The raw materials for producing sludge ceramsite mainly include sewage sludge, river mud, and clay. The ceramsite production process on this production line is as follows: raw material batching → aging → raw material loading → raw material mixing → granulation → shaping and screening → calcination → cooling → screening → storage.

Sludge and clay delivered from the factory are pre-mixed after batching. The mixed material then enters the aging warehouse for aging and storage. After aging, the qualified material is loaded by a forklift onto a box feeder, which feeds the material onto a belt conveyor. The box feeder then conveys the material to a twin-shaft mixer for mixing. After mixing in the twin-shaft mixer, the material is conveyed to a double-roller granulator for extrusion and granulation. The resulting raw material pellets are screened through a shaping screen to remove unqualified ceramsite particles smaller than 5mm. The qualified ceramsite is then delivered to the discharge pipe at the top of the kiln tail and enters the rotary kiln. A double-disc valve is installed at the top of the discharge pipe to lock in airflow, preventing gas from escaping as the material enters the kiln outlet. Unqualified material is screened out.

In the rotary kiln, raw material particles gradually move toward the kiln head as the kiln rotates. They are calcined into ceramsite at temperatures of 1050°C to 1200°C in the firing zone. They then enter a vertical cooler for cooling before being discharged from the discharge end. Cool air from the outside is forced into the cooler by a fan, exchanging heat with the hot ceramsite in a reverse direction. After being heated, it enters the kiln as high-temperature secondary hot air, significantly reducing the system's heat consumption. The rotary kiln is divided into two sections: the drying section and the roasting section. The speed of each section is adjustable, and the joints are sealed with stainless steel scales.

At the kiln outlet, an air cooler cools the high-temperature flue gas from approximately 250-300°C to around 100-120°C. The cooled flue gas is then passed through a bag filter for further purification. The bag filter can reduce emissions to below 30mg/Nm³, achieving standard emissions and clean production. The purified flue gas is then passed into the desulfurization tower for desulfurization. The desulfurized flue gas is then directed by a fan to the chimney for direct discharge.