DK3145687T3

DK3145687T3 - Sekventielt gennemløbsblandeanlæg

Info

Publication number: DK3145687T3
Application number: DK15736167.6T
Authority: DK
Inventors: Karl Enzenhofer
Original assignee: Geolyth Mineral Tech Gmbh
Priority date: 2014-05-20
Filing date: 2015-05-12
Publication date: 2018-10-29
Also published as: AT515881B1; HUE039845T2; EP3145687A2; EP3145687B1; WO2015176092A2; AT515881A1; PL3145687T3; ES2689310T3; WO2015176092A3; LT3145687T; SI3145687T1; HRP20181562T1

Description

CONTINUOUS MIXER APPARATUS FOR PRODUCING A FOAMED SLURRY AND METHOD FOR OPERATING SUCH A CONTINUOUS MIXER APPARATUS

The invention relates to a continuous mixing apparatus, which serves to mix pulverized and/or granular solids with a liquid into a slurry (pulpy mass) and foam up this slurry.

The advantages of the continuous mixing apparatus according to the invention are primarily valuable if the foamed slurry created therewith is a self-hardening mass, particularly a rapidly hardening mass, for example a mineral formulation such as aerated concrete, or a foamed mineral heat insulator. A problem with mixing pulverized and/or granular solids with liquid into a self-hardening, foamed slurry exists in that the slurry and foam must be mixed together well without destroying the foam structure. A further problem is that upon completion of the discharge from the mixer a residue of slurry remains as an adherence in the mixer and hardens there if the mixer isn’t promptly cleaned. By using a continuous mixer, with the help of which you can mix continuously over an extended period of time - and do not have to mix in individually separated batches with machine downtimes between said batches, -the cleaning effort is reduced, but cleaning must also be carried out here upon completed discharge or following an unscheduled stoppage of the mixer.

