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Environment Energy

BHS-Sonthofen presented with the German Resources Efficiency Award

Turning previous unusable materials into valuable resources

BHS-Sonthofen presented with the German Resources Efficiency Award

The trophy: The German Resources Efficiency Award 2016

BHS-Sonthofen and MSW Mineralstoffwerke Südwest received the German Resources Efficiency Award 2016 on 16 February 2017. The prestigious prize was awarded by the German Federal Minister for Economic Affairs and Energy to the two companies to commend the development and successful implementation of the Combimix process. This process turns a previously worthless mining by-product accumulated in quarries into a valuable building resource.

BHS developed the Combimix process based on their twin-shaft batch mixers and implemented it together with MSW at their quarry in Mönsheim. This marked the first German project of this kind. It helped to increase raw material efficiency from the previous level of 65-70% to around 93%.

In quarries and gravel pits, the Combimix process takes clay-and-rock mixtures – which previously had to be refilled or disposed at a landfill – and turns them into a marketable building material. Furthermore, this means that millions of tons of material previously considered worthless and dumped can now be reactivated.

BHS has also installed the Combimix system in several quarries in France using continuous mixers. Before the system was installed, in one facility more than 100,000 t of rock/clay mixture from the quarry had to be dumped every year. More than 90 % of contaminated feed material is now sold as rock grade thanks to the Combimix system. The plant manager is extremely pleased about the significant reduction in costs: „Before the mixer was installed, we had to break down 400,000 t of rock each year to obtain 300,000 t of salable material. The new procedure means we only require 330,000 t to achieve the same delivery quantity.“

The German Federal Ministry for Economic Affairs and Energy (Bundesministerium für Wirtschaft und Energie) awards the German Resources Efficiency Award to exemplary products that efficiently use raw materials and other materials, processes or services, as well as application-oriented research results. A jury comprising 14 members screened over 40 submissions to select four winners in the „Companies“ category and a single winner in the „Research Facilities“ category.

Andre Däschlein, Director of International Sales for Mixing & Crushing Technology at BHS, and Benedikt Fahrland, Managing Director of MSW Mineralstoffwerke Südwest GmbH & Co. KG, accepted the award presented by Uwe Beckmeyer, Parliamentary State Secretary of the Federal Minister for Economic Affairs and Energy at the „Efficient use of raw materials – Market success“ symposium.

A happy moment for Däschlein: „This award demonstrates yet again that deep industry know-how and close ties to their customers allow mid-sized companies, in particular, to create innovative processes and solutions that deliver true efficiency gains.“

Except from the laudation of State Secretary Beckmeyer: „The sparing and efficient use of natural resources is a key skill needed to create a sustainable society. This year“s winning projects serve as role models of innovative and competitive industrial entrepreneurship in Germany. They furthermore pave our way to becoming less dependent on resource imports.“

MSW introduced the process at their Mönsheim quarry in the summer of 2016. It allowed the company to increase their repository“s yield by 25%. To produce the same volume of the final product, it was previously necessary to extract about 620,000 tons of limestone annually. Now the total is around 188,000 tons less, which corresponds to a relative reduction of around 30%. It helped to increase raw material efficiency from the previous level of 65-70% to around 93%.

Dennis Kemmann, the Managing Director of BHS-Sonthofen GmbH, is already thinking ahead: „Our Combimix process holds a vast potential as it enables companies across the globe and throughout various industries to utilize resources more efficiently. In the context of rehabilitating contaminated soil, Combimix can be used to remove oil and other harmful substances. As a result, only a small fraction of the feed material needs to be dumped in hazardous waste landfills. The process is also viable for the cement industry. Here, it can be applied to processing limestone, a key ingredient that improves the burning process in rotary kilns and thus contributes to reducing fuel consumption.“

Background information:

The technology in detail: Combimix process

The unique characteristics of the BHS twin-shaft continuous mixer of type DKXC lays the foundation for the Combimix process. Specifically, this type of mixer is the first to allow regulation of the retention time of the material in the mixer within broad limits. Thanks to this feature, the lime has enough time to mix intensively with the clay, to dry and to undergo a chemical reaction that allows it to be reliably separated from the rock in the next processing step.

