Ceramsite firing device

Abstract

The utility model relates to the technical field of material preparation and processing, and particularly discloses a ceramsite firing device. Comprising a furnace body arranged on a supporting seat and a firing chamber in the furnace body; the firing chamber rotates at least through a pair of bearing seats arranged in the furnace body; a heating chamber is arranged between the firing chamber and the interior of the furnace body, and a heating mechanism is arranged in the heating chamber; the heating mechanism is arranged in a sectional manner to form at least two sections of heating areas, and the temperature of each section of heating area can be independently adjusted; an atmosphere control mechanism is further arranged outside the furnace body; the atmosphere control mechanism comprises a controller, a plurality of conveying pipelines for conveying different gases and a plurality of storage tanks for storing the different gases; the two ends of the conveying pipeline are communicated with the firing chamber and the storage tank respectively, and the variety and concentration of gas in the firing chamber are adjusted through the controller so as to meet the requirements of materials of different batches and different conditions.

Description

Technical Field

[0001] This utility model relates to the field of material preparation and processing technology, and in particular to a ceramic pellet firing device. Background Technology

[0002] Expanded clay aggregate, a lightweight and porous material, is mainly made from expanded clay, electrolytic manganese slag, and clay as raw materials, and is produced through high-temperature firing. It has been widely used in construction, horticulture, wastewater treatment, and many other fields. With the continuous advancement of industrialization, the demand for expanded clay aggregate production is also constantly increasing. However, traditional expanded clay aggregate firing equipment often encounters problems such as uneven heating, inaccurate atmosphere control, and discontinuous material sintering due to technological limitations. These problems severely restrict further improvements in production efficiency and product quality. Currently, expanded clay aggregate firing devices mainly use furnace heating. However, traditional firing devices typically use only a single heating method, making it difficult to precisely adjust the temperature according to the specific needs of different stages of the firing process. During firing, the accumulation of materials often leads to uneven firing temperatures, which may result in some parts of the expanded clay aggregate not being completely sintered, thus affecting the overall quality of the product. In addition, traditional equipment usually cannot accurately control the type and concentration of the atmosphere inside the firing chamber, which limits the chemical reactions during sintering and thus affects the sintering effect. Because the flow of materials in the firing equipment is relatively uniform or uneven, the temperature and atmosphere conditions in the firing chamber fail to cover the entire material. This can lead to local over-firing or unfiring of electrolytic manganese slag or other raw materials during the sintering process, thus affecting the quality of ceramsite or other products.

[0003] The patent "Vacuum Sintering Furnace" (publication number CN211601530U, hereinafter referred to as Prior Art 1) discloses a vacuum sintering furnace. Prior Art 1 designs a furnace chamber structure, including a furnace chamber and a furnace liner disposed inside the furnace chamber. A certain gap is intentionally left between the furnace liner and the furnace chamber to facilitate heat transfer and the installation of the furnace liner. The furnace liner itself is composed of an outer frame, inside which a heating element is installed to generate heat. An opening is designed at the lower part of the outer frame to facilitate heat dissipation and other possible functions. To receive material falling from the opening in the furnace liner, a receiving component made of high-temperature resistant material is specially provided inside the furnace chamber, located directly below the opening in the lower part of the furnace liner. The furnace chamber is designed to be circular, while the furnace liner is square; this design ensures the stability of the furnace liner within the furnace chamber. Connectors are provided at both ends of the furnace liner, and these connectors are fixedly connected to the inner wall of the furnace chamber to ensure the correct position and stability of the furnace liner within the furnace chamber. Longitudinal supports are installed on the inner wall of the furnace chamber, with their upper ends connected to the lower bottom surface of the furnace shell, further enhancing the furnace's stability. The receiving components include support columns fixed to the inner wall of the furnace chamber, with support plates at their upper ends, and carbon felt placed on top of these plates. This design effectively receives and disperses material falling from the furnace openings. Heating elements are evenly distributed along the space of the outer frame inside the furnace shell to ensure uniform heat transfer. The heating elements are composed of graphite rods, a material with excellent thermal conductivity and high-temperature resistance. Axial support bars are installed along the lower inner wall of the furnace shell, with two bars arranged symmetrically. This design further enhances the structural stability of the furnace shell and ensures uniform heat transfer.

