Introduction
Shale Ceramsite is a lightweight, porous granular material made from shale as the raw material, processed through crushing, sieving, and high-temperature roasting (above 1000°C). It has a round or oval appearance, with an interior full of tiny pores, and features such as light weight, high strength, and good thermal insulation.
Compared with traditional sand and gravel, Shale Ceramsite can reduce the dead weight of a building by 30%–50%, while also saving energy due to their excellent heat preservation properties. Compared with other lightweight aggregates (e.g., clay pellets), they offer higher strength and a wider range of applications.
Core features: lightweight, porous structure, high strength, low water absorption.
Advantage
Lightweight: The bulk density is approximately 600–1000 kg/m³, much lower than that of ordinary sand and gravel, which helps reduce the self-weight of structural components.
Porous Structure: Internal pores provide good thermal insulation (thermal conductivity: 0.2–0.4 W/(m·K)) and sound absorption.
High Strength: A cylinder compressive strength of 3.5–10 MPa meets the requirements for aggregates used in building structures.
Low Water Absorption: With a water absorption rate of ≤10%, its durability is superior to that of conventional lightweight aggregates.
Process
Raw Material Pretreatment
Shale needs to be crushed to a particle size of less than 30 mm and screened to remove impurities (e.g., quartz, carbonates, etc.).
In some processes, additives (e.g., coal dust) are required to adjust the expansion properties during roasting.
Key Stages of Roasting
Preheating Stage (200–600°C): Removes water and organic impurities from the shale to prevent cracking during roasting.
Expansion Stage (800–1200°C): Minerals in the shale (e.g., clay minerals) melt and release gases, forming a porous structure.
Cooling Stage: Rapid cooling is applied to stabilize the pore structure and prevent strength loss.
Influence of Raw Material Origin
China is rich in shale resources. Shale from regions such as Liaoning, Shandong, Henan, and Sichuan varies in mineral composition (e.g., illite and montmorillonite content), which significantly affects the performance of the roasted ceramic granules.
Application
Shale Ceramsite can be used to produce lightweight aggregate concrete, including thermal insulation lightweight aggregate concrete, structural thermal insulation lightweight aggregate concrete, and structural lightweight aggregate concrete. This type of concrete is lightweight, helping to reduce the overall weight of buildings, while also offering high strength. It is suitable for high-rise buildings, large-span bridges, and other structural projects.
Thermal Insulation Materials:
Shale ceramic granules can be directly used as thermal insulation materials, such as in roof insulation layers, heat insulation layers, pipe insulation, and furnace insulation. They can effectively reduce a building's energy consumption.
Refractory Materials:
Refractory bricks or blocks made from Shale Ceramsite can be used for lining heating furnaces, kiln cars in tunnel kilns, and other high-temperature environments, offering excellent refractory performance.
Petroleum Industry:
In petroleum extraction, shale ceramic granules can be used as proppants in oil well fracturing operations, helping to increase oil production.
Chemical Industry:
They can also serve as chemical fillers in reaction towers and other equipment, enhancing reaction efficiency and mass transfer performance.
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