Typical continuous mixers for producing self-hardening slurry from pulverized and/or granular solids and water have a conveyor and a mixer, wherein the conveyor continually moves the solids through an opening into the chamber of the mixer, wherein liquid is introduced into the chamber of the mixer by at least one additional opening, wherein the mixer mixes continually and wherein the slurry continually resulting in the mixer is continually filtered from the mixer by means of a further opening. There exist many methods and devices known from prior art in order to add a foam component or compressed air to the slurry in order to obtain an aerated or air void-containing building material. DE 3100443 A1 discloses a continuous mixer for concrete or foamed concrete, with which the solids are transported by means of a screw conveyor from the base of a feeding container into the chamber of a horizontally arranged mixer. The screw conveyor and the rotor of the mixer are positioned on a common shaft and are driven jointly by a motor. In the front part of the mixer, mixing water is added and the slurry is mixed. Foam is then added into the rear part of the mixer and mixed into the slurry. From the output of the mixer, the aerated slurry enters the reservoir of a pump, with which the aerated slurry is pumped to the place of use. A disadvantage of this intrinsically robust and simple structure is, firstly, that the aerated slurry produced in the mixer gently by folding in is transported by a pump being arranged downstream of the mixer, whereby there is the risk that the foam structure is destroyed in the pump or by the pumping action. In addition, the mixer can only then be emptied if the screw conveyor is already run dry. Rapid, unplanned disconnection, as can be required in the case of faults with any system components, leads thereby to considerable problems. DE 3629674 A1 and WO 2011044604 disclose similar continuous mixers, wherein however screw conveyors and mixer rotors have no common shaft and can be driven separately from one another. The mixer can thereby be emptied if only the screw conveyor and the further material supply are disconnected. When cleaning the mixer, which usually occurs by spraying cleaning fluid into the mixing chamber, cleaning fluid can however also enter the transported material found in the end area of the screw conveyor on the mixer side and form a self-hardening mass with this. EP 1065033 A2 discloses a continuous mixer, with which the pulverized and/or granular solids are supplied from the top into a vertically positioned mixing chamber and not as in the previously mentioned documents from one side into a horizontally arranged mixing chamber. At the bottom of the mixing chamber, a progressive cavity pump is connected, which serves to transport the slurry to the place of use. When cleaning the mixer by means of sprayed fluid, the risk is thereby somewhat reduced that fluid gets into the pulverized and/or granular solids that are not yet located within the mixing chamber and forms a curable mass with this. Through the construction, particularly through the vertical alignment of the material flow through the mixing chamber and the immediately following transportation through the pump without any intermediate container, the amount of produced slurry in a wide area can be adjusted and the amount of slurry in the system can be reduced. DE 2437231 A1 discloses a vertically positioned mixer having a progressive cavity pump at the bottom. In the centre of the preferably two-stage progressive cavity pump, compressed air is added to the slurry. On the exit side, a swirl chamber connects to the progressive cavity pump, into which a rapidly rotating tool further mixes the slurry that has been mixed with compressed air. The disadvantage is that the stirring tool is attached vertically in the swirl chamber and rotates rapidly, thereby the mixing section in the swirl chamber is limited to the diameter of the stirring tool and the structure of the air voids can be negatively affected by the brief, violent mixing. DE 3807250 A1 discloses a continual mixer for mixing a slurry and a foam component. The mixer is loaded with slurry by means of the hose line of a concrete pump, wherein the foam is also injected into the mixer. The disadvantage is that a premixed slurry is used, which is transported to the reservoir of a concrete pump and from this via a hose line to the mixer. The disclosed device is therefore suitable for use on a building site, on which a certain distance must be negotiated between the pump and place of use. This device is not suitable for producing prefabricated parts, such as thermal insulation panels from rapidly hardening, aerated slurry. DE 4408088 A1 discloses a method for the production of a porous, mineral lightweight insulating board. A slurry is thereby mixed in a first mixer, said slurry arriving in an intermediate container and being transported away from this with a pump by means of a pipeline. The pipeline of the slurry and the pipeline of the foam components are combined by means of a Y-shaped, branched mixing tube and homogenised by means of a static mixer. A static mixer has no rotating components. The mixing occurs by means of static obstacles, which cause turbulence of the components. It is disadvantageous that the mixing in the static mixer cannot be adjusted to a variable delivery rate. In addition, the cleaning of the static mixer is difficult as a material discharge from the static mixer is not possible following the standstill of the pump. In addition, a rapidly hardening mass has a tendency to stick to the complexly formed obstacles in the static mixer, wherein it is difficult to clean the areas behind the obstacles even with water that is pumped through the static mixer under pressure. DE 3735951 A1 describes a mixer pump for the production of lime milk. No foam is added to the lime milk. BE 889539 A2 clearly describes a continuous mixing apparatus, wherein a second mixer connects to a progressive cavity pump, wherein the housing of the second mixer has an inlet port for foam on the first, upper end. The second mixer is a vertical mixer.

The object of the invention is to create a Continuous mixing apparatus for the production of a very rapidly hardening, highly foamed slurry.

The sub-objects of the invention can be seen in the need that the slurry does not harden in the continuous mixing apparatus, the quantity and density of the generated aerated slurry should be adjustable in a wide area, a gentle foaming of the slurry is facilitated, a destruction of the foam structure is prevented, the production can be stopped at any time without major problems and the system can be cleaned quickly without terminating continuous operation.

To solve the objective according to the invention, it is proposed that solids and the mixing liquid are mixed to a flowable slurry in a first vertically arranged mixer, wherein at the bottom of the vertical mixing chamber a progressive cavity pump is attached, which conveys the premixed material under pressure from the first mixing chamber directly into the initial area of a second mixing chamber, wherein the second mixing chamber is arranged horizontally and has a rotating, horizontally arranged, elongated mixing device. Using a foam gun, the foam component is also conveyed under pressure into the initial area of the horizontal mixing chamber, wherein the slurry and the foam are moved through the horizontal mixing chamber, wherein the mixing device gently folds the foam component into the slurry. It is important that the inlet of the foam gun and the progressive cavity pump to the horizontal mixer are designed to be pressure-tight.

The amount of slurry and foam is therefore preferably selected such that the transportation through the horizontal mixing chamber occurs mainly by means of the higher flow rate of the foam. The amount of slurry, which is pumped into the horizontal mixer, is thereby preferably between 1 and 12 litres per minute, particularly preferable is an amount of 2 to 9 litres per minute. The amount of foam, which is pumped into the horizontal mixer, is preferably between 30 and 200 litres per minute, particularly preferably between 50 and 100 l/min. The ratio between the volume of foam and the volume of slurry is preferably between 200:1 and 30:12, particularly preferably between 50:1 and 5:1. At the rear end of the horizontal mixing chamber, there is an outlet, through which the premixed, aerated slurry leaves the continuous mixing apparatus and is preferably cast directly into moulds. At the outlet, a hose can also be connected where necessary, wherein the diameter of the hose should correspond to that of the horizontal mixing chamber.

