Mixing and Granulation Equipment for Continuous Casting Refractories

How Does an Intensive Mixer Improve Refractory Mixing and Granulation? 

CO-NELE intensive mixers integrate mixing, kneading, and granulation in a single machine, providing an efficient solution for preparing refractory materials used in continuous casting applications. By combining intensive mixing with adjustable liquid addition and granulation parameters, the equipment helps manufacturers achieve uniform material distribution, controlled granule size, and consistent bulk density without transferring materials between separate machines. 

For continuous casting refractories, where raw material consistency directly affects molding performance and finished product quality, integrating these processes can simplify production, reduce material handling, and improve process control. 

Mixing and Granulation Equipment for Continuous Casting Refractories

Intensive Mixing: Achieving Uniform Distribution of Refractory Materials 

Refractory formulations typically contain raw materials with significantly different physical properties, including particle sizes, densities, and viscosities. 

For example: 

• Magnesia: Has a true density generally exceeding 3.5 g/cm³. 

• Flake Graphite: Has a density of approximately 2.1–2.3 g/cm³. 

• Phenolic Resin: A viscous binder that can easily form agglomerates if not distributed properly. 

These differences make uniform mixing challenging. Heavy aggregates may segregate from lighter components, while viscous binders can cause localized agglomeration. Conventional mixing equipment may require longer processing times and still struggle to achieve the required homogeneity. 

How CO-NELE Intensive Mixing Technology Works 

CO-NELE intensive mixers utilize an inclined intensive mixing principle combined with three-dimensional turbulent material movement. 

Inside the mixing vessel, the mixing tools generate intensive material circulation and relative movement, producing three primary mixing effects: 

• Shearing: Breaks down agglomerates and promotes the dispersion of fine powders and binders. 

• Convection: Moves materials between different regions of the mixing vessel. 

• Diffusion: Improves the distribution of individual particles throughout the mixture. 

The combined action helps overcome differences in material density and physical properties, enabling rapid and uniform mixing of complex refractory formulations. Applications and Refractory Industry Experience 

CO-NELE intensive refractory mixers are designed for demanding powder mixing and granulation applications across the refractory industry. 

Typical applications include: 

• Magnesia-carbon bricks. 

• Continuous casting refractories. 

• Alumina-based refractory materials. 

• Refractory castables and dry mixes. 

• Specialized refractory powder formulations. 

CO-NELE has accumulated application experience among major refractory manufacturers in China and international markets. Companies referenced in CO-NELE's refractory industry project portfolio include Punaite, Lier, Ruitai, Sinosteel Luonai, Shannai, Refratechnik, RHI Magnesita, Vesuvius, and POSCO. 

Equipment configurations can be customized to meet different production requirements, whether customers need an individual intensive mixer or a complete production system integrating raw material feeding, mixing, granulation, conveying, and storage. 

Contact CO-NELE to discuss your refractory materials and arrange a free mixing and granulation test.