Industrial Mixer for Refractory industry.pptx

Refractory mixers

1. INDUSTRIAL MIXERS

2. Historical Background Mixing and its Purpose Classification of Mixing Equipment Types of Mixers Mixing tasks and Mixers used in the Refractory Industry Pan Mixer Mueller Mixer Ribbon Mixer Counter current Intensive Mixer. Eirich Mixer Planetary Mixer Orbiting Screw Mixer Mixing Time Global Suppliers Industrial mixers Company Confidential 14-06-2024 Overview 1

3. A Historical Background of Mixers The first mixer with rotating parts was patented in 1856 by Baltimore. The first mixer with electric motor is thought to be the one invented by American Rufus Eastman in 1885. In 1908 Herbert Johnson, an engineer for the Hobart Manufacturing Company invented an electric standing mixer, inspired from observing a baker mixing bread dough with a metal spoon. By 1915, his 20 gallon (80L) mixer was the standard equipment for most large bakeries. Industrial mixers have been continuously evolving both in terms of technological developments and increased performance. The capacity of mixers have also been increasing steadily. Today mixers are an integral part of the refractory industry, which engages them round the clock to meet the production demands. Company Confidential 14-06-2024 Industrial mixers 2

4. Covered Areas The aim of this presentation is to bring to light different mixers used in the refractory industry. Mixing different components to produce a homogenized mix is the primary criteria for manufacturing a good quality product, including refractory products. This presentation covers various mixers, their working principles & methods, tentative capacities, advantages & disadvantages. Company Confidential 14-06-2024 Industrial mixers 3

5. What is Mixing & what is it’s purpose? M ixing is defined as distribution of several components which are distinguished at least by one property. It is a physical & reversible process. It serves the following basic needs: - Shift the non-homogeneity of a batch to a homogenous state. - Produce a mix that is consistent with respect to different attributes like chemical composition, color, texture, reactivity and particle size. Mixing could be carried out by agitation, tumbling, centrifugal action and impact forces. Company Confidential 14-06-2024 Industrial mixers 4

6. Industrial mixers Company Confidential 14-06-2024 Classification of Mixing Equipment 5

7. What are the different types of Mixers? Company Confidential 14-06-2024 Industrial mixers Tumbling Mixers High Intimacy / High Shear Mixers Industrial Mixers Agitated Mixers High Intensity Mixers Double Cone V Cone Ribbon Mixer Screw Mixer Planetary Mixer Paddle Mixer Muller Mixer Pan Mixer Intensive Mixers Counter - current Co -current 6

8. Company Confidential 14-06-2024 Industrial mixers Mixing Tasks in the Refractory Industry Production of dry mixes Production of press-wet mixes Production of plastic bodies Agglomeration Kneading 7

9. Mixers used in Refractory Industry Company Confidential 14-06-2024 Industrial mixers Pan Mixer Muller Mixer Ribbon Mixer Counter Current Intensive Mixer Planetary Mixer Orbiting Screw Mixer 8

10. Industrial mixers Company Confidential 14-06-2024 Pan Mixer Pan mixers are of two types, they include - Stationary-Pan Mixer. Rotating-pan Mixer. In a Stationary Pan-Mixer , pan is stationary and the central shaft is driven, causing a circular motion on the pan floor. In a Rotating Pan-Mixer - The turret and the pan can rotate in opposite directions. Plows guide the flow of solids and guide the mix to discharge at the end. Fig. 1 Pan Mixer All Pan mixers consist of a cylindrical pan (fixed or rotating) while one or two sets of blades rotate inside the pan to mix the materials and a scraper that scrapes the wall of the pan to push materials inwards towards the rotating blades. 9

11. Industrial mixers Company Confidential 14-06-2024 Working Principle - Mixing by Rotating action of blades. Scraper Blades Fig. 2 Working of Pan Mixer Application - Suitable for mixing of refractory castables and mortars. Capacity - [50 - 3000] Ltrs. Advantages - Efficient Mixing. High material handling capacity. Disadvantages - The pan is usually emptied through a trap on the bottom, so removing materials sticking to walls is a bit difficult. 10