Thereby the following advantages arise compared with the prior art: • As no intermediate reservoir, pipelines or hoses exist, the amount of slurry or aerated slurry, which is located in the mixing system, is lower than with known devices and rapid emptying and cleaning are facilitated. • Through the vertical arrangement of the first mixer, it is avoided that the inlet for the solids, which is located at the upper end of the vertical mixer, comes into contact with mixing liquid during the operating mode. • Through the vertical arrangement of the first mixer and the vertically arranged progressive cavity pump, it is achieved that these can be almost completely drained when the material supply is stopped and the operation of the mixing device of the vertical mixer and progressive cavity pump is continued. • Through the horizontal arrangement of the second mixer, it is achieved that the foam and therefore the resulting pores are not compressed, as the influence of gravity is negligibly small compared with the vertical arrangement. Thereby a very regular pore size is facilitated. The influence of gravity is also negligible due to the very low dead weight of the aerated slurry, if the preferably high proportion is added to foam. • As a result of the outlet of the horizontal mixer leading preferably into the open air or a hose with a large diameter and as a result of the horizontal mixer and hose, where applicable, having a considerably greater diameter than the feed openings of the slurry and foam, the lifting of the foam into the horizontal mixer occurs virtually pressurelessly, whereby the foam and the resulting pores are not compressed or destroyed. This is particularly advantageous compared with static mixers, as the transportation of the slurry and foam by the static mixer occurs under pressure. • Through the rotating, elongated mixing device in the horizontal mixer, it is achieved that the material in this is also moved if the foam gun stops transportation. • The continuous mixing apparatus can process very rapidly self-hardening slurries, as the amount of slurry in the system is as low as possible, the self-hardening is constantly actively moved in each area of the system, the system can be drained virtually without residue and is easy to clean and can be taken apart.

The solid supply occurs preferably by means of a screw conveyor, which conveys the solids continually from the lower end of a reservoir to the upper end of the vertical mixer.

The shaft of the mixing device of the vertical mixer preferably has at the bottom a coupling, which actively connected with the rotor of the eccentric pump, such that the chamber of the vertical mixer with the thereon attached motor and the mixing device can be moved away from the progressive cavity pump and the solid supply opening, particularly can be pivoted away.

The vertical mixing chamber and/or the horizontal mixing chamber particularly preferably have supply valves for cleaning fluid, through which cleaning fluid can be fed in at high pressure. The vertical mixing chamber preferably has high-pressure injection nozzles, through which the necessary process water can also be fed in.

To realise the invention, vertical mixers can be used with progressive cavity pump, as are known from prior art. These can, for example, be applied as mortar mixing pumps (e.g. models of the PFT G4 series by Knauf PFT GmbH & Co. KG).

With the representational use of solids, which form very rapidly hardening masses upon contact with liquid or moisture, the improvements according to the invention as described below have proven to be advantageous. These improvements could be viewed as independent inventions, as the improvement of the individual components is also advantageous for another use or combination. In combination and for use in the representational continuous mixing apparatus and the preferably used very rapidly hardening slurry, these are particularly valuable.

The first preferred improvement according to the invention of the vertical mixer exists in that there is an additional lid or shut-off valve. The vertical mixer can thereby be sealed in an area between the feed opening of the solids and the feed opening of the mixing liquid. After the lid or the shut-off valve is closed, the mixer can be cleaned with cleaning fluid at high pressure or at normal pressure. The cleaning fluid is thereby injected through the feed opening of the mixing liquid, or through additional nozzles.

The second preferred improvement according to the invention of the vertical mixer exists in that this is designed to have two parts, wherein mixing water is only added to the second, lower section of the mixing chamber. The two sections are formed through the insertion of a panel, which has a sealable opening for the passage of solids. In the lower section of the mixing chamber, a mixing device is disposed, which sweeps over all surface areas of the inner side of the lower section of the mixing chamber at least once per revolution, such that no material can adhere to this and harden. The mixing device located in this section preferably has two plug-in couplings for connection to the rotor of the progressive cavity pump on one side and to the shaft of the motor on the other. The housing of the mixing chamber can be opened in the lower section and the mixing device can be removed.