[0004] Although the furnace structure in prior art 1 can achieve vacuum sintering of materials, it has a significant drawback. In prior art 1, the sintering chamber is fixed, and the material is also stationary within the sintering chamber during the sintering process. This static sintering method may lead to uneven material flow during sintering, thus affecting the stability of the sintering effect. Since the material cannot move or be stirred effectively within the sintering chamber, this may result in uneven sintering, thereby affecting the quality of the final product. Utility Model Content

[0005] In view of this, the present invention provides a ceramic pellet firing device to solve the problem that uneven material flow may occur in the firing devices of the prior art, resulting in unstable sintering effect.

[0006] This utility model provides a ceramic pellet firing device, including a furnace body mounted on a support base and a firing chamber inside the furnace body; the firing chamber rotates through at least a pair of bearing seats mounted inside the furnace body; a heating chamber is provided between the firing chamber and the interior of the furnace body, and a heating mechanism is provided in the heating chamber; the heating mechanism is segmented to form at least two heating zones, and the temperature of each heating zone can be independently adjusted; an atmosphere control mechanism is also provided outside the furnace body; the atmosphere control mechanism includes a controller, several conveying pipes for conveying different gases, and a storage tank for storing several different gases; the two ends of the conveying pipes are respectively connected to the firing chamber and the storage tank, and the controller is used to adjust the type and concentration of gases in the firing chamber.

[0007] Preferably, the furnace body is also provided with hatches at both ends; the hatches include a first hatch and a second hatch, which are respectively hinged to the two ends of the furnace body and can seal the firing chamber and the heating chamber.

[0008] Preferably, the furnace body is also provided with an exhaust pump, which is connected to the firing chamber through an exhaust pipe and controls the concentration of gas in the firing chamber by discharging gas from the firing chamber.

[0009] Preferably, the furnace body is further provided with a waste gas emission treatment mechanism; the waste gas emission treatment mechanism is connected to the exhaust pump and purifies the gas discharged by the exhaust pump.

[0010] Preferably, the two ends of the furnace body are the feeding end and the discharging end, respectively; the conveying pipe is located on the side near the feeding end; and the exhaust pipe is located on the side near the discharging end.

[0011] Preferably, the furnace body is inclined to control the flow direction of the material during firing; the feed end is set to the higher end, and the discharge end is set to the lower end.

[0012] Preferably, it also includes a feeding mechanism; the feeding mechanism includes a distributor and a vibrating conveyor; when the vibrating conveyor is conveying, one end of the vibrating conveyor is connected to the firing chamber.

[0013] Preferably, the support base includes at least a first support base and a second support base; the first support base and the second support base are respectively disposed at both ends of the furnace body; the first support base and the second support base have different heights, so that the furnace body is inclined.

[0014] Preferably, the heating mechanism includes a heating component, which is disposed on the furnace body and is arranged in an enclosing manner with the firing chamber.

[0015] Preferably, the plurality of conveying pipes further includes at least one cooling pipe; the cooling pipe is located on one side near the discharge end of the furnace body and communicates with the firing chamber.

[0016] The ceramic pellet firing device provided by this utility model has the following beneficial effects:

[0017] This invention employs a segmented adjustable temperature and atmosphere control system, which provides optimal heat and gas environment according to the needs of different stages in the firing process. This effectively improves the sintering quality of ceramsite or electrolytic manganese slag, achieving a more uniform and qualified sintering effect. Independent temperature adjustment of each heating zone allows for optimized adjustment based on the heat requirements of different materials, avoiding overheating, reducing energy consumption, and improving energy efficiency. The rotating sintering chamber design ensures uniform heating of the electrolytic manganese slag during firing, preventing incomplete or uneven sintering due to material aggregation or uneven flow, thereby improving production efficiency and sintering quality. Enhanced process controllability: The precise atmosphere control and temperature regulation system makes the entire firing process more controllable, adapting to the material requirements of different batches and conditions, and improving the flexibility and adaptability of the equipment. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments of this utility model will be briefly introduced below. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, and these are all within the protection scope of this utility model.

