Henan Hongke Heavy Machinery Co., Ltd. has delivered a 100,000 m³/year ceramsite (expanded clay aggregate) rotary kiln production line to a customer in Shandong Province, China. The line processes clay and shale into lightweight aggregate for construction applications.
This article covers the full project: customer background, the original problem, equipment configuration, delivery timeline, commissioning results, and customer feedback.
1. Customer Background
Location: Shandong Province, China
Industry: Building materials / lightweight aggregate production
Shandong is a major industrial and construction materials hub in eastern China. The province has abundant clay and shale resources, and local producers supply lightweight aggregates to concrete block manufacturers, precast plants, and insulation material suppliers across the region.
Our customer is a building materials producer in Shandong. They identified an opportunity to manufacture ceramsite locally, using clay and shale from nearby deposits, to serve growing demand from contractors and precast producers. The target capacity was 100,000 m³/year.
2. The Original Problem
Before approaching Henan Hongke Machinery, the customer faced several practical challenges:
| Problem | Impact |
|---|---|
| No local ceramsite supply | Contractors relied on distant sources; high cost, long lead times |
| Variable raw material | Local clay and shale varied in moisture, plasticity, and expansion behavior |
| Uncertain process parameters | No established reference for calcination temperature and residence time with local materials |
| Environmental requirements | Dust and emissions had to meet Shandong’s strict standards (DB37/2373-2018) |
| Capacity target | 100,000 m³/year required a robust, continuous line |
| Operational reliability | Equipment had to run consistently with minimal downtime |
The customer needed a complete production line—not just a kiln. Mixing, granulation, calcination, cooling, screening, and dust collection all had to work together.
3. Why the Customer Chose Henan Hongke Machinery
After evaluating several suppliers, the customer selected us for specific, practical reasons:
a) Complete line capability, not single-machine supply
Ceramsite production is a chain: raw material preparation → mixing → granulation → calcination → cooling → screening → dust collection. We demonstrated the ability to supply and integrate the full line, so the customer did not have to coordinate multiple vendors.
b) Design based on their actual clay and shale
We requested samples of the customer’s raw materials and reviewed their moisture, plasticity, and expansion characteristics before finalizing the kiln design and process parameters. The kiln internal structure and temperature profile were matched to their material.
c) Experience with environmental compliance in Shandong
Shandong enforces strict emission limits for building materials (particulates <10 mg/m³, SO₂ <50 mg/m³, NOx <100 mg/m³) . We designed the dust collection and gas treatment system to meet these requirements.
d) Factory inspection and reference review
The customer reviewed our manufacturing facility and similar ceramsite projects before signing.
e) Long-term support commitment
The customer wanted a supplier who would remain available for process optimization and spare parts after handover.
4. Equipment Configuration
The line is built around a rotary kiln, with a complete production chain from raw material feed to finished product screening.
| Parameter | Specification |
|---|---|
| Application | Ceramsite (expanded clay aggregate) production |
| Design capacity | 100,000 m³/year |
| Raw materials | Local clay and shale |
| Kiln type | Rotary kiln with refractory lining |
| Operating temperature | Up to 1,200°C (adjustable by zone) |
| Drive system | Heavy-duty gear drive with main and auxiliary motors |
| Sealing | Labyrinth seals with air purge |
| Control | PLC-based with temperature, speed, and feed monitoring |
Scope of supply:
| System | Function |
|---|---|
| Raw material storage and feeding | Clay/shale storage, controlled feed into process |
| Twin-shaft mixer | Crushing and homogenization of raw material |
| Granulator | Formation of green pellets at target size |
| Rotary kiln | Calcination and expansion of pellets |
| Cooler | Quenching of hot product to preserve strength |
| Vibrating screen | Classification of finished product by size |
| Dust collection system | Cyclone + bag filter for emission compliance |
| Conveying equipment | Material transfer between process stages |
| PLC control system | Process monitoring and data logging |
5. Delivery Timeline
| Stage | Status |
|---|---|
| Raw material testing and process design | Completed |
| Manufacturing at Henan Hongke facility | Completed |
| Factory assembly and no-load testing | Completed |
| Shipment to Shandong | Completed |
| On-site installation | Completed |
| Commissioning and trial production | Completed |
| Handover to customer | Completed |
6. Commissioning Results
| Performance Metric | Result |
|---|---|
| Product quality | Ceramsite with uniform size and density, meeting target specifications |
| Kiln temperature control | Stable across operating zones |
| Throughput | Meets design capacity for 100,000 m³/year |
| Expansion behavior | Consistent expansion with local clay/shale |
| Dust emissions | Within Shandong regulatory limits (particulates <10 mg/m³, SO₂ <50 mg/m³, NOx <100 mg/m³) |
| Operational stability | Continuous operation achieved |
| Product screening | Consistent size classification |
7. Customer Feedback
“The line has been running well since commissioning. The kiln handles our local clay and shale without the problems we were worried about. Product quality is consistent, and the dust control meets Shandong’s strict standards. The team was responsive during installation and commissioning.” — Production Manager, Shandong ceramsite producer
8. What This Means for the Customer
| Benefit | Practical Value |
|---|---|
| Local ceramsite supply | Shorter lead times, lower cost than distant sources |
| Consistent product quality | Stable offtake agreements with contractors |
| Full-line integration | Single point of responsibility |
| Environmental compliance | Meets Shandong emission requirements |
| Reliable operation | Continuous production with minimal downtime |
| Support for future expansion | Scalable design and ongoing technical support |
9. Building Long-Term Partnerships
Our commitment to the Shandong customer does not end at handover. We continue to provide:
Technical support on process optimization for different clay and shale sources
Spare parts availability for critical components
Maintenance guidance and preventive maintenance planning
Support for future capacity expansion or process adjustment
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been designing and manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for ceramsite, lime, dolomite, metallurgy, and mineral calcination
Rotary Dryers – for sludge, sand, gypsum, biomass, and industrial materials
Ball Mills – for ore, slag, cement, and chemical grinding
Crushers – for primary and secondary size reduction
We focus on one-stop solutions for mining and materials processing—complete systems, not just individual machines.
Let’s Talk About Your Ceramsite Project
If you are planning a ceramsite production line using local clay or shale, we can discuss kiln sizing, process configuration, and expected output based on your raw material data.
Contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
Rotary Kilns | Rotary Dryers | Ball Mills | Crushers – Built for Reliability, Backed by Service