The improvement according to the invention of the progressive cavity pump consists therein that this is mounted with its lower end in or on the housing of the horizontal mixer, such that the housing of the progressive cavity pump is secured on its lower end against horizontal displacement and distortion. A further improvement according to the invention of the progressive cavity pump can exist therein that this is provided on its lower end with a bearing plate for mounting the rotor, wherein this bearing plate is connectable directly with the inlet opening of the horizontal mixer in a pressure-tight manner. The rotor of the progressive cavity pump is particularly preferably mounted directly into the mixer housing of the horizontal mixer. A part of the rotor preferably protrudes into the feed opening of the housing of the horizontal mixer, such that the shell surface of this opening is swept by the rotor.

Due to the fact that the progressive cavity conveys directly from the top without a connecting piece in the horizontal mixing chamber and the feed opening is swept from underneath by the horizontal mixing device, no adherence and hardening of material occurs between the progressive cavity pump and the horizontal mixer. The connection of the progressive cavity pump and the mixer housing preferably occurs in a detachable manner, for example by means of clamping levers, electrical linear drive or a pneumatic or hydraulic cylinder, such that the horizontal mixer housing can be moved away from the progressive cavity pump if necessary.

The particularly preferable improvement according to the invention of the horizontal mixer exists therein that the mixing device of the horizontal mixer consists of an elongated shaft, on which flexible deformable mixing elements preferably made of high-strength steel are attached. These mixing elements are exposed to bending forces and vibrations during operation, whereby a change in the form of the flexible spring steel occurs, which results in the loosening of deposits. This is particularly advantageous if the solids have no proportion of coarse-grained particles, which would otherwise contribute to the loosening of deposits.

The ends of the mixing elements are preferably in contact with the inner wall of the mixing chamber, such that these constantly sweep the material adhered to the inner wall during operation. The mixing elements are particularly preferably designed such that all the surface areas of the inner wall are swept during a revolution of the mixing device. The mixing elements are particularly preferably produced from a 0.5 - 1.5 mm thick spring steel sheet and prestressed against the inner wall of the mixing chamber.

The invention is explained in more detail on the basis of the drawings.

Fig. 1: shows the continuous mixing apparatus according to the invention in a lateral part sectional view.

Fig. 2: shows a particularly preferable continuous mixing apparatus according to the invention in a lateral part sectional view.

Fig. 3: shows the bearing plate of the progressive cavity pump in the lateral sectional view and from above.

Fig. 4: shows a vertical mixer according to the invention with closed shut-off elements in a lateral part sectional view and in the sectional view from above.

Fig. 5: shows a vertical mixer according to the invention in the lateral sectional view.

Fig. 6: shows the exemplary structure of a particularly preferable shut-off element in the sectional view.

Fig. 7: shows a particularly preferable vertical mixer according to the invention in the sectional view.

Fig. 8: shows a horizontal mixer according to the invention in the view from behind and in the lateral sectional view.

Fig. 9: shows a further horizontal mixer according to the invention in the view from behind and in the lateral sectional view.

Fig. 10: shows a further horizontal mixer according to the invention in the view from behind and in the lateral sectional view.

Fig. 11: shows the particularly preferable mounting of the progressive cavity pump in the lateral sectional view.

Fig. 12: shows the particularly preferable design of the continuous mixing apparatus according to the invention in a lateral sectional view.

Fig. 13: shows the particularly preferable design of the continuous mixing apparatus according to the invention in the dismantled state.

As can be seen in Fig. 1, the solid pulverized to granular solids are conveyed from a reservoir 1 by means of a conveyor 2 into the vertical mixer 3. A progressive cavity pump 4 is disposed at the bottom of the vertical mixer 3. The vertical mixer 3 has at least one inlet 3.3, to introduce the mixing liquid, which can consist of water or water with various fluid additives. The inlet 3.3 is disposed beneath the feed opening for the solids, whereby mixing water is prevented from getting on or into the conveyor 2.

