsite.

[0019] To facilitate industrialization, the sludge-free ceramsite preparation device of the present invention automatically completes the ceramsite preparation process in a cycle according to a preset preparation program through a control system, and monitors the on-site situation in real time through a monitoring agency, so that the staff can adjust the control parameters of the preparation program in a timely manner.

[0020] The various mechanisms of the sludge-free ceramsite preparation device of the present invention can efficiently and coordinately complete the ceramsite preparation, as detailed below:

[0021] The mixing mechanism of the present invention can mix dry powder evenly, and quantitatively feed the material to the feeding mechanism through the feeding solenoid valve and weight sensor at the bottom of the mixing chamber. The screw conveyor of the feeding mechanism is aligned with the feeding end of the granulation mechanism only when it is necessary to feed the material to the granulation mechanism, so as to avoid interference with other mechanisms. It also allows the monitoring mechanism above to more completely monitor the image inside the feeding end of the granulation mechanism after the feeding is completed.

[0022] The granulation mechanism of this invention is equipped with an angle adjustment unit, which can adjust the tilt angle to adapt to more granulation scenarios; the spraying unit, through a telescopic component, can enter the feeding end of the granulation mechanism only when needed; the spraying unit integrates a brush and a spray pipe, which can not only perform water spraying operations but also perform brushing operations on the granulation mechanism, and the design of the telescopic component can adjust the different working heights and working surface tilt angles of the brush and the spray pipe, so that during operation, the working surfaces of the brush and the spray pipe are always parallel to the plane direction of the feeding end of the granulation mechanism.

[0023] The rotary drive component of the spraying unit of this invention has a built-in rotary joint. The addition of the rotary joint solves the contradiction between the static water supply path and the rotating water outlet path. The rotary joint has a sealed overall structure, with its fixed end stationary and its rotating end able to rotate freely. Water passes sequentially through the water supply pipe, the water inlet end, the rotary joint, the rotating rod, and the spray pipe, and is finally sprayed out from the atomizing nozzle on the spray pipe.

[0024] The discharge port of the granulation mechanism of the present invention adopts an electric gate integrated into the side wall of the round pot, and the position is determined by the position detection achieved by the proximity switch receiving end and the transmitting end, ensuring that the unloading operation of the granulation mechanism can only be carried out in the only correct position, effectively preventing malfunction and material leakage.

[0025] The screening mechanism of the present invention can effectively switch between a working position and an idle position. In the working position, the feed guide channel of the screening mechanism is aligned with the discharge port of the granulation mechanism, while in the idle position, the feed guide channel of the screening mechanism is away from the discharge port of the granulation mechanism, exposing the waste trough, so as to avoid waste contaminating the screening mechanism and affecting the granulation quality.

[0026] The return feeding mechanism of the present invention includes a return feeding guide trough, a conveyor belt with evenly distributed partitions connected in sequence, and a hopper with a solenoid valve and a weight sensor at the bottom. Before the return feeding starts, the hopper is used to close the conveyor belt. After the return feeding starts, the hopper rotates to receive the returned ceramsite with the opening horizontally upward. After the hopper reaches the preset weight, the solenoid valve is opened to return the ceramsite to the granulation mechanism. This design avoids the returned ceramsite from entering the granulation mechanism too early, affecting the original granulation process and weight calculation. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the structure of a silt-free ceramsite preparation device according to Embodiment 1 of the present invention;

[0029] Figure 2 This is a schematic diagram of the stirring mechanism of a sludge-free ceramsite preparation device according to Embodiment 1 of the present invention;

[0030] Figure 3 This is a schematic diagram of the structure of a spraying unit in a sludge-free ceramsite preparation device according to Embodiment 1 of the present invention;

[0031] Figure 4 This is a schematic diagram of the internal structure of a rotary drive component in a sludge-free ceramsite preparation device according to Embodiment 1 of the present invention;

[0032] Figure 5 This is a schematic diagram of the granulation mechanism of a sludge non-fired ceramsite preparation device according to Embodiment 1 of the present invention;

[0033] Figure 6 This is a schematic diagram of the tilt angle adjustment unit of a sludge-free ceramsite preparation device according to Embodiment 1 of the present invention;

[0034] Figure 7 This is a schematic diagram of the screening mechanism of a sludge-free ceramsite preparation device according to Embodiment 1 of the present invention;

[0035] Figure 8 This is a schematic diagram of the structure of a return mechanism of a sludge non-fired ceramsite preparation device according to Embodiment 1 of the present invention;

[0036] Explanation of reference numerals in the attached figures:

[0037] 1-Pelletizing mechanism; 100-Round pot; 101-Round pot rotary motor; 102-Base plate; 103-Frame; 104-Inclined connecting rod; 105-Slider; 106-Lead screw; 107-Base plate rotary motor; 108-Base plate slide rail; 109-Support; 2-Monitoring mechanism; 3-Spraying unit; 301-Telescopic bracket; 3011-Fixed frame; 30110-First rotating block; 3012-First telescopic rod; 30120-Second rotating block; 3013-Second telescopic rod; 3014-Rotation drive component; 30140-Rotating rod; 30141-Rotary joint; 30142-Driven gear; 30143-Drive gear; 30144-Rotating rod rotary motor; 30145-Positioning bearing; 301 46-Water inlet; 302-Spray pipe; 303-Drain brush; 4-Agitating mechanism; 401-Agitating bin; 402-Agitating drive motor; 403-Agitating shaft; 404-Agitating blades; 405-Agitating bin slide rail; 406-Electric cover plate; 5-Feeding mechanism; 6-Electric gate; 7-Screening mechanism; 701-Screen; 702-Vibration motor; 703-Feed guide channel; 7041-Support slide rail; 7042-Base; 8-Returning mechanism; 801-Returning guide channel; 802-Baffle plate; 803-Conveyor belt; 804-Conveyor belt drive unit; 805-Hopper; 806-Hopper rotation drive unit; 9-Control system; 10-Collection box; 11-Waste trough; 12-Water supply pipe; 1201-Limit ring. Detailed Implementation

[0038] The technical solutions of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use.

