Brazil's robust industrial base, encompassing steel, cement, and non-ferrous metal production, drives a continuous demand for high-performance refractory materials. The quality of these refractories hinges on the mixing process. This case explores how a major Brazilian refractory manufacturer overcame production bottlenecks by integrating CONELE Intensive Mixer into their operation.
The Customer's Challenge:
Our client, a prominent refractory producer in Brazil, was struggling with the limitations of their traditional mixers. Their production of high-value, complex formulation refractories was hampered by:
* Inadequate Mix Homogeneity: Difficulty in achieving a perfectly uniform distribution of fine powders, binders, and additives, leading to weak spots and inconsistent product quality.
* Long Mixing Cycles: Extended processing times were required to achieve a sub-optimal mix, limiting overall production capacity.
* High Maintenance Costs: Frequent wear and tear of mixer components due to the abrasive nature of raw materials resulted in excessive downtime and high spare part costs.
* Inability to Handle Advanced Formulations: Their old equipment could not efficiently process modern recipes requiring intense shear and precision mixing.
The CONELE Solution:
After a detailed technical review, the customer chose the CONELE CR Intensive Mixer. The decision was driven by its proven capabilities in the global refractory industry:
* Superior Intensive Mixing Principle: The combination of a rotating mixing tool and a counter-rotating pan creates intense shear forces and convective movement. This ensures every particle is coated evenly and agglomerates are completely broken down.
* Robust, Abrasion-Resistant Design: Constructed with high-grade steel and lined with wear-resistant materials in critical areas, the mixer is built to withstand the harsh abrasive loads 24/7.
* Energy and Time Efficient: The intensive mixing action achieves perfect homogeneity in a significantly shorter time compared to traditional mixers, reducing cycle times and energy consumption per batch.
* Sealed and Dust-Free Operation: The closed design prevents dust emission, protecting the working environment and ensuring no loss of valuable raw materials.
Results and Benefits Delivered:
The installation of the CONELE refractory intensive mixer delivered transformative results:
* Perfect Product Homogeneity: The consistent and uniform mix quality significantly improved the density, strength, and performance of the final refractory products.
* Productivity Increase: Mixing cycle times were reduced by over 35%, enabling the production of more batches per shift and meeting rising demand.
* Reduced Operating Costs: Dramatic reduction in maintenance downtime and lower power consumption per batch led to a substantial decrease in overall operating expenses.
* Versatility: The mixer handles a wide range of formulations, from traditional castables to advanced low-cement and no-cement refractories with ease.
* Enhanced ROI: The combination of higher output, superior product quality, and lower operating costs ensured a rapid return on investment.
Back To The List
To address the need for highly homogeneous mixing and stable granulation in honeycomb zeolite production, this project selected the CO-NELE CRV24 honeycomb zeolite mixing and granulation machine as the core front-end process equipment.
CONELE intensive mixer can serve as core material processing equipment for environmental technology, supporting various processes ranging from industrial waste pretreatment, waste solidification, resource recovery, secondary fuel preparation to contaminat
A refractory materials manufacturer selected two CONELE CR19 750L intensive mixers as key mixing equipment for the large-scale production of various high-end refractory products during a production line upgrade.
Our after-sales service is at your disposal for all
questions
We will contact you within 24 hours.
en
Search
