With the increasingly stringent environmental protection policies in my country and the in-depth promotion of the concept of circular economy, the resource utilization of industrial solid waste such as fly ash has become the focus of coal-fired power plants, building materials companies and environmental protection industries. In the fly ash treatment process, humidification and mixing are the key links to prevent dust pollution, improve transportation safety and subsequent utilization efficiency. Traditional single-shaft mixing equipment often faces pain points such as uneven mixing, high energy consumption, and easy wear. The twin-shaft mixer is becoming the preferred solution for improving quality and efficiency in the industry with its unique design and technical advantages.
1. Challenges and demands of fly ash treatment: As a by-product of coal-fired power plants, fly ash has the characteristics of fine particle size, low density and easy dust. If it is not fully humidified, it is easy to cause dust diffusion during transportation and storage, which not only pollutes the environment, but also endangers the health of workers. At the same time, the moisture content of fly ash after humidification needs to be precisely controlled between 10% and 15%: too low a moisture content cannot suppress dust, and too high a moisture content will cause agglomeration, affecting its reuse in cement, concrete and other fields. Traditional single-shaft mixers are often difficult to meet the requirements due to insufficient mixing intensity and poor mixing uniformity, and the equipment wears quickly and has high maintenance costs. More efficient and reliable alternatives are urgently needed.
2. Core technical advantages of double-shaft mixers: The double-shaft mixer adopts an innovative structural design of double spiral shafts mixing in opposite directions + staggered blades, combined with an intelligent control system, to provide a full range of optimization solutions for fly ash humidification and mixing:
2.1. Efficient mixing and uniform humidification:
The double-shaft mixer uses two parallel spiral shafts to rotate synchronously in opposite directions to form strong shear force and convection motion, and the fly ash and atomized water are mixed in three dimensions in the body. The blade angle is optimized by fluid mechanics to avoid material accumulation or dead corners, ensure that the moisture content fluctuation range is ≤±1%, and eliminate dust or agglomeration problems from the source.
2.2. Low energy consumption and long life:
2.2.1 Power system innovation: The combination of variable frequency motor + hard gear reducer is adopted, and the power is reduced by 15%-20% compared with single-axis equipment, and the energy consumption cost is significantly reduced.
2.2.2 Wear-resistant design: The mixing blades and the inner lining of the cylinder are made of high chromium alloy or ceramic composite material, which has a wear resistance of more than 3 times, a service life of more than 50,000 hours, and a maintenance cycle extended by 60%.
2.3. Intelligent control and precise adaptation:
Integrated PLC control system, real-time monitoring of material flow, humidity and equipment operation status, and support one-key adjustment of speed, water addition and discharge speed. According to different fly ash characteristics (such as fineness, initial moisture content), multiple sets of process parameters can be preset to realize full-process automation.
3. Application scenarios:
Double-axis mixers have been widely used in coal-fired power plant ash storage discharge system, fly ash transportation pretreatment line, building materials production line (such as aerated bricks, ceramsite preparation) and other scenarios.
Conclusion: Henan Zhengzhou Mining Machinery Co.,Ltd. has established cooperative relations with many companies in the industry. The main products of the process system include: rotary kiln, ball mill, vertical preheater, single drum cooler, vertical cooler, dryer, granulator, feeder, dust collector, elevator, double shaft mixer, magnetic separator, flotation machine, classifier and other complete sets of machinery and equipment in the industry; from the original single machinery and equipment production enterprise, it has gradually developed into a high-tech enterprise with full-process technology integrating scientific research, design, manufacturing, installation, commissioning and operation guarantee. It is a comprehensive company with the ability to develop and produce a complete set of environmental protection, building materials, mining and metallurgical process technology and equipment. It has won unanimous praise from customers with first-class service and excellent quality.
