In March 2017, Vortex got an inquiry from Ferro company which is one of the biggest specialty material manufacturer in the world. Ferro produce color and glass science, particle engineering, surface application and formulation allow them to develop materials that meet the most demanding requirements in a wide range of applications.
Material: Mixing of dry, ball milled, porcelain enamel glass powder (200#), silica flour (200#), powdered clays and other mineral based powdered materials.
Bulk density: 1.1-1.2
Duty: Continuous, 24 hrs/day, 7 days per week
At first, customer prefers to use horizontal ribbon blender to mix their product but we think horizontal paddle mixer is better because of following issue:
A. Mixing Agitator
Considering product is high abrasive, the agitator must be replaceable in the future if mixing part broken. If use ribbon, it is very hard to change in the future because ribbon is welded on shaft. So, we decide to choose paddle type agitator for customer and paddles are bolted on shaft which can be changed if broken.
B. Construction Material
In order to meet wear resistance requirement, we choose high chromium steel for paddle which has good wear resistant result. As for vessel and shaft, we choose 16Mn Steel and we think it is enough because the vessel is static and friction force is not big.
C. Drive Part
To enable starting when full of product, a heavy duty hydraulic motor that customer want to use for driving the mixer but they also concern this is too complicated to operate in working. So, in order to make drive part easy and good, we design fluid coupling and drum coupling between shaft connection and motor reducer connection. This has a big torque when start the mixer at beginning and we also choose frequency converter motor for customer to start the mixer smoothly.
Fully sealed, heavy duty, roller bearings are securely mounted on support pedestals forming part of the end plate structure of the mixer.
E. Shaft Seal
Fully engineered, adjustable, air purged, lantern ring type, packed gland seals are installed on the outside of each end plate on the mixer. The gland pressure shall have access for easy adjustment. The mixer shaft at each end contains a replaceable, hardened wear sleeve in the area of the seal gland, to prevent the seal from wearing the shaft.
In order to minimize the dead space of mixing, we use pneumatic flap valve which can totally match the vessel bottom and valve body.
We meet many customers mix high abrasive product. When we design the mixer, we must consider mixing agitator, construction material, drive unit, bearing and seal. Paddle Mixer and Plough Shear Mixer is better than ribbon mixer if mixing such kind of abrasive product.