In the vertical mixer 3, the solids are mixed with the mixing liquid to a flowable slurry, which directly enters the progressive cavity pump 4 from the under end of the vertical mixer 3. The shaft of the vertical mixing device 3.1 has a connection to the rotor 4.1 of the progressive cavity pump 4, such that the shaft and the rotor 4.1 are driven by a common drive, the motor 3.2. The progressive cavity pump 4 pumps the slurry directly into the horizontal mixer 5. The slurry enters from above through the slurry inlet port 5.3.1 into the housing 5.3 of the horizontal mixer 3 into its mixing chamber. Through the inlet port for foam 5.3.2, foam is inserted into the horizontal mixer 5 by means of a foam gun. The slurry inlet port 5.3.1 and the inlet port for foam 5.3.2 is positioned in the front area of the mixer housing 5.3. The mixer housing 5.3 is designed to be elongated and has preferably a ring-shaped cross-section, is therefore preferably constructed as a horizontal hollow cylinder, which is sealed on one or both ends with a panel. In the rear area of the mixer 5, the housing 5.3 has the outlet 5.3.3, through which the slurry mixed with foam leaves the continuous mixing apparatus. The horizontal mixing device 5.1 is disposed in the mixer 5.3. This consists of an elongated shaft, which is provided with a number of mixing elements 5.1.1. The shaft can be mounted on both sides of the mixer 5 in its housing 5.3. The horizontal mixing device 5.1 is driven with the motor 5.2 and rotates thereby around its own axis. The rotation of the mixing elements 5.1.1 occurs thereby in an angle of 90 ° to the direction of transport of the slurry and the foam. The mixing section of slurry and foam is defined by the length of the mixing chamber of the horizontal mixer 5. The aerated slurry preferably passes directly from the outlet 5.3.3 into a mould 6, in which it can harden into an element, particularly into a panel or a panel geometry. Instead of the mould 6, the slurry could be filled into preformed construction elements, such as bricks, in order to improve their thermal insulation properties.

Fig. 2 shows a continuous mixing apparatus according to the invention, wherein details, particularly preferred details of the embodiment, are shown.

The conveyor 2 is preferably a screw conveyor. The screw conveyor 2.1 is driven by a motor 2.2. The screw conveyor 2.1 preferably protrudes a little into the mixing chamber of the vertical mixer 3.

The shaft of the vertical mixer 3 is preferably connected by means of a plug-in coupling with the rotor 4.1. The vertical mixer 3 can thereby be detached from the progressive cavity pump 4, particularly pivoted away from this. If the vertical mixer 3 is pivoted into the operating position, the parts of the plug-in coupling engage again.

The progressive cavity pump 4 can be firmly connected on its lower end with a bearing plate 4.2, which for example can be formed of high-strength steel. The bearing plate 4.2 acts as a bearing for the rotor 4.1, as this is only connected by means of a plug-in coupling with the shaft of the vertical mixing device 3.1. The rotor 4.1 is disposed with an off-centre part-region of its lower end decentrally on the bearing plate 4.2. The vertically acting forces are transferred from the off-centre part of the rotor 4.1 to the bearing plate 4.2. The rotor 4.1 can preferably also be mounted directly in or on the housing 5.3. The housing 5.3 can preferably be moved away from the progressive cavity pump 4 and is for example fixable to this by means of two clamping levers or a pneumatic cylinder 9.

In Fig. 3, an exemplary bearing plate 4.2 is shown. The body of the support plate 4.2 is formed as a panel with a central opening, preferably ring-shaped. An additional, radial guidance of the rotor 4.1 can occur, if this has on its lower end a pin positioned off-centre of the rotary axis, which rotates on the shell surface of the opening of the bearing plate 4.2. The central opening could also be formed as a slot, i.e. a longitudinal oval, wherein the diameter of the pin corresponds to the width of the slot.

On the outer shell surface of the bearing plate 4.2 or on the horizontal 4.3 of the progressive cavity pump 4, the first engagement point of a not shown clamping lever seal (or an electromechanical, pneumatic or hydraulic drive) is disposed, its second engagement point abuts on the housing 5.3 of the horizontal mixer 5. By tightening the clamping lever, the horizontal mixer 5 is pressed against the bearing plate 2.4. To improve the seal action, a seal made of rubber or comparable material can be attached between the bearing plate 2.4 and the housing 5.3.