[0019] Figure 1 This is a schematic diagram of a ceramic pellet firing device;

[0020] Figure 2 This is a schematic diagram of the cross-sectional structure of part of the furnace body;

[0021] Figure 3 This is a schematic diagram of the feeding structure of a ceramic pellet firing device;

[0022] Parts and their numbers in the diagram:

[0023] 110 - First support seat, 120 - Second support seat;

[0024] 200-Furnace body, 211-First hatch, 212-Second hatch, 221-Firing chamber, 222-Heating chamber, 223-Feed end, 224-Discharge end, 225-Bearing seat;

[0025] 310 - Heating element;

[0026] 410 - Controller, 420 - Delivery pipe, 421 - Cooling pipe;

[0027] 500 - Exhaust pump; 510 - Exhaust pipe;

[0028] 600 - Exhaust gas emission treatment mechanism, 610 - Distributor, 620 - Vibrating conveyor. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. It should be noted that, in this document, relational terms such as "first" and "second" are merely used to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. In the description of this utility model, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. Unless otherwise specified, embodiments of the present invention and the various features thereof can be combined with each other, all within the protection scope of the present invention.

[0030] Example 1

[0031] Please see Figure 1This utility model provides a device for sintering ceramsite, particularly for the sintering process of electrolytic manganese slag. As is well known, the sintering equipment widely used in the market mainly includes rotary kilns and belt furnaces. These devices are typically designed to process slag or powdery materials with uniform particle size distribution, and they exhibit relatively stable performance in temperature control. However, due to the unique physical and chemical properties of electrolytic manganese slag, these conventional sintering devices struggle to achieve the desired ceramsite formation effect. During the sintering process, uneven temperature distribution negatively impacts the formation of ceramsite and its final physical properties. Traditional methods to improve the sintering effect include increasing the output power of the heat source or extending the sintering time, but these measures often lead to a significant increase in energy consumption and production costs. Therefore, this utility model proposes a ceramsite sintering device to solve the problem of uneven material flow in the prior art, thereby improving the stability of the sintering process and ensuring the quality and production efficiency of the ceramsite.

[0032] Please see Figure 1 and Figure 2 In this embodiment, a firing apparatus for ceramsite is provided. The firing apparatus includes a furnace body 200 mounted on a support base and a firing chamber 221 located inside the furnace body 200. The firing chamber 221 is a space for placing the material to be fired, while the furnace body 200 provides the necessary thermal environment for the firing process.

[0033] Further, please see Figure 1 The support structure comprises multiple parts, specifically two main components: a first support 110 and a second support 120. In practical applications and operations, engineers and technicians will assess the necessity of adding additional support structures, such as a third or fourth support, based on the specific length of the furnace body 200 and the magnitude of the forces it bears. This design consideration aims to further enhance the structural rigidity of the furnace body 200, ensuring its stability under high-temperature and heavy-load operating conditions, thereby effectively protecting the furnace body 200 from damage and extending its service life.

[0034] Please see Figure 1These two supports are respectively located at both ends of the furnace body 200 to ensure the stability and uniform stress distribution of the furnace body 200. The first support 110 and the second support 120 are set at different heights, thus giving the entire furnace body 200 an inclined structure. This inclined structure allows the material to be processed (electrolytic manganese slag) to gradually move towards the lower end of the furnace body 200 within the firing chamber 221 as firing progresses. This arrangement allows the material to pass through multiple chambers with different firing temperatures in sequence, thereby achieving thorough processing under different temperature conditions. This arrangement effectively solves the problem of uneven sintering temperature control caused by the static, stagnant accumulation of material when processing electrolytic manganese slag in traditional sintering equipment.