[0039] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to explain the relative positional relationship and movement between components in a specific posture. If the specific posture changes, the directional indication will also change accordingly. These terms are used only for the convenience of describing the invention and for simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the invention. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0040] Furthermore, in the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0041] Example 1

[0042] This embodiment describes a device for preparing non-fired ceramsite from silt, such as... Figure 1 As shown, the system includes a stirring mechanism 4, a feeding mechanism 5, a granulation mechanism 1, a screening mechanism 7, and a return mechanism 8. The stirring mechanism 4 stores and mixes dry powder, which includes dehydrated sludge. The feeding mechanism 5 is located at the outlet of the stirring mechanism 4 and adds the mixed dry powder and water to the granulation mechanism 1. The granulation mechanism 1 is located at the outlet of the feeding mechanism 5, receives the mixed dry powder and water, and rotates it to form ceramsite. The screening mechanism 7 is located at the outlet of the granulation mechanism 1 and transfers ceramsite that meets the target size to the collection box 10 and transfers ceramsite that does not meet the target size to the return mechanism 8. The return mechanism 8 is located between the screening mechanism 7 and the granulation mechanism 1 and returns ceramsite that does not meet the target size to the granulation mechanism 1 for regranulation.

[0043] The sludge-free ceramsite preparation device of this embodiment also includes a control system 9; the stirring mechanism 4, feeding mechanism 5, granulation mechanism 1, screening mechanism 7 and return mechanism 8 are respectively signal-connected to the control system 9, and under the control of the preset preparation program of the control system 9, the sludge-free ceramsite preparation device can automatically complete the ceramsite preparation process. Figure 1As shown, the control system 9 has three buttons: start, stop, and alarm. The start and stop buttons serve as on-site start and stop buttons for the preset preparation program of the control system 9, respectively. The alarm button is used to send a signal to an external monitoring terminal to remind staff to remotely control the control system 9. The sludge-free ceramsite preparation device of this embodiment can automatically execute the sludge-free ceramsite preparation according to a preset preparation program, or it can remotely control the sludge-free ceramsite preparation process. It can also send a signal on-site to remind staff to remotely take over the control of the sludge-free ceramsite preparation device. The sludge-free ceramsite preparation device of this embodiment also includes a monitoring mechanism 2, which is installed on the top of the device and used to monitor and record the entire ceramsite preparation process in real time. The video signals collected by the monitoring mechanism 2 are transmitted to an external monitoring terminal, allowing staff to observe the device's operating status and ceramsite preparation status, and manually adjust the control parameters of the preparation program based on the feedback from the monitoring screen. The control parameters include the start and stop timing of each mechanism, the start duration, the execution sequence of each mechanism's process, and the switching from the granulation process to the washing process.

[0044] Based on the three control methods described above for the preparation of sludge-based non-fired ceramsite, the sludge-based non-fired ceramsite preparation device can upgrade ceramsite production from an operation dependent on manual experience to a precise, stable, and remotely manageable modern industrial process. Specifically, this is manifested in: avoiding human error by executing preset preparation programs; adjusting programs in real time through remote control to meet the actual preparation process requirements on site; and providing real-time alarms and remote intervention, enabling immediate warnings and allowing professional personnel to remotely intervene for diagnosis or intervention when abnormalities are detected on site, without requiring professional personnel to be stationed on site, promptly contacting off-site assistance, and reducing the requirements for on-site personnel's familiarity with the procedures. The three control methods complement each other, thereby better realizing the industrialization and promotion of non-fired ceramsite.

[0045] like Figure 2 As shown, the stirring mechanism 4 includes: a stirring chamber 401, a stirring drive motor 402, a stirring shaft 403, stirring blades 404, a stirring chamber slide rail 405, and an electric cover plate 406; the stirring chamber 401 stores dry powder and has an opening at the top; the output shaft of the stirring drive motor 402 is connected to the stirring shaft 403 extending into the stirring chamber 401, and the stirring drive motor 402 is signal-connected to the control system 9; the stirring shaft 403 inside the stirring chamber 401 is circumferentially equipped with stirring blades 404; two electric cover plates 406 are installed on the stirring chamber slide rail 405 at the top opening of the stirring chamber 401, driven by the control system 9, and slide towards or away from each other along the stirring chamber slide rail 405 to open or close the top opening of the stirring chamber 401; Figure 2As shown, the two electric cover plates 406 are respectively provided with grooves that fit the stirring shaft 403, so that the electric cover plates 406 cooperate with the stirring shaft 403 to seal the stirring chamber 401, and the stirring blades 404 at the end of the stirring shaft 403 can stir and mix the dry powder in the sealed stirring chamber 401.

[0046] The bottom of the mixing chamber 401 is equipped with a feeding solenoid valve for controlling the opening and closing of the bottom of the mixing chamber 401 and a weight sensor for collecting weight data of the mixing chamber 401; such as Figure 1 As shown, the feeding mechanism 5 includes an electric turntable, a screw conveyor, and a spraying unit 3. The feed inlet of the screw conveyor is connected to the feeding solenoid valve of the mixing chamber 401. The feeding solenoid valve signal is connected to the control system 9. According to the signal of the control system 9, the feeding solenoid valve is opened to feed material into the screw conveyor or closed to stop feeding material into the screw conveyor. The screw conveyor is connected to the rotating end of the electric turntable. The electric turntable signal is connected to the control system 9. According to the signal of the control system 9, the screw conveyor is rotated by an angle so that the output port of the screw conveyor is aligned with or away from the feed end of the granulation mechanism 1. The drive unit of the screw conveyor is connected to the control system 9 to add the mixed dry powder into the granulation mechanism 1. The drive unit of the spraying unit 3 is connected to the control system 9 to add water into the granulation mechanism 1.

[0047] In this embodiment, the screw conveyor serves as a metering and conveying component, connecting to and supporting the upper mixing chamber 401 via its inlet. The control system 9 drives the electric turntable to rotate, swinging the screw conveyor's outlet to align with the inlet of the granulation mechanism 1, i.e., the opening of the circular pot 100. The drive unit of the screw conveyor is then activated, and according to a preset speed and time, the built-in screw rotates to quantitatively and continuously add the mixed dry powder to the granulation mechanism 1. After feeding is complete, the electric turntable rotates again, moving the screw conveyor back to its standby position to avoid interference with other mechanisms and allowing the upper monitoring mechanism 2 to more completely monitor the contents of the circular pot 100 after feeding.

