Lump Conditioning Blade for Cohesive Mixture Breakdown
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Solution Overview
Problem
Current mixers are inefficient in breaking down cohesive lumps in paste-like mixtures, particularly in materials like moistened tailing fines, which can lead to pumping issues in industrial applications such as minefill production.
Innovation Solution
The introduction of a lump conditioning blade with a serrated working edge, oriented nearly perpendicular to the mixing direction, which smears lumps against the boundary walls of the mixing chamber, reducing lump size by forcing them through a defined 'smearing gap' and increasing surface area for water penetration, combined with conventional mixing blades that scrape off the smeared mixture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixing blades are used with leading surface at angle to direction of motion, then mixing effectiveness is improved, but lump breaking capability deteriorates
Solution Approach 1:
The mixing system is segmented into two distinct blade types: conventional mixing blades for effective mixing and lump conditioning blades specifically designed for breaking lumps. This segmentation allows each blade type to specialize in its function without compromise.
Solution Approach 2:
Different parts of the mixing system have different local qualities - mixing blades have leading surfaces at angles optimized for mixing, while lump conditioning blades have leading surfaces perpendicular to motion optimized for lump breaking. Each location in the mixer has the appropriate blade quality for its specific function.
2Ease of operation
If leading edge of paddle is adjusted directly adjacent to boundary wall, then cleaning effectiveness is improved, but lump breaking capability deteriorates
Solution Approach 1:
The system segments the boundary interaction function into two parts: mixing blades that scrape the wall for cleaning, and lump conditioning blades that maintain spacing for effective lump breaking through the smearing action.
Solution Approach 2:
Different blades have different local qualities in their relationship to the boundary wall - mixing blades are positioned adjacent to the wall for scraping and cleaning, while lump conditioning blades are positioned at controlled spacing to create the smearing gap necessary for lump breakdown.
3Manufacturing precision
If lump conditioning blade working edge is supported at controlled space from boundary wall, then lump breaking capability is improved, but mixing efficiency deteriorates
Solution Approach 1:
The mixing system is divided into specialized zones: lump conditioning blades operate at controlled spacing from the wall to break lumps through smearing, while mixing blades operate adjacent to the wall to efficiently mix and scrape material. This segmentation prevents mixing efficiency loss.
Solution Approach 2:
The mixer achieves multi-functionality by combining blades with different functions - lump conditioning blades that break lumps and mixing blades that mix and scrape. This universal design allows the single mixing system to perform both lump breaking and efficient mixing without compromise.
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
Effectively reduces lump size and improves the uniformity of the mixture, enhancing the predictability and pumpability of materials like minefill by breaking down agglomerates and ensuring consistent moisture content.
Implementation Method 1
lumps are forced to pass between a working edge of the lump conditioning blade and the boundary wall
Implementation Method 2
The introduction of a lump conditioning blade with a serrated working edge, oriented nearly perpendicular to the mixing direction, which smears lumps against the boundary walls
Implementation Method 3
increasing surface area for water penetration
Data Source
Figure 1
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AI summary
A mixer having i) a vessel defining a mixing chamber surrounded by boundary walls for receiving a mixture containing lumps therein, ii) a plurality of mixing blades, and iii) a driving mechanism supporting the mixing blades in the mixing chamber for mixing motion relative to the vessel so as to mix the mixture within the mixing chamber of the vessel, further includes at least one lump conditioning blade. The lump conditioning blade is supported by the driving mechanism such that the lump conditioning blade is movable in a working direction along a respective one of the boundary walls with a working edge of the blade being maintained at a prescribed space from the boundary wall which is effective to reduce a lump size of the lumps in the mixture as the mixture passes between the working edge of the lump conditioning blade and the boundary wall.