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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

Science Research Technology

BHS-Sonthofen: Cubical shaped grains with round edges

BHS-Sonthofen: Cubical shaped grains with round edges

The crushing chamber of the rotor impact mill.

Rotor impact mills for sand processing: Unique process increasingly being used for other applications.

At BAUMA 2013, BHS-Sonthofen is showcasing its unique rotor impact mills, which are not manufactured by any other company in the world. They produce crushed sand with special characteristics that cannot be achieved in the same quality with any other machine: the grains are cubical, but their edges are rounded. Dry mortar produced with this type of sand is easier to use and makes concrete easier to pump.

Last year BHS-Sonthofen delivered numerous RPM-type rotor impact mills for new dry mortar factories in fast-growing Asia and the Middle East, further consolidating its position as market leader in machinery for producing dry mortar sands. BHS rotor impact mills employ a globally unique principle.

These rotor impact mills are increasingly being used for other applications than manufacturing sand for the dry mortar industry; for instance, they are being employed more and more frequently to make sand for ready-mixed concrete, as the concrete containing such sand has excellent pumping properties. Around the world, the number of rotor impact mills is also growing in the asphalt industry, in the manufacture of surfaces for sports facilities, as well as for grinding limestone, dolomite, gypsum, anhydrite and quick lime.

When it comes to crushing rocks, the rotor impact mill works best on slightly to moderately abrasive material. It can process feed sizes up to 56 mm. Larger feed sizes can be used for materials that are easy to crush, such as quick lime. Throughput can reach 75 t/h.

The horseshoe-shaped hammers in BHS rotor impact mills are also absolutely unrivaled. The input material is fed into the machine from above through the centrally-located feed tube. When it hits the rotor, it is accelerated outward at high speed by the centrifugal forces, where it is then caught by the horseshoe-shaped hammers, which impel it against the anvil ring of the annular housing.

The rock breaks upon impact and assumes its cubical form. Repelled by the anvil ring, which is available in toothed and smooth versions, the material hits the hammers again, is further crushed, and thrown back against the anvil ring. This repeats until the material is small enough to pass through the gap between the rotor and the anvil ring, and falls out through two discharge chutes.

The multi-phase crushing process serves to grind the edges of the particles, closely approximating the way sand is produced in nature. In practical applications, the rounded grain form makes it easier to process the material. For example, plaster made from this sand is easier to spread than if made from sand with sharp edges. The same effect makes the rotor impact mill an attractive choice for producing sand for ready-mixed concrete, which is then easier to pump.

The sand produced has a high proportion of grains sized between 0 and 2 mm. Compared to conventional impact mills, the rotor impact mill results in a considerably higher proportion of useful grains.

The gap between the horseshoe hammers and the anvil ring is adjustable and the peripheral speed of the rotor is variable, making the BHS rotor impact mill flexible for use in a wide range of applications. It also effectively processes fine off-spec gravel fractions, making it an efficient and future-proof solution.

The adjustable hammers can be installed and set manually without any special tools or lifting devices. They ensure the output grain-size curve of the BHS rotor impact mill remains constant over the entire service life of the wearing parts, maintaining a consistent quality of the final product.

The entire inlet cover can be pivoted for optimum accessibility, which greatly simplifies maintenance of the machine.

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

About BHS-Sonthofen GmbH

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

We have been working in the „crushing technology“ sector for more than 100 years, manufacturing crushing machines that are used for processing minerals in quarries and gravel pits and in the mining industry. Our products include state-of-the-art impact crushers and mills with horizontal and vertical shafts.

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