[0048] like Figure 1 and Figure 3As shown, the spraying unit 3 includes a telescopic bracket 301, a spray pipe 302, and a brush 303; the telescopic bracket 301 includes a fixed frame 3011, a telescopic component, and a rotary drive component 3014 connected in sequence; the fixed end of the fixed frame 3011 is connected to the fixed end of the telescopic component, the telescopic end of the telescopic component is connected to the rotary drive component 3014, the telescopic component is connected to the control system 9, and the telescopic component extends and retracts according to the signal of the control system 9 to drive the rotary drive component 3014 to enter or exit the feed end of the granulation mechanism 1; the rotary drive component 3014 has an opening at its end from which a rotating rod 3014 extends. 0. One end of the rotating rod 30140 is rotatably connected to the inside of the rotating drive component 3014, and the other end of the rotating rod 30140 outside the rotating drive component 3014 is symmetrically connected to the nozzle 302 and the brush 303. The rotating drive component 3014 is provided with a water inlet end 30146 connected to the external water supply. The water inlet end 30146 is connected to the rotating rod 30140 and the nozzle 302 in sequence through pipes. The nozzle 302 is evenly distributed with atomizing nozzles. The rotating drive component 3014 is signal-connected to the control system 9, and drives the rotating rod 30140 to rotate according to the signal of the control system 9. The water inlet end 30146 is provided with a water meter (not shown in the figure) to measure the water supply. Figure 4 As shown, in this embodiment, the water inlet 30146 is connected to the atomizing nozzle of the spray pipe 302 through the built-in pipe of the rotary drive 3014.

[0049] like Figure 4 As shown, the rotary drive component 3014 includes a rotary joint 30141, a driven gear 30142, a driving gear 30143, a rotary rod rotary motor 30144, and a positioning bearing 30145. The water inlet end 30146 is connected to the fixed end of the rotary joint 30141. The rotating end of the rotary joint 30141 is connected to the rotary rod 30140. Driven gears 30142 and positioning bearings 30145 are fixed at different heights on the outer periphery of the rotary rod 30140 within the rotary drive component 3014. Driven gear 30142 meshes with the gear ring of the driving gear 30143. The driving gear 30143 is connected to the output end of the rotary rod rotary motor 30144. The rotary rod rotary motor drive unit is connected to the control system 9. The inner ring of the positioning bearing 30145 is connected to the outer periphery of the rotary rod 30140, and the outer ring is fixed inside the rotary drive component 3014.

[0050] The addition of the rotary joint 30141 resolves the conflict between the static water supply path and the rotating water outlet path; the rotary joint 30141 has a sealed overall structure, with its fixed end stationary while its rotating end can rotate freely; for example... Figure 4 As shown, water passes sequentially through the water supply pipe 12, the water inlet end 30146, the rotary joint 30141, the rotating rod 30140, and the nozzle 302, and is finally sprayed out from the atomizing nozzle on the nozzle 302.

[0051] According to the signal from the control system 9, the rotary rod rotary motor drive unit drives the drive gear 30143 to rotate, thereby driving the rotary rod 30140 to rotate through the driven gear 30142. At the same time, the positioning bearing 30145 provides radial support for the rotary rod 30140, so that the rotary rod 30140 rotates around its own axis without deflection.

[0052] like Figure 3 As shown, the telescopic component includes a first rotating block 30110, a first telescopic rod 3012, a second rotating block 30120, and a second telescopic rod 3013 connected in sequence; the first rotating block 30110 and the second rotating block 30120 are respectively equipped with servo motors; the end of the fixed frame 3011 is connected to the fixed end of the first telescopic rod 3012 through the first rotating block 30110, and the telescopic end of the first telescopic rod 3012 is connected to the fixed end of the second telescopic rod 3013 through the second rotating block 30120; the first rotating block 30110 drives the first telescopic rod 3012 to rotate around the axis of the end of the fixed frame 3011; the second rotating block 30120 drives the second telescopic rod 3013 to rotate around the axis of the telescopic end of the first telescopic rod 3012; the first telescopic rod drive unit and the second telescopic rod drive unit respectively drive the telescopic ends of the first telescopic rod 3012 and the second telescopic rod 3013 to extend and retract; the servo motors, the first telescopic rod drive unit, and the second telescopic rod drive unit are respectively signal-connected to the control system 9.

[0053] The control system 9 coordinates the rotation angle and extension stroke of the two telescopic rods, enabling the second telescopic rod 3013 to always extend and retract along the plane perpendicular to the feed end of the granulation mechanism 1 with an adjustable tilt angle, thereby allowing the nozzle 302 and brush 303 to enter or exit the feed end of the granulation mechanism 1, and adjusting the height of the nozzle 302 and brush 303 to adapt to water spraying and brushing operations.

[0054] like Figure 3 As shown, the nozzle 302 is connected to an external water supply via a water supply pipe 12. Limiting rings 1201 for the water supply pipe 12 are distributed on the fixed ends of the fixing frame 3011 and the first telescopic rod 3012. The water supply pipe 12 is typically made of a non-rigid material. The limiting rings 1201 are used to constrain the extension path of the water supply pipe 12 to prevent it from sagging and touching the round pot 100, causing wear or affecting the rotation of the round pot 100.

[0055] like Figure 1 and Figure 3As shown, the first rotating block 30110 rotates at an angle such that the first telescopic rod 3012 is horizontal to the feed end plane of the granulation mechanism 1, and the telescopic end of the first telescopic rod 3012 extends or retracts horizontally towards or away from the feed end plane of the granulation mechanism 1; the second rotating block 30120 rotates at an angle such that the second telescopic rod 3013 is perpendicular to the feed end plane of the granulation mechanism 1, and the telescopic end of the second telescopic rod 3013 extends or retracts perpendicularly towards or away from the feed end plane of the granulation mechanism 1. This is because the feed end of the granulation mechanism 1, i.e., the round pot 100, has an adjustable tilt angle. Therefore, the extension and retraction of the first telescopic rod 3012 and the second telescopic rod 3013 need to be adapted to the tilt angle of the round pot 100. The telescopic end of the second telescopic rod 3013 enters or exits the round pot 100 opening perpendicularly to the plane of the round pot 100 opening.

