Here’s a detailed guide on Perlite Crushers and Drying Systems for processing raw perlite ore into expanded perlite products:
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1. Perlite Processing Overview
Perlite is a volcanic glass that expands when heated. The typical processing steps include:
– Crushing → Drying → Preheating → Expanding (in a furnace) → Classification.
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2. Perlite Crushers
# Types of Crushers Used
1. Jaw Crusher (Primary Crushing)
– Reduces raw perlite ore (typically 10–20 cm) to smaller chunks (~2–5 cm).
– Low dust generation; good for initial size reduction.
2. Hammer Mill or Impact Crusher (Secondary Crushing)
– Further crushes perlite into finer particles (0.5–2 mm) suitable for expansion.
– Adjustable screens control final particle size.
3. Roll Crusher (Optional for Uniform Sizing)
– Produces evenly sized granules with minimal fines.
# Key Considerations
– Avoid over-crushing to prevent excessive fines, which reduce expansion efficiency.
– Use dust suppression systems (e.g., 
er sprays or enclosed crushing) to handle silica dust.
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3. Perlite Drying Systems
After crushing, perlite must be dried to reduce moisture (typically <1% for optimal expansion).
# Common Dryers
1. Rotary Dryer
– Most widely used for perlite drying.
– Heated by natural gas, propane, or electricity.
– Operates at 150–300°C; avoids premature expansion.
2. Fluidized Bed Dryer
– Efficient for fine perlite particles (<1 mm).
– Uniform heating and shorter drying time.
3. Flash Dryer
– For very fine perlite; integrates with grinding systems.
# Drying Parameters
– Temperature: Below 300°C to prevent pre-expansion.
– Moisture Target: ≤1% residual moisture.
– Fuel: Natural gas is common due to clean combustion.
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4. Integrated Crushing & Drying Plant Setup
A typical flow might include:
1. Raw ore → Jaw crusher → Hammer mill → Screener (to remove fines).
2. Crushed perlite → Rotary dryer → Cyclone separator (dust
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