12. Muller Mixer Company Confidential 14-06-2024 Industrial mixers In a Muller Mixer the Muller wheels move in a circular chamber to ride over the material, producing shearing action that causes size reduction as well as intermixing of material. Fig. 3 Muller Mixer Muller mixer mixes materials via kneading, shearing, smearing, and blending to uniform consistency. Mulling produces just enough pressure to move, intermingle and push particles into place without crushing, grinding or distorting the ingredients. The result is a final mixture of truly uniform consistency in both physical and chemical structure. 11

13. Company Confidential 14-06-2024 Industrial mixers Fig. 4 Working of Muller Mixer Working Principle - smearing, rubbing and somewhat skidding action. Application - Suitable for mixing raw materials for refractory brick making. Advantages - Good mixer for batches of heavy solids and pastes Effective in coating the granular particles with liquid. Capacity - [80 - 1000] Ltrs. Disadvantages - It is not easy to clean or to empty these mixers. 12

14. Ribbon Mixer Company Confidential 14-06-2024 Industrial mixers They are of two types - Vertical Ribbon mixer Horizontal Ribbon mixer Fig. 5 Vertical Ribbon Mixer Fig. 6 Horizontal Ribbon Mixer In a Vertical Ribbon mixer the ribbon rotates slowly during operation. This action creates a shearing zone at the wall, where the material moves in a helical fashion upward and flows down centrally. It is designed to operate with 90% full of solids. In a Horizontal Ribbon mixer the ribbon mixes the product in a trough by pushing it along the axis in both directions and displacing it by centrifugal force. Segregation may occur, resulting in separation into the bottom of the trough. 13

15. Company Confidential 14-06-2024 Industrial mixers The size of ribbon widely affects the operational advantages. A broad ribbon can be used for lifting or conveying purposes, while a narrow ribbon can cut the materials. Fig. 7 Direction of movement of solids in ribbon mixer Working Principle - agitation and mixing action. Application - Suitable for dry powder mix only. (e.g.- refractory mortar) Capacity - [100 - 2000] Ltrs Advantages - These mixers can handle products ranging from free-flowing to cohesive powders and even slurries. Disadvantages - Emptying the entire contents may be difficult due to the small clearance between the trough and the ribbon. 14

16. Industrial mixers Company Confidential 14-06-2024 High quality and sophisticated refractories need quick & more homogeneous mixing. This paved the way for CCIM where the mixing tools & high energy rotor are eccentrically placed & rotate in counter clockwise direction within the clockwise rotating pan. Counter Current Intensive Mixer Fig. 8 Counter Current Intensive Mixer Fig. 9 Inside view Working Principle - Operation is based on counter current principle Application - Mainly in refractory industry for mixing raw materials for shaped and unshaped products. 15

17. Industrial mixers Company Confidential 14-06-2024 Fig. 10 Working of Counter Current Intensive Mixer Capacity - [250 - 750] Ltrs Advantage - A very high mixing effect is achieved with the pan. Disadvantage - Limited mixing volume is a dis -advantage. 16

18. Eirich Mixer Company Confidential 14-06-2024 Industrial mixers It is also a counter – current intensive mixer. The name “Eirich” is a commercial name. It is a part of this presentation as it has an overwhelming presence in major refractory units world-wide . The “D” type Eirich mixers, with horizontally positioned mixing pan, are operated as standard mixers in many older refractory units mostly, the mixing qualities achieved with these mixers are still sufficient. In recent years, the “R” type mixers have partially replaced the D-type Mixers in the refractory industry. For difficult mixing tasks or if e.g. a higher bulk density of bricks is to be achieved, mixers with inclined mixing pan are definitely the better mixers. There are of two types of Intensive Eirich mixers – “D” type Eirich mixer. “R” type Eirich mixer. 17