[0056] When starting work:

[0057] The telescopic end of the second telescopic rod 3013 enters the working position, moves horizontally above the granulation mechanism 1 with the opening of the round pot 100, and then extends vertically into the granulation mechanism 1. After the first telescopic rod 3012 extends horizontally above the granulation mechanism 1 with the feed end of the granulation mechanism 1, the second telescopic rod 3013 extends vertically into the granulation mechanism 1 with the feed end of the granulation mechanism 1.

[0058] When spraying water, adjust the extension stroke of the second telescopic rod 3013 so that the spray pipe 302 is close to the mouth of the round pot 100 and the brush 303 does not contact the bottom of the round pot 100. The spray pipe 302 rotates and sprays water. The rotating rod and the rotating motor 30144 drive the spray pipe 302 to rotate and form a horizontal circular water spray surface.

[0059] During cleaning, the extension and retraction stroke of the second telescopic rod 3013 is adjusted so that the brush 303 contacts the bottom of the round pot 100. The brush 303 rotates to clean, and the rotating rod and the rotating motor 30144 drive the brush 303 to rotate to form a horizontal circular cleaning surface.

[0060] At the end of the work:

[0061] When the device is reset and withdrawn, the second telescopic rod 3013 retracts to the outside of the granulation mechanism 1, driving the nozzle 302 and brush 303 to exit the granulation mechanism 1 vertically, and the first telescopic rod 3012 retracts to a position away from the granulation mechanism 1.

[0062] The spraying unit 3 is activated according to the signal from the control system 9, adding atomized water to the granulation mechanism 1 in the form of spray. The feeding mechanism 5 achieves switching and positioning of the feeding point through an electric turntable, realizes the metering and conveying of dry powder through a screw conveyor, and realizes uniform spraying of water through the spraying unit 3. All of these are centrally controlled by the control system 9, and can automatically complete the addition of dry and wet materials to the granulation mechanism 1 according to the preset formula and process, thereby realizing automated feeding.

[0063] like Figure 1 As shown, the granulation mechanism 1 is equipped with an electric gate 6 as a discharge port. The electric gate 6 is connected to the control system 9. A waste trough 11 is provided outside the discharge port of the granulation mechanism 1 to receive and discharge the waste generated by cleaning the granulation mechanism 1.

[0064] like Figure 4 As shown, the granulation mechanism 1 includes a circular pot 100, a circular pot rotary motor 101, a base plate 102, and a tilt adjustment unit. The opening of the circular pot 100 is the feed end. A weight sensor is provided at the bottom of the circular pot 100 and is rotatably connected to the upper surface of the base plate 102 via a slewing bearing. The circular pot rotary motor 101 is fixed to the lower surface of the base plate 102. The output end of the circular pot rotary motor 101 passes through the surface of the base plate 102 and connects to a drive gear located on the upper surface. The drive gear meshes with the outer ring gear of the slewing bearing. The inner ring of the slewing bearing is fixedly connected to the base plate 102, and the outer ring is fixedly connected to the bottom of the circular pot 100. The circular pot rotary motor drive unit drives the circular pot rotary motor 101 to work, and drives the outer ring of the slewing bearing and the circular pot 100 to rotate through gear meshing. The circular pot rotary motor drive unit is connected to the control system 9. The tilt adjustment unit is connected to the bottom of the base plate 102 and is connected to the control system 9 to adjust the tilt angle of the circular pot 100. The tilt adjustment unit includes a frame. 103, tilting link 104, slider 105, lead screw 106, base plate rotary motor 107, and support 109 with base plate slide rail 108; frame 103 is hinged to one end of base plate 102; support 109 is fixed to frame 103 under base plate 102; base plate rotary motor 107 is fixed to support 109, output end of base plate rotary motor 107 is connected to lead screw 106, drive motor signal of base plate rotary motor 107 is connected to control system 9; outer periphery of lead screw 106 A slider 105 is fitted with a lead screw 106; the slider 105 has a groove that fits into the base plate slide rail 108; the base plate rotary motor 107 drives the lead screw 106 to rotate, converting the rotational motion of the lead screw 106 into the linear motion of the slider 105 along the base plate slide rail 108; one end of the inclined connecting rod 104 is rotatably connected to a fixed point on the base plate 102, and the other end is rotatably connected to the slider 105, and the slider 105 slides along the base plate slide rail 108 to adjust the tilt angle at the hinge point between the base plate 102 and the frame 103.

[0065] like Figure 4As shown, the frame 103 is hinged to one end of the base plate 102 as a fixed fulcrum; the base plate rotary motor 107 drives the lead screw 106 to rotate, which drives the slider 105 meshing with it to move linearly along the base plate slide rail 108; the length of the inclined connecting rod 104 is fixed, the distance between the fixed point on the base plate 102 and the hinge is fixed, the distance between the slider 105 and the hinge changes, and the slider 105 pushes the base plate 102 through the inclined connecting rod 104, thereby converting the linear displacement of the slider 105 into the rotational motion of the round pot 100 driven by the base plate 102 around the hinge axis, so as to realize the adjustment of the tilt angle of the base plate 102 and the round pot 100.