It is also conceivable not to attach the bearing plate 4.2 to the housing 4.3 of the progressive cavity pump 4, but rather to connect the bearing plate 4.2 firmly with the housing 5.3 of the horizontal mixer 5, for example to weld and press by means of tensioning or a pneumatic cylinder 9 the housing 5.3 with the bearing plate 4.2 against the progressive cavity pump 4. The slurry inlet port 3.5.1 could also be designed itself with two differently sized opening cross-sections in order to create a bearing surface for the rotor 4.1 in the same way as the bearing plate 4.2.

The vertical mixer preferably has a shut-off element 7. This shut-off element 7 can be entered into the mixing chamber of the vertical mixer 3 such that a separation being impervious to liquid of the conveyor 2 and the parts of the vertical mixer 3 coming into contact with the mixing liquid can be created. This shut-off element 7 can for example seal the feed opening as a lid 7.1, through which the conveyor 2 transports into the mixing chamber of the vertical mixer 3. The shut-off element 7 can as a shut-off valve 7.2 seal the vertical mixer 3 in a cross-sectional area, which is positioned between the material supply of solids and the inlet 3.3. The shut-off valve 7.2 consists preferably of two valves, which can be moved into the vertical mixer 3 horizontally from two sides. In the closed state, the two abutting faces of the valves abut one another, wherein bother abutting faces have a semicircular recess, which serves to receive the shaft of the vertical mixing device 3.1. The abutting faces, and the recesses of the two valves are preferably provided with rubber or a comparable material, in order to improve the sealing effect.

Fig. 4 shows the vertical mixer 3 with closed shut-off element 7. Thereby two variations of the shut-off element 7 are shown, wherein only one of these is used when implementing the device.

The shut-off element 7 can be designed as a slidably held lid 7.1. This lid 7.1 can be inserted into the connecting line of mixer 3 and conveyor 2. When shutting off, the conveyor 2 is first moved somewhat away from the mixer 3, whereupon the lid 7.1 is moved into the resulting gap and closes this in a sealing manner.

The shut-off element 7 can be designed as a shut-off valve 7.2. This shut-off valve 7.2 consists preferably of two valves, which can be moved into the mixer 3 horizontally from two sides. Both valves have a recess, with which they enclose the shaft of the vertical mixing device 3.1 in the shut-off state. On the lateral surfaces, on which the valves come into contact with one another and with the shaft, these can be provided with rubber or a comparable material.

It is also conceivable that a shut-off valve 7.2 is attached in place of the lid 7.1 in the area of the discharge opening of the conveyor. In this case, it is not necessary to move the conveyor 2 away from the mixer 3 and the shut-off valve 7.2 only has one valve.

Fig. 5 shows the particularly preferable embodiment of the vertical mixer 3 with a two-part mixing chamber. The separation into two subsections occurs by means of a separator plate 3.4. The actual mixing element 3.1.1 is thereby arranged in the lower subsection of the mixing chamber. The separator plate 3.4 has an opening positioned concentrically to the shaft of the vertical mixing device 3.1. The gap between the shaft and the separator plate forms the opening for the passage of solids from the upper section of the vertical mixer 3 into the lower section.

In Fig. 5, the shut-off element 7 is designed as an automatically adjustable sealing body 7.3, which can separate in a sealing manner the two sections of the vertical mixing chamber. The sealing body 7.3 has a hollow cylindrical form, wherein this is tapered at the bottom and at the top in the form of a truncated cone. The opening in the separator plate 3.4 is formed as a funnel shape, such that the shell surface of the truncated cone of the sealing body 7.3 abuts the shell surface of the opening in the closed state. The hollow cylinder of the sealing body 7.3 encloses the drive shaft of the vertical mixing device 3.1, wherein the sealing body 7.3 can be moved along the drive shaft.

The drive shaft of the vertical mixing device 3.1 is rotatably mounted with regards to the part of the sealing body 7.3, which abuts the separator plate 3.4 in the closed state. Thereby the mixing element 3.1.1 and the rotor 4.1 of the progressive cavity pump 4 can also still be driven following the impervious separation of the two subsections of the mixing chamber. The upper section of the mixing chamber should not have any areas, in which solids can be deposited, i.e. no horizontal surface areas. In addition, the upper section preferably has a funnel-shaped interior form. In the example, this is solved in that above the separator plate 3.4 a funnel insert, for example made of plastic, is used in the mixing chamber. The movement of solids through the opening of the separator plate 3.4 can be supported by means of a vibrator or shaker, which is fastened externally on the housing of the upper section of the mixing chamber.