The new process thus conserves limestone resources and extends the usable lifetime of quarries. Because less material will be classified as unmarketable, Combimix also creates space in landfills and backfills. Furthermore, this means that millions of tons of material previously considered worthless and dumped can now be reactivated. Given that roughly 25% of the material no longer needs to be backfilled, the BHS method also helps to make space in the landfill – space that can be used to deposit other materials.

Small limestone deposits or those previously labeled unprofitable can be turned into viable sites at very little effort using this technology. For example, the method allows for the extended operation of quarries that were on the verge of being shut down due to a large share of clay in the rock or because of insufficient backfill capacity.

Combimix also contributes to securing resources by providing the means necessary to reactivate large quantities of dumped materials that had been considered unmarketable in previous decades. As a result, millions of tons of material can be processed and sold at a profit.

Another innovation is that operators can now opt for a dry process instead of a wet process. In many quarries, not enough water is available for wet processing in a log washer, and the subsequent water treatment as well as sludge disposal prescribed by law are extremely costly.

BHS is the only mixer manufacturer to offer a continuous twin-shaft mixer with adjustable retention time, which is precisely the tool needed for this task.

MSW case study

The shell limestone extracted at the Mönsheim quarry operated by MSW Mineralstoffwerke Südwest has a high clay and silt content, which contaminates the valuable rock. For this reason, an average of 30 to 35% of the material extracted at the quarry could not be marketed. On top of that, the clayey screen waste had to be backfilled on site as overburden.

In the summer of 2016, MSW commissioned a Combimix system based on a customer-specific twin-shaft batch mixer that admixes the clayey screen waste with approx. 1% fine-ground high-calcium lime.

The mixer processes the material such that the clay cleanly separates from the rock in the next process step. Thanks to this, the use of raw materials, normalized to an annual production of 365,000 t, is reduced by roughly 130,000 t. This figure corresponds to a reduction of 25%, so the resource efficiency is boosted from 65 to 70% to approx. 93%.

As an added benefit, the Combimix process reduces the energy needed for processing. The annual consumption was reduced by around 235,000 kWh and 100,000 liters of diesel. This results in a total power reduction in the order of 17%.

While MSW previously produced a maximum of 280 t salable material per hour, the supply capacity has now increased to 430-460 t per hour, despite the reduced resource expenditure.

About BHS-Sonthofen

BHS-Sonthofen GmbH is an owner-operated group of companies in the field of machinery and plant engineering based in Sonthofen, Germany. The company offers technical solutions for mechanical process technology, concentrating primarily on mixing, crushing, recycling and filtration. With more than 350 employees and several subsidiaries, BHS-Sonthofen has a global presence.

The Mixing Technology division produces batch and continuous mixers and offers the full range of process technology services for mixing applications. The twin-shaft batch mixer, which is considered a global benchmark in the concrete industry, is a key product.

Building companies use the mixers first and foremost to produce transport, precast, high-performance and dam concrete or concrete paving blocks. BHS mixers are also highly suited for mixing dry mortar, cement and sand-lime products or for processing clay-and-rock mixtures.

They are widely used for processing mineral mixes, landfill substances, fly ash, dusts or other bulk materials or for the conditioning of sludges and the production of suspensions. The latter is often done in the context of backfilling mines or depositing mineral waste.

For further information, please visit: www.bhs-sonthofen.de

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen, Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

English Press Releases

BHS-Sonthofen: New twin-shaft mixers for dry building materials

Mixing technology for the dry building materials and cement industry: Individual solutions for a wide range of mixtures

BHS-Sonthofen: New twin-shaft mixers for dry building materials

A dry powder batch mixer of type DMX 3600 has proven itself for years in a German dry mortar plant.

At Powtec 2016, BHS-Sonthofen displays dry powder batch mixers of the DMX series. They are adapted to the special requirements of mixing dry materials, such as cement, dry mortar, bonding compounds and dry shotcrete.

