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
A rotating mixing disk tosses sand upward, while a high-speed rotor at an eccentric position reorganizes the material flow, coating each grain of sand with a uniform coating of bentonite within 90 seconds. This is a technological revolution taking place a
Discover how the Co-Nele 25L Intensive Mixer—the ultimate carbon black granulator machine—boosts density by 180% with zero dust emissions. Lab-to-production solutions for batteries, tires, and polymers.
Intensive Mixer Efficient and uniform mixing to improve the quality of saggers,The CR20 inclined intensive mixer adopts a unique inclined design, combined with high-strength mixing blades, to ensure that the material achieves a highly uniform mixing effec
Our after-sales service is at your disposal for all
questions
We will contact you within 24 hours.
en
Search