[0066] The side wall of the circular pot 100 is equipped with an electric gate 6 connected to the control system 9. A proximity switch receiver is located at the lower end of the base plate 102, and a proximity switch transmitter is correspondingly located on the electric gate 6. The proximity switch receiver and transmitter are connected to the control system 9, so that when the electric gate 6 is aligned with the lower end of the base plate 102, it serves as the discharge port of the granulation mechanism 1. In this embodiment, the discharge port of the granulation mechanism 1 uses an electric gate 6 integrated into the side wall of the circular pot 100, and its positioning is determined by position detection achieved through the cooperation of the proximity switch receiver and transmitter. The electric gate 6 is fixedly installed on the side wall of the circular pot 100 and rotates with the circular pot 100. A proximity switch receiver is installed at a preset discharge low point on the inclined base plate 102, and a proximity switch transmitter is correspondingly installed on the electric gate 6. When the circular pot 100 rotates to the low discharge point, the proximity switch transmitter on the electric gate 6 moves to the sensing area of ​​the proximity switch receiver on the base plate 102, triggering a signal and transmitting it to the control system 9. At this time, the control system 9 determines that the discharge port is aligned. Figure 1 As shown, the electric gate 6 is allowed to open to the left, allowing the material inside the round pot 100 to be discharged through the electric gate 6. This design ensures that the discharge operation of the granulation mechanism 1 can only be performed in one correct position, effectively preventing malfunctions and material leakage.

[0067] During the granulation process, under the rotation of the circular pan 100, the dry powder undergoes a regular tumbling motion along the pan wall. Water is evenly sprayed in a fine mist from atomizing nozzles above the pan 100 onto the rotating dry powder. In this continuous tumbling motion, the dry powder gradually adheres, aggregates, and rounds, resulting in a gradual increase in particle size, forming ceramsite. The moisture content of the ceramsite during the granulation stage is based on meeting the target particle size, not the final moisture content. Achieving uniform final moisture content and ceramsite hardness depends on subsequent curing and drying processes.

[0068] like Figure 7As shown, the screening mechanism 7 is mounted on a movable support and includes a screen 701, a vibrating motor 702, and a feed guide trough 703. The screen 701 has a uniformly distributed perforated mesh and is set at an angle. The higher end of the screen 701 is the feed end, and the lower end is the discharge end. The screen 701 is used to separate ceramsite of different sizes into oversize and undersize particles. The oversize particles are those that meet the target size and are discharged into the collection box 10 from the discharge end. The undersize particles are those that do not meet the target size and fall through the screen 701 into the collection box 10. The feed end of the return mechanism 8 is connected to the screen 701; the vibration motor 702, as the excitation source, is installed on both sides of the screen 701 to drive the screen 701 to vibrate, and the drive unit of the vibration motor 702 is connected to the control system 9; the feed guide trough 703 is connected to the feed end of the screen 701 to receive the ceramsite output by the granulation mechanism 1 and guide the ceramsite into the central area of ​​the screen 701; the drive unit of the moving support is connected to the control system 9, and drives the moving support to work and drive the feed guide according to the signal of the control system 9. The feed channel 703 is aligned with or away from the outlet of the granulation mechanism 1; the movable support includes two parallel support slide rails 7041 and a base 7042 slidably connected to the two support slide rails 7041; a screening mechanism 7 is installed on the base 7042; each support slide rail 7041 has a limiting plate (not shown in the figure) at both ends; when the base 7042 contacts the limiting plate (not shown in the figure), the feed channel 703 is aligned with or away from the outlet of the granulation mechanism 1; the movable support drive unit uses a cylinder (not shown in the figure), the cylinder body (not shown in the figure) is fixed to the support slide rail 7041, and the piston rod end (not shown in the figure) is connected to the base 7042; the solenoid valve (not shown in the figure) of the cylinder is connected to the control system 9, and by controlling the intake and exhaust of the cylinder (not shown in the figure), the base 7042 is driven to slide back and forth between the limiting positions at both ends of the support slide rail 7041, so that the feed channel 703 is aligned with or away from the outlet of the granulation mechanism 1. The limiting positions at both ends of the support slide rail 7041 refer to the contact between the base 7042 and the limiting plates at both ends of the support slide rail 7041 (not shown in the figure). A shock-absorbing spring is provided between the screen 701 and the base 7042 to isolate vibration and prevent it from being transmitted to the outside of the screening mechanism 7.

[0069] In one specific embodiment, such as Figure 1 As shown, the screening mechanism 7 is located to the left front of the electric gate 6, and the limiting position is as follows: Figure 7 As shown, the base 7042 contacts the limiting plate (not shown in the figure) on the left side of the bracket slide rail 7041. At this time, the feed guide channel 703 is away from the discharge port of the granulation mechanism 1, exposing the waste trough 11, and the screening mechanism 7 is in an idle position; the second limiting position is as follows: Figure 1As shown, the base 7042 contacts the limiting plate (not shown in the figure) on the right side of the support slide rail 7041. At this time, the feed guide channel 703 is aligned with the discharge port of the granulation mechanism 1, blocking the waste trough 11, and the screening mechanism 7 is in the working position. The design of the movable screening mechanism 7, which switches between idle and working positions, can prevent waste that should be directly discharged from entering the screening mechanism 7, thus affecting the subsequent granulation quality. It can also make the overall structure of the device more compact and improve the granulation efficiency.

[0070] like Figure 1 and Figure 8 As shown, the return mechanism 8 includes a return guide trough 801, a conveyor belt 803 with evenly distributed partitions 802, and a hopper 805 with a solenoid valve and a weight sensor at the bottom, connected in sequence; the conveyor belt drive unit 804, the solenoid valve and weight sensor of the hopper 805, and the hopper rotation drive unit 806 are respectively signal-connected to the control system 9; the return guide trough 801 is located below the screen 701 to receive ceramsite that does not meet the target size and guides it to the feed end of the conveyor belt 803; the conveyor belt drive unit 804... The drive conveyor belt 803 moves upward at an incline, lifting and transporting the ceramsite through the partition 802. The hopper 805, connected to the discharge end of the conveyor belt 803, is driven by the hopper rotation drive unit 806 to rotate around the discharge end of the conveyor belt 803. This ensures that the hopper 805 closes the discharge end of the conveyor belt 803 before it starts, and rotates to a horizontal, upward-facing position after the conveyor belt 803 starts to receive the returned ceramsite. Once the hopper 805 reaches a preset weight, the solenoid valve opens, returning the ceramsite to the granulation mechanism 1. The return mechanism 8 automates the return process by executing commands from the control system 9.