[0035] Because electrolytic manganese slag has a certain degree of viscosity, it is prone to clumping in traditional equipment due to uneven temperature and accumulation. This not only affects the uniform firing of the material but may also lead to uneven heat conduction, thus affecting the final sintering effect. The firing device in this embodiment can effectively avoid these problems and improve sintering efficiency and quality.

[0036] Please see Figure 1 In this embodiment, the firing chamber 221 includes at least one pair of bearing seats 225, which are installed within the internal structure of the furnace body 200. This arrangement enables the firing chamber 221 to rotate. Through this rotation mechanism, the material can be continuously tumbled during the sintering process. This tumbling action plays a crucial role in preventing material accumulation, as accumulated material often leads to uneven heating. By ensuring continuous tumbling of the material at high temperatures, uniform heating of the material can be effectively promoted. Furthermore, this rotation mechanism helps reduce the risk of caking of sticky manganese slag at high temperatures, thereby improving the efficiency and quality of the sintering process. Further, the rotation of the material during sintering also promotes the movement of the material towards the lower end of the furnace body 200, which contributes to uniform material distribution and more efficient heat exchange, thereby further optimizing the entire sintering process.

[0037] In this embodiment, a heating chamber 222 is provided between the firing chamber 221 and the interior of the furnace body 200, and a dedicated heating mechanism is configured inside the heating chamber 222. This heating mechanism is constructed according to a segmented design, thus forming at least two independent heating zones. Each independent heating zone is equipped with a temperature regulating device, allowing the temperature of each zone to be adjusted individually. This arrangement allows operators to set different temperatures between different heating zones or maintain the same temperature across all heating zones as needed during sintering operations, thereby meeting the requirements of sintering processes for different materials and processes.

[0038] Please see Figure 1 In this embodiment, an atmosphere control mechanism is also provided on the outside of the furnace body 200, and this mechanism plays a crucial role. It includes an intelligent controller 410 and multiple delivery pipes 420 for conveying different types of gases. In addition, multiple storage tanks are provided for storing various gases. One end of each delivery pipe 420 is connected to the firing chamber 221, and the other end is connected to the storage tank. Through the adjustment of the intelligent controller 410, the type and concentration of gases in the firing chamber 221 can be controlled, thereby achieving atmosphere control during the sintering process.

[0039] In this embodiment, the atmosphere control mechanism can introduce inert gas, gas to regulate oxygen concentration, or gas to accelerate the cooling process. By precisely controlling the oxidizing or reducing atmosphere, the formation conditions of the ceramsite can be effectively optimized, thereby significantly improving the quality and density of the ceramsite. Furthermore, introducing cooling gas can effectively help accelerate the material cooling process, further improving production efficiency and product quality.

[0040] Please see Figure 1 In this embodiment, the furnace body 200 is equipped with hatches at both ends, including a first hatch 211 and a second hatch 212. These two hatches are hinged to both ends of the furnace body 200, and their function is to effectively seal the firing chamber 221 and the heating chamber 222, thereby preventing gas and temperature leakage within the firing chamber 221. This arrangement ensures safety and efficiency during the firing process.

[0041] Furthermore, a drive motor is installed on the first hatch 211. When the first hatch 211 is closed, the output shaft of the drive motor will start working, which is responsible for driving the firing chamber 221 inside the furnace body 200 to rotate. This rotation mechanism helps to ensure uniform temperature distribution during the firing process, thereby improving the firing quality.

