Intensive mixer: an efficient mixing and granulation tool for molecular sieve production

In the field of molecular sieve production, the Intensive mixer, as an advanced equipment, is playing a vital role. It can skillfully complete the two key process steps of mixing and granulation in the same equipment, bringing many advantages to molecular sieve production.

Working principle and process

Mixing principle 

AKW Intensive mixer, its equipment structure contains unique ingenuity. The inclined cylinder is tilted at a specific angle. During the rotation process, the material is driven by the cylinder to be transported upward. After reaching a certain height, it falls downward under the influence of gravity. The material is thus initially mixed in the horizontal and vertical directions. At the same time, the high-speed rotor and mixing disk equipped inside the equipment usually rotate in opposite directions (they can also rotate in the same direction when special process requirements are required). The high-speed rotor is in an eccentric position. When the material is transported to the mixing range of the high-speed rotor, it will experience high-intensity mixing movement. This is because the rapid rotation of the high-speed rotor generates a strong shear force, which makes the material form a highly uniform mixing effect in the mixing disk. In addition, the multifunctional scraper located in a fixed position plays an important role in the whole mixing process. It constantly disrupts the flow of materials and continuously transports the materials to the mixing area of ​​the high-speed rotor. At the same time, it effectively prevents the materials from sticking to the wall and bottom of the mixing disk, ensuring that the materials participate in the mixing 100%, which effectively guarantees the high efficiency and uniformity of the mixing.

Granulation process

After the materials are fully mixed, the Intensive mixer starts the granulation process with its own special design. By precisely controlling the key parameters such as stirring speed, granulation pressure, and material flow rate, the uniformly mixed materials are gradually gathered and formed in the equipment. For example, some Intensive mixers use the centrifugal force generated by high-speed rotation to cause the materials to agglomerate into particles with a certain size and shape in a specific mold or working area. In addition, the equipment can flexibly adjust these parameters according to different molecular sieve production requirements, thereby producing molecular sieve particles with uniform particle size and regular shape to meet a variety of industrial application scenarios.

Equipment advantages

High efficiency and energy saving

Traditional molecular sieve production often requires multiple devices to work together to complete mixing and granulation. Not only is the equipment investment cost high, but also the material will consume a lot of energy during the transfer process between different equipment. The Intensive mixer integrates the two major processes into one, greatly reducing the power demand and equipment energy consumption in the material transfer link. At the same time, it reduces the energy consumption of the equipment during operation and improves energy utilization by optimizing key components such as the mixing system, transmission system and control system. According to actual data comparison, compared with traditional equipment, the Intensive mixer can reduce energy consumption by 30% - 50%, effectively helping enterprises save production costs.

Excellent quality

During the mixing process, the Intensive mixer can achieve a uniform distribution of various components in the molecular sieve raw materials at the microscopic level with advanced mixing technology and precise parameter control. This is crucial to ensure the performance stability of molecular sieve products. Each molecular sieve can exert consistent adsorption performance and selectivity when used. Moreover, in the granulation stage, the equipment can accurately control the particle size and shape of the particles. Taking particle size control as an example, the error can be controlled within a very small range, and the produced molecular sieve particles have a regular shape, which is conducive to improving the effect of molecular sieves in practical applications and enhancing the competitiveness of products in the market.

Easy to operate

Intensive mixers are usually equipped with advanced automatic control systems, such as PLC control systems. The operator only needs to pre-set the mixing time, stirring speed, tilt angle, granulation parameters and other process parameters on the control interface, and the equipment can run automatically and stably to complete the whole process of mixing and granulation. This automated operation mode greatly reduces manual intervention and reduces the labor intensity of operators. At the same time, it avoids product quality fluctuations caused by improper manual operation, and improves the stability of the production process and the reliability of product quality.

Wide range of applications

Whether it is powdered or granular raw materials, or materials with different viscosity characteristics, the Intensive mixer can easily cope with it. In the production of molecular sieves, for different types of molecular sieve formulas, including raw materials containing various active ingredients, auxiliary ingredients and different particle size requirements, the Intensive mixer can adjust its own operating parameters and structural configuration to achieve efficient mixing and granulation, showing strong versatility and adaptability.