[0071] When conveying at an incline, the partitions 802 of the conveyor belt 803 can effectively prevent the ceramsite from sliding back and evenly distribute the ceramsite within each partition 802, thereby achieving stable upward incline conveying.

[0072] In one specific embodiment, a weight sensor is provided at the bottom of the collection box 10; a weight sensor is provided at the bottom of the collection box 10, a weight sensor is provided to collect the weight data of the mixing chamber 401, a weight sensor is provided at the bottom of the round pot 100 to collect the weight data of the round pot 100, and a water meter is provided at the water inlet 30146 to measure the water supply. Therefore, the sludge non-fired ceramsite preparation device of this embodiment can calculate the dry material content and water content of the ceramsite in the collection box 10, which is convenient for the subsequent curing and drying processes to uniformly control the moisture content and improve the strength.

[0073] like Figure 1As shown, to reduce the floor space and facilitate industrialization, the sludge-free ceramsite preparation device can be integrated into a multi-layer frame 103: A stirring mechanism 4 and a feeding mechanism 5 are installed on the left platform of the multi-layer frame 103; a control system 9 is located below the left platform, with three buttons: start, stop, and alarm; a monitoring mechanism 2, a spraying unit 3, and a granulation mechanism 1 are arranged from top to bottom on the right platform; a screening mechanism 7, a collection box 10, and a return mechanism 8 are located at the front of the right platform. The movable support for the screening mechanism 7 can be detached from or integrated into the multi-layer frame 103.

[0074] Example 2

[0075] Based on Example 1, this example introduces a method for preparing non-fired ceramsite from silt, including the following steps:

[0076] The dry powder is stored and mixed by the stirring mechanism 4;

[0077] The mixed dry powder and water are added to the granulation mechanism 1 through the feeding mechanism 5;

[0078] The granulation unit 1 receives the mixed dry powder and water and rotates it to form ceramsite by rolling the mixture.

[0079] The screening mechanism 7 transfers ceramsite that meets the target size to the collection box 10 and ceramsite that does not meet the target size to the return mechanism 8.

[0080] The ceramsite that does not meet the target size is returned to the granulation mechanism 1 for regranulation via the return mechanism 8.

[0081] The dry powder material comprises mineral powder, dehydrated sludge, and solid water glass in a mass ratio of 1200:1800:78.1. This dry powder material formulation is a mix proportion designed primarily to improve cylinder compressive strength. Cylinder compressive strength refers to the pressure when a certain size of expanded clay aggregate is placed inside a standard cylindrical tube and pressure is applied using a pressure head, measuring the pressure when the expanded clay aggregate bed is pressed to a certain depth. It reflects the ability of the expanded clay aggregate mass to resist external force damage in concrete. This dry powder material formulation, designed primarily to improve cylinder compressive strength, can optimize the basic strength of individual expanded clay aggregates. Subsequent control of the particle shape and gradation of the expanded clay aggregates optimizes the mass packing structure and stress mechanism of the expanded clay aggregates, thereby improving the cylinder compressive strength of the expanded clay aggregate mass.

[0082] Alternatively, a dry powder formulation can be made with sodium perborate, mineral powder, dehydrated sludge, and solid water glass in a mass ratio of 450:1000:4000:130.2. This formulation is designed with the primary goal of reducing bulk density. The resulting ceramsite is porous and meets the cylinder compressive strength standard. Reducing the bulk density makes the ceramsite as light as possible, thereby minimizing the self-weight of the ceramsite's packing structure.

[0083] After spraying water onto the surface of the collected ceramsite, it is first naturally cured for 1 day to ensure uniform water content inside the ceramsite. Then, it is placed in a low-temperature and humid environment at 80℃ for 3 days to allow it to undergo an alkali-activated reaction, forming a hydration product with uniform internal texture and a strength greater than 2.5MPa.

[0084] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.

Claims

1. A device for preparing non-fired ceramsite from silt, characterized in that, It includes a mixing mechanism (4), a feeding mechanism (5), a granulation mechanism (1), a screening mechanism (7), and a return mechanism (8); The stirring mechanism (4) stores and stirs dry powder, which includes sludge after dehydration treatment. The feeding mechanism (5) is located at the outlet of the mixing mechanism (4) to add the mixed dry powder and water to the granulation mechanism (1). The granulation mechanism (1) is located at the outlet of the feeding mechanism (5), receiving the mixed dry powder and water and rotating to make the mixture roll to form ceramsite. The screening mechanism (7) is located at the discharge port of the granulation mechanism (1), which transmits the ceramsite that meets the target size to the collection box (10) and transmits the ceramsite that does not meet the target size to the return mechanism (8). The return mechanism (8) is located between the screening mechanism (7) and the granulation mechanism (1) to return ceramsite that does not meet the target size to the granulation mechanism (1) for regranulation.

2. The apparatus for preparing non-fired ceramsite from silt according to claim 1, characterized in that, It also includes a control system (9); the stirring mechanism (4), the feeding mechanism (5), the granulation mechanism (1), the screening mechanism (7) and the return mechanism (8) are respectively connected to the control system (9); Alternatively, the stirring mechanism (4), feeding mechanism (5), granulation mechanism (1), screening mechanism (7), and return mechanism (8) are respectively connected to the control system (9); the control system (9) is equipped with three buttons, namely start, stop, and alarm. The start and stop buttons are used as the on-site start and stop buttons of the preparation program preset by the control system (9), and the alarm button is used to send a signal to the external monitoring terminal on-site to remind the staff to remotely control the control system (9); it also includes a monitoring mechanism (2), which is installed on the top of the sludge non-fired ceramsite preparation device and is used to monitor and record the entire process of ceramsite preparation in real time; the video signal collected by the monitoring mechanism (2) is transmitted to the external monitoring terminal so that the staff can observe the device operation status and ceramsite preparation status, and manually adjust the control parameters of the preparation program according to the feedback from the monitoring screen.

