Auger-Based On-Site Particulate Mixing for Moisture Uniformity
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Solution Overview
Problem
There is a need for devices and methods that can efficiently mix particulate substances like sand and salt with liquids, such as distilled concentrated solutes and magnesium chloride, to create uniform mixtures on-site for industrial applications.
Innovation Solution
A mixer system comprising a hopper, first and second augers, and a liquid tank, where the first auger conveys particulate matter from the hopper to a mixing housing, the liquid is applied through nozzles in the mixing housing, and the combined material is conveyed out by the second auger, with hydraulic and control systems for precise operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mixing methods are used, then mixing capability is provided, but mixing efficiency and uniformity are insufficient
Solution Approach 1:
The mixing system is divided into distinct functional zones: a first mixing zone for initial blending, a second mixing zone for thorough mixing, and a discharge zone. Multiple augers are segmented into different types (conveying auger, mixing auger, discharge auger) with specialized functions. This segmentation allows each zone to optimize for its specific mixing task, improving overall efficiency and uniformity.
Solution Approach 2:
The system employs dynamically adjustable mixing parameters including variable auger speeds, adjustable liquid application rates through nozzles, and controllable mixing time. The hydraulic system enables dynamic adjustment of auger rotation speeds and liquid tank positioning, allowing real-time optimization of mixing conditions to achieve uniform mixtures efficiently.
2Productivity
If on-site mixing is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The mixing apparatus is designed as a multi-functional on-site mixing system that can handle various particulate substances (salt, sand, chips) and liquid solutions (distilled concentrated solutes, magnesium chloride). The same core mechanism of augers and liquid application nozzles serves multiple mixing functions, reducing the need for separate specialized equipment and justifying the complexity through versatile productivity.
Solution Approach 2:
The system incorporates automated control features where the control system regulates auger speeds, liquid application rates, and mixing parameters without constant manual intervention. The hydraulic system automatically adjusts components based on operational requirements, reducing the operational complexity burden and enabling autonomous efficient mixing.
3Manufacturing precision
If liquid application is increased, then mixing uniformity improves, but moisture content control becomes difficult
Solution Approach 1:
The control system monitors mixing parameters and liquid application rates, adjusting them based on feedback from moisture sensors and operational conditions. This feedback mechanism ensures that liquid is applied uniformly at optimal rates to achieve desired mixing uniformity while preventing excessive moisture content, maintaining precise control through continuous adjustment.
Solution Approach 2:
Multiple nozzles are positioned at different locations within the mixing housing to apply liquid locally to specific zones of the particulate material. This localized liquid application ensures uniform distribution without creating concentrated moisture zones, allowing precise control of overall moisture content while achieving mixing uniformity through targeted liquid delivery.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient mixing of up to 200 tons of particulate matter per hour, producing uniform mixtures with controlled moisture content, and can be automated with machine learning for enhanced functionality.
Implementation Method 1
a first auger operatively connected to the hopper... the first auger conveys a material from the hopper to the mixing housing
Implementation Method 2
the liquid is applied through nozzles in the mixing housing
Implementation Method 3
a second auger operatively engaged with the mixing housing... the combined material is conveyed out of the mixing housing by the second auger
Data Source
AI summary
The disclosed apparatus, systems and methods relate to devices, systems and methods for mixing particulate matter such as salt with moisture. In various implementations, the mixer is transportable. In various implementations the mixer comprises a hopper, at least one auger, and a mixing housing. Various implementations, additionally include at least one liquid tank.