The mixers are specially tailored to the production of dry material mixtures. Since dry building materials encompass a wide range of aggregates, cements and admixtures, different application-specific drive variants are available for the mixers with different speeds and different mixing tools. These can be individually configured according to the application, e.g., for abrasive or adherent input materials.

They are suitable for mixtures containing all manner of aggregates, cement, small dry components, plastic fibers and cellulose. With an extensive modular system and various options, they can be customized to the products of the user, from fine-grained materials such as cement to mortar mixtures with coarse particles up to 8 mm in size. BHS offers a range of machines with throughput rates of up to 300 t per hour.

Compared with single-shaft mixers, they offer considerably better mixing with short mixing cycles. Furthermore, the DMX mixers are more compact than single-shaft mixers and also represent good value for money.

Homogeneous mixtures

BHS has developed the DMX series on the basis of the twin-shaft batch mixers (type DKX), which have been used in thousands of concrete mixing applications. The mixing mechanism consists of mixing tools that are arranged in the form of a discontinuous spiral on each of two counter-rotating mixing shafts. They generate a three-dimensional spiral motion with intensive exchange of material in the turbulent zone of overlap between the two mixing cycles.

Thanks to the sophisticated mixing mechanism, the speed of the mixer can be less than that for comparable single-shaft or intensive mixers while still producing a greater mixing effect. This considerably reduces the energy consumption and is also gentler on sensitive components in the material to be mixed, such as perlite, styrofoam or expanded clay – the particles are not crushed.

Compared with other mixing systems, twin-shaft mixers are filled to a much greater extent, making them more compact for a comparable throughput rate. In the case of new plants, these mixers are thus ideal because of their small dimensions; for modification to existing plants, they allow the installation of a more powerful mixer in the existing space.

Residue-free discharge

Since many manufacturers produce different products in succession, a residue-free discharge of the trough is important. In the case of the DMX, this is carried out by means of large, hydraulically operated discharge door wings that are available in two variants for fine and coarse-grained mixture products. The discharge door wing for fine-grained mixtures has a seal to prevent fine-grained materials, such as cement, from escaping; it is also waterproof. The mixing shafts are fitted with special sealing air seals.

Excellent resistance to wear

Depending on the abrasiveness of the mixture, various wear liners are available. All wearing parts in the mixer, such as mixing arms or blades, are screw-fitted and are thus easy to adjust or exchange. This simplifies maintenance and increases the availability of the plant.
Tests in our BHS technical center

Every dry material mixture has different characteristics; for this reason, BHS conducts tests at its in-house technical center on request. These tests give the customer the certainty that his outlay is well invested and that the new plant is future-proof.

BHS-Sonthofen at Powtec in Nürnberg/Germany,
April 19 to 21, 2016:
Hall 4, booth 4-227

About BHS-Sonthofen

BHS Sonthofen GmbH is an owner-operated group of companies in the machinery and plant engineering field, based in Sonthofen (Germany). The company offers technical solutions for mechanical process engineering, concentrating primarily on mixing, crushing, recycling and filtration. With more than 350 employees and several subsidiaries, BHS-Sonthofen has a global presence.

The Mixing Technology division produces batch and continuous mixers with single and twin-shaft technology and offers a full range of process technology for mixing. The spectrum extends from conventional applications in the concrete industry for transport, precast, dam or high-performance concrete and the mixing of dry mortar, cement, mineral mixes, landfill construction materials or other bulk materials to the conditioning of sludges, the production of suspensions or applications in mining.

For more information, see www.bhs-sonthofen.de.

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen, Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Science Research Technology

BHS-Sonthofen: New twin-shaft mixers for dry building materials

BHS-Sonthofen: New twin-shaft mixers for dry building materials

The twin-shaft batch mixers of the new DMX series.

Individual solutions for a wide range of mixtures

At BAUMA 2013, BHS-Sonthofen unveils twin-shaft mixers of the new DMX series. They are adapted to the special requirements of mixing dry materials, such as cement, dry mortar, bonding compounds and dry shotcrete.