In Fig. 6, the cross-section of an exemplary sealing body 7.3 is shown. This is translationally slidably mounted in an outer sleeve. The outer sleeve is connected with the housing of the mixer, for example as shown by means of two supports. The outer sleeve and the sealing body 7.3 have an opening for passage of the drive shaft of the vertical mixing device 3.1, wherein at these points seals (not shown) can be provided. The sealing body 7.3 can be adjustable hydraulically, pneumatically or by means of an electrical drive.

In Fig. 7, a further advantageous variation of the vertical mixer 3 is shown, wherein the conveyor 2 here provides material into a drop shaft. The drop shaft leads into an opening in the housing of the mixing chamber, wherein the opening is positioned at a distance to the passage opening of the drive shaft of the vertical mixing device 3.1. The drop shaft is sealable by means of a shut-off valve 7.2. The discharge opening of the drop shaft is preferably provided diagonally towards the inlet 3.3 in the top side of the mixer housing. The simple structure and simple sealability are advantageous to this embodiment.

According to the invention, at least one air pressure nozzle can be present in the transition area of the solid to slurry zone of the vertical mixer 3, i.e. in the area of the discharge opening of the drop shaft or the opening in the separator plate 3.4, which leads to better insertion of the pulverized solids, particularly the cement powder.

By closing the shut-off element 7, 7.1, 7.2, 7.3 before the beginning of the cleaning of the continuous mixing apparatus, it can be guaranteed that even during high-pressure cleaning of the vertical mixer 3 no cleaning fluid passes to the conveyor 2 and forms a self-hardening mass with the solids found there. This has the advantage that cleaning can occur at any time, without the conveyor 2 having to be previously emptied.

As shown in Fig. 2, the vertical mixer 3 and/or the horizontal mixer 5 preferably have at least one nozzle inlet 8, through which cleaning fluid can be sprayed preferably at high pressure. This facilitates the rapid and automated cleaning of the continuous mixing apparatus. The spraying of cleaning fluid can also take place exclusively or additionally through the inlet 3.3, wherein the cleaning fluid is pumped in the further course of action through the progressive cavity pump 4 into the horizontal mixer 5.

The inlet port for foam 5.3.2, the inlet 3.3 and the cleaning nozzles 8 have non-return valves, which prevent the slurry or cleaning fluid penetrating into one of the pipelines for foam, mixing water and cleaning fluid.

The mixing elements 5.1.1 are preferably designed of high-strength steel, which leads to a self-cleaning effect of the same.

Fig. 8-10 show horizontal mixers 5 according to the invention. As shown here, the motor 5.2 is preferably not disposed on the back end of the horizontal mixer 5, but at its front end, i.e. at the end at which the supply of slurry and foam occurs. Thereby the back end of the horizontal mixer 5 can be designed to be open, as an outlet 5.3.3. The mounting of the drive shaft in the passage opening at the front end of the housing 5.3 must take place in a pressure-tight manner.

The mixing elements 5.1.1 are made of a flexible material, particularly of high-strength sheet steel or wear-resistant plastic. The individual mixing elements 5.1.1 are preferably formed by means of a support, which runs parallel and at a distance to the drive axis of the horizontal mixing device 5.1. The support is connected with the drive shaft by means of two shanks, which preferably abut at their two ends. Of course, more than two supports can also be provided, particularly to increase the stability if the support is made of thin sheet metal and/or is very long. The mixing elements 5.1.1 are in radial terms longer than the distance between the shaft and the housing interior, such that the mixing elements 5.1.1 abut the housing interior and are prestressed against the same. Torques due to the prestressing on the shaft can be balanced out in that the mixing elements 5.1.1 are attached to one another in a radially offset manner, such that the radially acting forces of the prestressing cancel each other out. It is important that the supports of the mixing elements 5.1.1 in total sweep the entire shell surface of the inner side of the housing 5.3 at least once during a revolution. Lateral cover areas of the inner side of the housing 5.3 can each be swept by the adjoining shank of the mixing element 5.1.1 connected to the cover area. As during a revolution all internal surfaces of the housing 5.3 are therefore swept, the slurry or aerated slurry are prevented from adhering to this and hardening. In areas, in which two or more mixing elements 5.1.1 overlap on one circumference range, the inner side of the housing 5.3 is swept several times per revolution. In addition to the described mixing elements 5.1.1, for example in the area between two shanks of a mixing element mixing element 5.1.1 and radially offset to these, other forms of mixing elements 5.1.1 can also be attached to the shaft. These could for example be designed as high-strength steel sheets, which do not extend to the inner surface of the housing 5.3.