3. The apparatus for preparing non-fired ceramsite from silt according to claim 2, characterized in that, The stirring mechanism (4) includes: a stirring chamber (401), a stirring drive motor (402), a stirring shaft (403), stirring blades (404), a stirring chamber slide rail (405), and an electric cover plate (406). The mixing chamber (401) stores dry powder and has an opening at the top; The output shaft of the stirring drive motor (402) is connected to the stirring shaft (403) that extends into the stirring chamber (401), and the stirring drive motor (402) is connected to the control system (9). The mixing shaft (403) inside the mixing chamber (401) is provided with mixing blades (404) in the circumferential direction. Two electric cover plates (406) are installed on the mixing chamber slide rail (405) at the top opening of the mixing chamber (401). Driven by the control system (9), they slide in opposite directions along the mixing chamber slide rail (405) to open or close the top opening of the mixing chamber (401). The bottom of the mixing chamber (401) is equipped with a feeding solenoid valve for controlling the opening and closing of the bottom of the mixing chamber (401) and a weight sensor for collecting the weight data of the mixing chamber (401). The feeding mechanism (5) includes an electric turntable, a screw conveyor and a spraying unit (3); The feed port of the screw conveyor is connected to the feeding solenoid valve of the mixing chamber (401). The feeding solenoid valve signal is connected to the control system (9). According to the signal of the control system (9), the feeding solenoid valve is opened to feed material to the screw conveyor or closed to stop feeding material to the screw conveyor. The screw conveyor is connected to the rotating end of the electric turntable. The electric turntable signal is connected to the control system (9). According to the signal of the control system (9), the screw conveyor is driven to rotate by an angle so that the output port of the screw conveyor is aligned with the feed end of the granulation mechanism (1) or away from the feed end of the granulation mechanism (1). The drive unit of the screw conveyor is connected to the control system (9) to add the mixed dry powder into the granulation mechanism (1). The drive unit of the spraying unit (3) is connected to the control system (9) to add water to the granulation mechanism (1).

4. The apparatus for preparing non-fired ceramsite from silt according to claim 3, characterized in that, The spraying unit (3) includes a telescopic bracket (301), a spray pipe (302), and a brush (303). The telescopic support (301) includes a fixed frame (3011), a telescopic component, and a rotary drive component (3014) connected in sequence; the fixed end of the fixed frame (3011) is connected to the fixed end of the telescopic component, the telescopic end of the telescopic component is connected to the rotary drive component (3014), the telescopic component is connected to the control system (9) by signal, and the telescopic component telescopically drives the rotary drive component (3014) to enter or exit the feed end of the granulation mechanism (1) according to the signal of the control system (9); the rotary drive component (3014) has an opening at the end of its end extending out a rotating rod (30140), one end of which is rotatably connected to the rotary drive component. Inside the drive unit (3014), the other end of the rotating rod (30140) outside the rotating drive unit (3014) is symmetrically connected to the nozzle (302) and the brush (303); the rotating drive unit (3014) is provided with a water inlet (30146) connected to the external water supply, and the water inlet (30146) is connected to the rotating rod (30140) and the nozzle (302) in sequence through pipes, and the nozzle (302) is evenly distributed with atomizing nozzles; the rotating drive unit (3014) is connected to the control system (9) by signal, and drives the rotating rod (30140) to rotate according to the signal of the control system (9); The granulation mechanism (1) is equipped with an electric gate (6) as the discharge port. The electric gate (6) is connected to the control system (9). A waste trough (11) is provided outside the discharge port of the granulation mechanism (1) to receive and discharge the waste generated by the cleaning granulation mechanism (1).

5. The apparatus for preparing non-fired ceramsite from silt according to claim 4, characterized in that, The rotary drive component (3014) includes a rotary joint (30141), a driven gear (30142), a driving gear (30143), a rotary rod rotary motor (30144), and a positioning bearing (30145). The inlet pipe (30146) is connected to the fixed end of the rotary joint (30141); the rotating end pipe of the rotary joint (30141) is connected to the rotating rod (30140); the outer circumference of the rotating rod (30140) in the rotary drive (3014) is fixed with a driven gear (30142) and a positioning bearing (30145) at different heights; the driven gear (30142) meshes with the gear ring of the driving gear (30143); the driving gear (30143) is connected to the output end of the rotating rod rotary motor (30144); the rotating rod rotary motor drive unit signal is connected to the control system (9); the inner ring of the positioning bearing (30145) is connected to the outer circumference of the rotating rod (30140), and the outer ring is fixed inside the rotary drive (3014).

6. The apparatus for preparing non-fired ceramsite from silt according to claim 4, characterized in that, The telescopic component includes a first rotating block (30110), a first telescopic rod (3012), a second rotating block (30120), and a second telescopic rod (3013) connected in sequence; the first rotating block (30110) and the second rotating block (30120) are respectively equipped with servo motors; The end of the fixed frame (3011) is connected to the fixed end of the first telescopic rod (3012) via the first rotating block (30110), and the telescopic end of the first telescopic rod (3012) is connected to the fixed end of the second telescopic rod (3013) via the second rotating block (30120). The first rotating block (30110) drives the first telescopic rod (3012) to rotate around the end axis of the fixed frame (3011); the second rotating block (30120) drives the second telescopic rod (3013) to rotate around the telescopic end axis of the first telescopic rod (3012); the first telescopic rod driving unit and the second telescopic rod driving unit respectively drive the telescopic ends of the first telescopic rod (3012) and the second telescopic rod (3013) to extend and retract. The servo motor, the first telescopic rod drive unit, and the second telescopic rod drive unit are respectively connected to the control system (9).

