Continuous Mixer Eccentric Screw Pump Foam Structure Protection
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Solution Overview
Problem
Existing continuous mixing systems for producing self-curing foamed slurries face challenges such as destruction of the foam structure during mixing, residue adhesion in the mixer, and difficulties in rapid cleaning and unplanned shutdowns, which affect the quality and efficiency of the process.
Innovation Solution
A continuous mixing plant design featuring a vertically arranged mixer with an eccentric screw pump feeding a horizontally arranged mixer, where the foam is introduced via a pressure-tight connection, allowing for gentle foaming and easy cleaning, with a rotating mixing tool that separates the foam from the slurry and ensures minimal pressure on the foam, enabling adjustable slurry and foam quantities and quick system emptying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If foam is added to slurry in a horizontal mixer with a pump, then continuous mixing is achieved, but the foam structure is destroyed by the pump
Solution Approach 1:
The mixing process is divided into two separate stages: first mixing slurry and foam in a horizontal mixer without a pump, then transferring to a vertical mixer for final mixing. This segmentation prevents the pump from destroying the foam structure while maintaining continuous mixing capability.
Solution Approach 2:
A transfer conduit acts as an intermediary between the horizontal and vertical mixers, allowing the foamed slurry to be transferred without direct pump contact. The conduit system with cleaning nozzles enables continuous operation while protecting the foam structure.
2Productivity
If a continuous mixer operates for extended periods, then productivity increases, but residue adhesion and hardening in the mixer increases
Solution Approach 1:
The system maintains continuous mixing and transferring operations without batch interruptions. The horizontal and vertical mixers operate continuously with automated transfer, maximizing productivity while preventing residue hardening through constant motion and cleaning.
Solution Approach 2:
The system incorporates self-cleaning nozzles that automatically clean the transfer conduit and mixer surfaces during operation. This self-service cleaning prevents residue adhesion and hardening, enabling extended continuous operation without manual intervention.
3Loss of time
If the mixer is designed for rapid emptying, then cleaning time is reduced, but the mixing process becomes more complex
Solution Approach 1:
Instead of designing a single complex mixer that can both mix and empty rapidly, the system inverts the approach by using two simpler mixers with different functions: a horizontal mixer for initial mixing and a vertical mixer for final mixing and easy emptying. This inversion reduces individual component complexity while achieving the overall goal.
Solution Approach 2:
The system transitions from a single horizontal mixing dimension to a two-dimensional approach with horizontal and vertical mixers. The vertical mixer's orientation provides rapid emptying capability through gravity-assisted discharge, adding a dimensional solution to the cleaning time problem without over-complicating individual mixer design.
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
This design prevents foam structure destruction, allows for rapid and complete emptying and cleaning of the system, and produces foamed slurries with consistent pore size and quality, suitable for rapidly curing materials like foamed concrete.
Implementation Method 1
an eccentric screw pump being attached to the lower end of the vertical mixing chamber, which conveys the premixed slurry under pressure directly into the initial area of a horizontal mixing chamber
Implementation Method 2
The foam component is also conveyed under pressure into the initial area of the horizontal mixing chamber via a foam cannon
Implementation Method 3
the slurry and the foam being conveyed through the horizontal mixing chamber, with the mixing tool gently separating the foam component from the slurry
Data Source
Figure 1
Figure 2~3
Figure 4~7
AI summary
The invention relates to a continuous mixer apparatus and a method for producing a foamed slurry, wherein solids and mixing liquid are mixed in a vertical mixer (3) to form a flowable slurry, and at the bottom end of the vertical mixer (3) there is a vertically arranged eccentric screw pump (4). The outlet of the eccentric screw pump (4) leads directly and pressure-tightly into the first front end of the housing (5.3) of a horizontal mixer (5) which has a foam inlet (5.3.2) at the front end.