[0042] Please see Figure 1 An exhaust pump 500 is installed outside the furnace body 200, and this exhaust pump 500 is connected to the firing chamber 221 inside the furnace body 200 via an exhaust pipe 510. Through the action of this exhaust pump 500, the gas inside the firing chamber 221 can be effectively discharged, thereby controlling the gas concentration inside the chamber and ensuring that the gas environment during the firing process reaches an ideal state. In addition, the exhaust pump 500 also has the function of discharging waste gas from inside the furnace body 200, thus preventing excessive accumulation of waste gas inside the furnace body 200 and maintaining a clean and safe internal environment.

[0043] An exhaust gas treatment mechanism 600 is installed on the outside of the furnace body 200. This mechanism is connected to the exhaust pump 500. Its main function is to receive the gas discharged by the exhaust pump 500 and effectively purify the gas to ensure that the gas discharged into the environment meets environmental protection standards.

[0044] Please see Figure 1 The furnace body 200 has a feeding end 223 and a discharging end 224 at its two ends, respectively. To facilitate the conveying and processing of materials, the conveying pipe 420 is arranged on the side of the furnace body 200 near the feeding end 223. At the same time, the exhaust pipe 510 is set on the side of the furnace body 200 near the discharging end 224. This design can ensure that the exhaust gas generated during the material burning process can be discharged in a timely manner.

[0045] Please see Figure 1 The furnace body 200 is designed with an inclined structure, which can effectively control the flow of materials during the firing process. Specifically, the feed end 223 of the furnace body 200 is set at a relatively high position, while the discharge end 224 is located at a relatively low position. This height difference helps the materials to move smoothly from the feed end 223 to the discharge end 224 under the action of gravity, thereby completing the entire firing process.

[0046] Please see Figure 3 In this embodiment, a feeding mechanism is also installed on the outside of the furnace body 200; this feeding mechanism includes a distributor 610 and a vibrating conveyor 620. Specifically, when the vibrating conveyor 620 performs its conveying task, one end of it is directly connected to the firing chamber 221 inside the furnace body 200.

[0047] The main function of the distributor 610 is to evenly distribute the material onto the vibrating conveyor 620, ensuring that the material does not become clogged during transport and avoiding uneven distribution. The vibrating conveyor 620, utilizing its built-in vibration mechanism, smoothly and continuously transports the material from the feed end 223 into the firing chamber 221 within the furnace body 200. This material transport method using the vibrating conveyor 620 not only significantly improves the material transport efficiency but also, due to the vibration generated during operation, further mixes and disperses the material as it is transported to the firing chamber 221. This helps improve the uniformity of the firing process, thereby enhancing the quality of the final product. It is worth noting that the operating speed of the vibrating conveyor 620 can be flexibly adjusted according to the type of material and the specific requirements of the firing process. This design allows the feeding mechanism to adapt to various production needs and conditions.

[0048] Please see Figure 2In this embodiment, the heating mechanism includes one or more heating elements 310, which are disposed at appropriate positions on the furnace body 200. These heating elements 310 are arranged in an enclosing manner with the firing chamber 221, ensuring uniform heating. By controlling various temperature levels, the heating elements 310 can ensure that the material reaches the ideal sintering temperature during firing, thereby guaranteeing uniform and consistent temperature during the firing process, or temperature variations according to a specific increasing or decreasing relationship. To further improve heating efficiency and energy saving, the heating elements 310 typically employ high-efficiency heating materials, such as resistance heating wires or ceramic heating plates. Furthermore, the design of the heating elements 310 also incorporates a good heat insulation structure, such as using high-temperature resistant insulation materials and optimizing the furnace body 200 structure, to reduce heat loss and ensure the stability and continuity of the furnace temperature, thereby improving the efficiency and quality of the entire firing process.

[0049] Please see Figure 1 The plurality of conveying pipes 420 further include at least one cooling pipe 421; the cooling pipe 421 is located on the side near the discharge end 224 of the furnace body 200 and communicates with the firing chamber 221. When cooling is required, liquid nitrogen can be added through an atmosphere control mechanism, so that the material can be cooled down rapidly during the cooling process, preventing over-burning or heat damage, and ensuring the production of high-quality products.