7. The apparatus for preparing non-fired ceramsite from silt according to claim 2, characterized in that, The granulation mechanism (1) includes a round pot (100), a round pot rotary motor (101), a bottom plate (102), and an tilt adjustment unit; The opening of the round pot (100) is the feeding end. The bottom of the round pot (100) is equipped with a weight sensor and is rotatably connected to the upper surface of the base plate (102) through a slewing bearing. The round pot rotary motor (101) is fixed on the lower surface of the base plate (102). The output end of the round pot rotary motor (101) passes through the surface of the base plate (102) and is connected to the drive gear located on the upper surface. The drive gear meshes with the outer ring gear of the slewing bearing. The inner ring of the slewing bearing is fixedly connected to the base plate (102), and the outer ring is fixedly connected to the bottom of the round pot (100). The round pot rotary motor drive unit drives the round pot rotary motor (101) to work. Through gear meshing, it drives the outer ring of the slewing bearing and the round pot (100) to rotate. The round pot rotary motor drive unit signal is connected to the control system (9). The tilt angle adjustment unit is connected to the bottom plate (102), and the tilt angle adjustment unit is connected to the control system (9) to adjust the tilt angle of the round pot (100); The tilt adjustment unit includes a frame (103), a tilting link (104), a slider (105), a lead screw (106), a base plate rotary motor (107), and a support (109) with a base plate slide rail (108). The frame (103) is hinged to one end of the base plate (102); the support (109) is fixed to the frame (103) under the base plate (102); The base plate rotary motor (107) is fixed on the support (109). The output end of the base plate rotary motor (107) is connected to the lead screw (106). The drive motor signal of the base plate rotary motor (107) is connected to the control system (9). A slider (105) is fitted around the outer periphery of the lead screw (106) to engage with the lead screw (106); the slider (105) has a groove that fits into the base plate slide rail (108); the base plate rotary motor (107) drives the lead screw (106) to rotate, converting the rotational motion of the lead screw (106) into the linear motion of the slider (105) along the base plate slide rail (108); One end of the inclined connecting rod (104) is rotatably connected to a fixed point on the base plate (102), and the other end is rotatably connected to the slider (105). The slider (105) slides along the base plate slide rail (108) to adjust the tilt angle of the hinge point between the base plate (102) and the frame (103). The side wall of the round pot (100) is provided with an electric gate (6) that is connected to the signal control system (9). The bottom plate (102) is provided with a proximity switch receiver and a proximity switch transmitter on the electric gate (6). The proximity switch receiver and transmitter are respectively connected to the control system (9) so that when the electric gate (6) is aligned with the bottom plate (102), the electric gate (6) serves as the discharge port of the granulation mechanism (1).

8. The apparatus for preparing non-fired ceramsite from silt according to claim 2, characterized in that, The screening mechanism (7) is mounted on a movable support and includes a screen (701), a vibrating motor (702), and a feed guide channel (703). The screen (701) is evenly distributed with a hollowed-out mesh and is set at an angle. The high end of the screen (701) is the feed end and the low end is the discharge end. The screen (701) is used to separate ceramsite of different sizes into oversize and undersize. The oversize is ceramsite that meets the target size and is discharged into the collection box (10) from the discharge end. The undersize is ceramsite that does not meet the target size and falls through the screen (701) into the feed end of the return mechanism (8) below. The vibration motor (702) is installed on both sides of the screen (701) as the excitation source to drive the screen (701) to vibrate. The drive unit of the vibration motor (702) is connected to the control system (9). The feed guide channel (703) is connected to the feed end of the screen (701) and is used to receive the ceramsite output by the granulation mechanism (1) and guide the ceramsite into the central area of ​​the screen (701); The moving bracket drive unit is connected to the control system (9) and drives the moving bracket to work according to the signal of the control system (9), so that the feed guide channel (703) is aligned with or away from the discharge port of the granulation mechanism (1); The movable support includes two parallel support slide rails (7041) and a base (7042) slidably connected to the two support slide rails (7041); a screening mechanism (7) is installed on the base (7042). Each section of the support slide rail (7041) is provided with a limiting plate at both ends. When the base (7042) contacts the limiting plate, the feed guide channel (703) is aligned with or away from the discharge port of the granulation mechanism (1). The moving support drive unit uses a cylinder. The cylinder body is fixed to the support slide rail (7041), and the piston rod end is connected to the base (7042). The solenoid valve signal of the cylinder is connected to the control system (9). By controlling the cylinder to inlet and outlet, the base (7042) is driven to slide back and forth between the limit positions at both ends of the support slide rail (7041), so that the feed guide channel (703) is aligned with or away from the outlet of the granulation mechanism (1).

9. The apparatus for preparing non-fired ceramsite from silt according to claim 8, characterized in that, The return mechanism (8) includes a return guide trough (801), a conveyor belt (803) with evenly distributed partitions (802) connected in sequence, and a hopper (805) with a solenoid valve and a weight sensor at the bottom; the conveyor belt drive unit (804), the solenoid valve and weight sensor of the hopper (805), and the hopper rotation drive unit (806) are respectively connected to the control system (9). The return flow channel (801) is located below the screen (701) to receive ceramsite that does not meet the target size and guides it to the feed end of the conveyor belt (803); The conveyor belt drive unit (804) drives the conveyor belt (803) to move upward at an incline and lift the ceramsite through the partition (802); The hopper (805) connected to the discharge end of the conveyor belt (803) is driven by the hopper rotation drive unit (806) to rotate around the discharge end of the conveyor belt (803), so that the hopper (805) closes the discharge end of the conveyor belt (803) before the conveyor belt (803) starts. After the conveyor belt (803) starts, the hopper (805) rotates to the point where the opening is horizontal and upward to receive the returned ceramsite. After the hopper (805) reaches the preset weight, the solenoid valve is opened to return the ceramsite to the granulation mechanism (1).

10. A method for preparing non-fired ceramsite from silt, characterized in that, The sludge-free ceramsite preparation device according to claim 1 prepares ceramsite, comprising: Dry powder is stored and mixed by a stirring mechanism (4); The mixed dry powder and water are added to the granulation mechanism (1) through the feeding mechanism (5). The granulation mechanism (1) receives the mixed dry powder and water and rotates it to make the mixture roll and form ceramsite. The screening mechanism (7) transfers the ceramsite that meets the target size to the collection box (10) and the ceramsite that does not meet the target size to the return mechanism (8). The ceramsite that does not meet the target size is returned to the granulation mechanism (1) by the return mechanism (8) for regranulation; The dry powder comprises: mineral powder in a mass ratio of 1200:1800:78.1, dehydrated sludge, and solid water glass. Alternatively, sodium perborate, mineral powder, dehydrated sludge, and solid water glass in a mass ratio of 450:1000:4000:130.2.

Images