19. Industrial mixers Company Confidential 14-06-2024 In the mixing pan, the material to be mixed is transported upwards by wall friction and falls back again at the highest point through gravity. This process is supported by the wall / bottom scraper by which the material is circulated and thrown into the rotor. Fig.10 Intensive Eirich Mixer 18

20. Company Confidential 14-06-2024 Industrial mixers Fig. 11 Working of “D” type Eirich Mixer 19

21. Company Confidential 14-06-2024 Industrial mixers Fig. 12 Working of “R” type Eirich Mixer 20

22. Company Confidential 14-06-2024 Industrial mixers Working Principle “R” type “D” type counter current intensive mixing. counter-flow/cross-flow intensive mixing. Application “D” type “R” type suitable for lower density brick batches, glass batches etc. dry mixes, brick press bodies/ramming mixes, resin-bonded mixes, plastic mixes Capacity “D” & “R” type - [75 - 1500] Ltrs Advantages - Adaptable to any kind of mix, all mixing tasks can be fulfilled by variation of speed. It can be used for all consistencies in the refractory industry. Disadvantages - This type of mixers have almost no shortcomings in terms of mixing a wide variety of refractory mixes. 21

23. Planetary Mixer Company Confidential 14-06-2024 Industrial mixers The Double Planetary mixer has two sets of agitators and a set of high speed dispersing shaft revolving around the container axle and at the same time rotating at high speed, allowing materials to be mixed rapidly under the action of strong shearing and kneading force. In a Single Planetary mixer the mixing tools along with the agitator rotate inside the fixed pan at slow speed and simultaneously the agitator tools rotate in its own axis at a higher speed. Fig. 13 Single Planetary Mixer Fig. 14 Double Planetary Mixer They are of two types - Single Planetary Mixer. Double Planetary Mixer. 22

24. Company Confidential 14-06-2024 Industrial mixers Working Principle – Shear between the moving blade and stationary wall. Some tumbling action is also generated due to sloping blades. Fig. 15 Working of a Double Planetary Mixer Application – In mixing materials for pre-cast products, castables, plastic mass. Capacity - [100 - 2000] Ltrs Advantages - The discharged mixed materials are easily. It can be used with a vacuum system to realize vacuum mixing. Disadvantage - High power requirement. 23

25. Company Confidential 14-06-2024 Industrial mixers Orbiting Screw Mixer They are of two types - V-Cone Screw Mixer. Double-Cone Screw Mixer. V-Cone Screw Mixer consists of a vertical vessel with a rotating screw to achieve circulation of material, intermixing of solid grains and shear action to the ones in contact with the screw or the walls of container. Double-Cone Screw Mixer consists of two cones and two rotating screws for better performance and more efficient mixing. Fig. 16 V-Cone and Double-Cone Mixer 24

26. Company Confidential 14-06-2024 Industrial mixers Working Principle – Inner asymmetric spiral upgrade materials by rotation. Tumbler low-speed rotation makes material circle motion. Fig. 17 Working of a Double Screw Mixer Application - Screw mixers are normally used for free-flowing grains and blending unshaped refractory products. Capacity - [180 - 18000] Ltrs Advantages - Gentle blending action due to rotation of the screw on its axis. Nearly 100% discharge is obtainable Easy to clean after use Disadvantages - Requires large freed room for installation. It is a bit expensive. 25

27. Mixing Time What is Mixing Time? It is the time required to produce a uniform mix. The mixing time is reckoned from the time when all the solid materials have been put in the mixer. Which factors determine Mixing Time? The time varies with the type of mixer and its size. Strictly speaking it is not the mixing time but the no. of revolutions of the mixer that is to be considered, because there is an optimum speed of rotation for each mixer. Industrial mixers Company Confidential 14-06-2024 ( 1m 3 = 1000 lit) Fig. 18 A gross relationship between mixer capacity and mixing time 26

28. Criteria For Mixer Selection Industrial mixers Company Confidential 14-06-2024 27

29. Company Confidential 14-06-2024 Industrial mixers Global Suppliers Eirich, Germany. Laeis , Germany. Blastcrete , USA. Uelzener , Germany. 28

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