There are significant differences between the refractory high-efficiency intensive mixer and the mixer in terms of function, structure, application scenario and performance. The following is a comparative analysis from three dimensions: core principle, technical characteristics and application effect:

intensive mixer

1. Refractory Mixer Differences in core principles

High efficiency intensive mixer

Three-dimensional mixing technology is adopted, and the multi-dimensional flow field mixing of materials is realized through the inclined mixing mechanism and high-strength shear force.

Equipped with a planetary running system, the mixing tool rotates while revolving, forming a complex movement trajectory and effectively eliminating the mixing dead angle.

The principle of counter-flow and cross-flow mixing is integrated to achieve uniform dispersion of materials without dead angles in a short time, especially suitable for high-viscosity, ultra-fine powder and multi-component complex materials.

Conventional Refractory mixers

Single-shaft or double-shaft rotary mixing is mostly used, relying on the shear force in a single direction for mixing.

The mixing trajectory is relatively fixed, which is difficult to cope with high viscosity or ultra-fine powder materials, and is prone to agglomeration and segregation.

Uniformity needs to be improved by extending the mixing time, but it may lead to overheating of the material or structural damage.

2. Comparison of technical characteristics

High efficiency intensive mixer vs Conventional refractory mixers

Mixing efficiency :The mixing time is shortened by more than 40%, and the processing capacity of a single batch is increased by 30%, and the mixing time is longer and the efficiency is relatively low

Uniformity control: The CV value of mixing uniformity is ≤5%, which meets the high standard certification of GB/T 2988-2022, and the uniformity is greatly affected by the characteristics of the material

Energy consumption performance: 20%-30% lower energy consumption, high energy consumption with energy recovery system, lack of energy-saving design

The degree of automation is equipped with a PLC touch screen, which supports digital parameter setting and real-time monitoring, with a low degree of automation and manual operation

Convenient maintenance, compact structure, wear-resistant coating treatment, low failure rate and easy maintenance parts wear quickly, and high maintenance costs

intensive mixer

3. High efficiency intensive mixer and Conventional Refractory mixers Differences in application effects

High efficiency intensive mixer 

In the production of refractory materials, the density consistency of the finished brick can be increased by 15%, and the standard deviation of flexural strength can be reduced to ±0.3MPa at 1550°C.

Sealed structure Negative pressure dust removal design, dust emission concentration < 10mg/m³, in line with environmental protection standards.

Adapt to multi-scale raw materials (nano-scale micro powder to coarse aggregate ≤ 50mm) to meet the needs of complex formulations.

Conventional refractory mixers

It is easy to lead to uneven distribution of magnesia and binder, and the flexural strength of the finished product fluctuates greatly at high temperature.

The dust emission control ability is weak, and it is difficult to meet the requirements of modern environmental protection.

The adaptability to raw materials is poor, and it is necessary to make up for the limitations of the equipment by adjusting the process parameters.

The high-efficiency intensive mixer has significantly improved the efficiency and quality of refractory production through technological innovation, especially suitable for scenarios with high demand for mixing uniformity, environmental protection requirements and automation. Although the cost of traditional mixers is low, there are obvious shortcomings in complex material handling and energy saving and environmental protection. Enterprises can choose suitable equipment according to their own production scale, raw material characteristics and cost control needs.