March 17, 2016

bauma premiere: Twin-shaft batch mixer (DKXK) for the sand-lime brick industry

DKXK for producing sand-lime mixtures

The first twin-shaft batch mixer (DKXK) used by a manufacturer of sand-lime bricks

At bauma 2016, BHS-Sonthofen introduces a new generation of twin-shaft DKXK-type batch mixers equipped with a rubber trough specially designed for producing sand-lime bricks. This new type of batch mixer features particularly low wear to the trough – an important factor when processing abrasive mixtures such as sand-lime bricks.

The new DKXK variant that BHS has developed for the proven twin-shaft batch mixer is optimally tailored to the task of producing sand-lime bricks. This new innovation allows the sand-lime brick industry to take advantage of BHS-Sonthofen twin-shaft mixing technology. The results are homogeneous mixing, short mixing times and low wear. The intensive mixing process also ensures that a high percentage of the lime used in each mixture is utilized, which in turn produces a very dense packing mixture.

The first mixer of this new generation – which has a 2,300-liter capacity – commenced operations in February 2016 in Baden-Baden as the main mixer upstream of the reactor. The client had been operating a BHS-manufactured twin-shaft batch mixer of similar design since 1971, which they recently replaced with a more powerful state-of-the-art unit.

Sand-lime bricks are made of sand mixtures containing a high silicate, quicklime and water content. This material is highly abrasive. Considerable wear occurs in previously used conventional mixing systems such as intensive mixers. The reason for this high wear is that the fine sand acts like sandpaper on the mixing tools and on the mixer’s trough wall.

BHS has therefore specifically developed the DKXK type of mixer for producing lime mixtures as an alternative version to the internationally proven twin-shaft batch mixer of type DKX. Instead of a steel trough with a lining made of wear tiles, BHS builds their sand-lime brick mixer with a rubber mixing trough that pulsates when mixing, thus effectively preventing sticky mixing material from caking. This reduces blade and trough lining wear and results in a lower power consumption of the motor.

This solution is tried and tested with BHS’s highly reliable single-shaft continuous mixers. The DKXK mixing blades can optionally be equipped with Widia plates, which significantly increase the system’s service life.

The new DKXK mixer variant offers several advantages when compared with the intensive mixers that have been used in the sand-lime brick industry until now: In contrast to the circular motion of other mixing systems, the three-dimensional mixing principle of the twin-shaft batch mixer produces a more intensive exchange of material, which leads to shorter mixing times while consuming less energy. In addition, the mixer requires less maintenance because wear parts are easy to replace. This is another reason why the twin-shaft batch mixer by BHS-Sonthofen is an economical alternative for producing sand-lime mixtures.

In the future, BHS-Sonthofen will offer the twin-shaft batch mixer of type DKXK for the sand-lime brick industry with a filling volume ranging from 1,000 to 6,500 liters.

DKXK with rubber mixing trough

DKXK with rubber mixing trough for producing sand-lime mixtures

DKXK with rubber mixing trough and spiral mixer

DKXK with rubber mixing trough and spiral mixer

Three-dimensional mixing principle of the DKXK

Three-dimensional mixing principle of the twin-shaft batch mixer (DKXK)

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