The new mixers are specially tailored to the production of dry material mixtures. They are suitable for mixtures containing all manner of aggregates, cement, small dry components, plastic fibers and cellulose. With an extensive modular system and various options, they can be customized to the products of the user, from fine-grained materials such as cement to mortar mixtures with coarse particles up to 8 mm in size. BHS offers a range of machines with throughput rates of up to 300 t per hour.

Compared with single-shaft mixers, they offer considerably better mixing with short mixing cycles. Furthermore, the DMX mixers are more compact than single-shaft mixers and also represent good value for money.

Mixers from BHS have proven their worth in numerous applications in the cement industry and in the production of dry mortar. One recent example is the replacement with a BHS mixer of an intensive mixer in a dry mortar plant.

Homogeneous mixtures

BHS has developed the DMX series on the basis of the twin-shaft batch mixers, which have been used in thousands of concrete mixing applications.

The mixing mechanism consists of mixing tools that are arranged in the form of a discontinuous spiral on each of two counter-rotating mixing shafts. They generate a three-dimensional spiral motion with intensive exchange of material in the turbulent zone of overlap between the two mixing cycles. Counterblades positioned at the ends of the shafts deflect the material in such a way that all material is repeatedly routed back into the mixing process. Due to the three-dimensional motion and the recirculation of the material, there are no dead zones anywhere in the mixing trough, unlike with single-shaft mixers.

Thanks to the sophisticated mixing mechanism with the directed three-dimensional motion pattern, the speed of the mixer can be less than that for comparable single-shaft or intensive mixers while still producing a greater mixing effect. This considerably reduces the energy consumption and is also gentler on sensitive components in the material to be mixed, such as perlite, styrofoam or expanded clay – the particles are not crushed.

Compared with other mixing systems, twin-shaft mixers are filled to a much greater extent, making them more compact for a comparable throughput rate. In the case of new plants, these mixers are thus ideal because of their small dimensions; for modification to existing plants, they allow the installation of a more powerful mixer in the existing space.

Custom adaptation

Since dry building materials encompass a wide range of aggregates, cements and admixtures, different application-specific drive variants are available for the mixers with different speeds and different mixing tools. These can be individually configured according to the application, e.g., for abrasive or adherent input materials.

Due to the very good mixing effect, agitators, which generally have high power consumption and rates of wear, only need to be used for their actual intended purpose: disintegrating undesired agglomerations.

An optional sampling device is available, allowing the quality of the mixture to be checked at any time.

Residue-free discharge

Since many manufacturers produce different products in succession, a residue-free discharge of the trough is important. In the case of the DMX, this is carried out by means of large, hydraulically operated discharge door wings that are available in two variants for fine and coarse-grained mixture products. The discharge door wing for fine-grained mixtures has a seal to prevent fine-grained materials, such as cement, from escaping; it is also waterproof.

The mixing shafts are fitted with special sealing air seals.

Excellent resistance to wear

Depending on the abrasiveness of the mixture, various wear liners are available. All wearing parts in the mixer, such as mixing arms or blades, are screw-fitted and are thus easy to adjust or exchange. This simplifies maintenance and increases the availability of the plant.

Tests in our BHS technical center

Every dry material mixture has different characteristics; for this reason, BHS conducts tests at its in-house technical center on request. These tests give the customer the certainty that his outlay is well invested and that the new plant is future-proof.

BHS-Sonthofen at BAUMA in Munich, April 15 to 21, 2013:
Hall B2, booth 325/420

About BHS-Sonthofen

BHS-Sonthofen GmbH offers innovative and efficient mechanical process solutions for mixing, crushing, recycling and filtration applications.

Since development of the first twin-shaft batch mixer in 1888, the company has demonstrated its innovative strength time and again with numerous new products. DKX twin-shaft batch mixers are regarded as the global benchmark where demanding mixing applications in the concrete industry are concerned.

For more information, visit www.bhs-sonthofen.de.

Kontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt:
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstrasse 83
52072 Aachen, Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de