[0050] During processing, the material (electrolytic manganese slag) is evenly fed into the rotary firing chamber 221 through the feeding system. As the firing chamber 221 rotates, the material gradually passes through multiple heating zones. The temperature and atmosphere of each heating zone are controlled separately to ensure that the material is gradually sintered and shaped under suitable conditions. After sintering, the finished ceramic granules are rapidly cooled by cooling gas and then discharged through the discharge end 224. At the same time, the waste gas emission treatment device purifies the generated waste gas to ensure compliance with environmental protection requirements.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A ceramic pellet firing apparatus, characterized in that, It includes a furnace body (200) mounted on a support base and a firing chamber (221) inside the furnace body (200); the firing chamber (221) rotates at least by a pair of bearing seats (225) mounted inside the furnace body (200); A heating chamber (222) is provided between the firing chamber (221) and the interior of the furnace body (200), and a heating mechanism is provided in the heating chamber (222); the heating mechanism is arranged in a segmented manner to form at least two heating zones, and the temperature of each heating zone can be adjusted independently; An atmosphere control mechanism is also provided outside the furnace body (200); the atmosphere control mechanism includes a controller (410), several conveying pipes (420) for conveying different gases, and a storage tank for storing several different gases; the two ends of the conveying pipes (420) are respectively connected to the firing chamber (221) and the storage tank, and the controller (410) is used to adjust the type and concentration of gas in the firing chamber (221).

2. The ceramsite firing apparatus according to claim 1, characterized in that, The furnace body (200) is also provided with hatches at both ends; the hatches include a first hatch (211) and a second hatch (212), the first hatch (211) and the second hatch (212) are respectively hinged to the two ends of the furnace body (200), and can close the firing chamber (221) and the heating chamber (222).

3. The ceramsite firing apparatus according to claim 1, characterized in that, An exhaust pump (500) is also provided outside the furnace body (200). The exhaust pump (500) is connected to the firing chamber (221) through an exhaust pipe (510) and controls the concentration of gas in the firing chamber (221) by discharging the gas inside the firing chamber (221).

4. The ceramsite firing apparatus according to claim 3, characterized in that, The furnace body (200) is also provided with a waste gas emission treatment mechanism (600); the waste gas emission treatment mechanism (600) is connected to the exhaust pump (500) and purifies the gas discharged by the exhaust pump (500).

5. The ceramsite firing apparatus according to claim 3, characterized in that, The furnace body (200) has a feeding end (223) and a discharging end (224) at its two ends, respectively; the conveying pipe (420) is located on the side near the feeding end (223); and the exhaust pipe (510) is located on the side near the discharging end (224).

6. The ceramsite firing apparatus according to claim 5, characterized in that, The furnace body (200) is inclined to control the flow direction of the material during firing; the feed end (223) is set to the higher end, and the discharge end (224) is set to the lower end.

7. The ceramsite firing apparatus according to claim 1, characterized in that, It also includes a feeding mechanism; the feeding mechanism includes a distributor (610) and a vibrating conveyor (620); when the vibrating conveyor (620) is conveying, one end of the vibrating conveyor (620) is connected to the firing chamber (221).

8. The ceramsite firing apparatus according to claim 6, characterized in that, The support base includes at least a first support base (110) and a second support base (120); the first support base (110) and the second support base (120) are respectively disposed at both ends of the furnace body (200); the first support base (110) and the second support base (120) have different heights, so that the furnace body (200) is inclined.

9. The ceramsite firing apparatus according to claim 1, characterized in that, The heating mechanism includes a heating component (310), which is disposed on the furnace body (200) and is arranged in a wrapping manner with the firing chamber (221).

10. The ceramsite firing apparatus according to claim 1, characterized in that, The plurality of conveying pipes (420) also include at least one cooling pipe (421); the cooling pipe (421) is located on one side near the discharge end (224) of the furnace body (200) and communicates with the firing chamber (221).

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