As shown in Fig. 8, the mixing elements 5.1.1, especially in the two end areas of the horizontal mixer 5, can be formed differently. At the front end of the mixing chamber, on which the slurry inlet port 5.3.1 is located, the thickness of the spring steel sheet should have a somewhat thicker dimension, for example 1.5 mm. At the back end of the mixing chamber, on which the outlet 5.3.3 is located, a larger number of mixing elements 5.1.1 can be provided on the same circumference range of the shaft. In the example, these are two mixing elements 5.1.1, which are arranged to each other at an angle of 180 °. The number of mixing elements 5.1.1 at one circumference range could also be larger, particularly three to each other at an angle of 120 °, four to each other at an angle of 90 °, five to each other at an angle of 12 ° and so on. Through the embodiment with several mixing elements 5.1.1 arranged radially offset to one another, the horizontal mixing device 5.1 in is supported and guided in the housing 5.3 such that a separate mounting of the shaft on the back end of the mixing chamber can be avoided. Thereby the outlet 5.3.3 can extend over the entire back side surface of the housing 5.3.

As shown in Fig. 10, the back end of the pipe-shaped horizontal mixing chamber can also be largely opening during the positioning of the shaft, if a for example circle segment-shaped bearing plate 5.4 is provided, which is connected with its one end with the housing 5.3 and has in the area of the other end a recess for the mounting of the shaft.

As shown in Fig. 9, the shanks of the mixing element 5.1.1 can be attached to the shaft radially offset to one another. Depending on the direction of the displacement with regards the rotational direction, the delivery of the aerated slurry is thereby supported, or counteracted.

In a further, not shown variation, the outlet 5.3.3 can have a lid or a shut-off valve. Thereby the horizontal mixer 5 can be closed in a sealed manner. For example, the horizontal mixer 5 can be sealed during cleaning and filled with cleaning fluid, which is circulated through the horizontal mixing device 5.1. For example, the outlet 5.3.3 can also be closed in the time periods, during which a filled mould 6 is replaced for an unfilled mould 6.

In Fig. 11, the particularly preferable embodiment is shown, with which the progressive cavity pump 4 conveys directly into the horizontal mixing chamber without a bearing plate 4.2. As shown, the rotor 4.1 can thereby preferably protrude into the slurry inlet port 5.3.1, wherein the bottom of the rotor 4.1 preferably sweeps the shell surface of the slurry inlet port 5.3.1. The rotor 4.1 of the progressive cavity pump 4 is not mounted at its bottom end. This is possible if an upwardly aligned force is effected on the rotor 4.1, during operation of the progressive cavity pump 4 through its rotating movement into the approximately helical housing 4.3. To secure the housing 4.3 against displacement or to support this, an insert 4.4 is used in the housing 5.3 of the horizontal mixer 5, which serves to horizontally and vertically mount the progressive cavity pump 4 and forms the slurry inlet port 5.3.1. To secure the housing 4.3 of the progressive cavity pump 4 against distortion, a retaining pin 4.3.1 protrudes from this, which engages in a U-shaped retaining panel being attached to the housing 5.3. The insert 4.4 is replaceable and the device can thereby be adapted to the dimension of the respectively used progressive cavity pump 4.

As shown further in Fig. 11, a pneumatic cylinder 9 can preferably about the horizontal mixer 5. In place of the pneumatic cylinder 9, a hydraulic cylinder or an electromechanics linear drive could also be used. Through the pneumatic cylinder 9, the horizontal mixer 5 can selectively be pressed against the progressive cavity pump 4 or moved away from this. The insert 4.4 can have at the upper edge of its opening a phase, which serves to centre the progressive cavity pump 4 during insertion.

In Fig. 12, a particularly preferable mixing system according to the invention is shown, which can be considered the best mode of the invention. The vertical mixer 3 is designed in two parts, wherein in the upper area the supply of the solids occurs through the screw conveyor 2.1 and in the lower area the mixing liquid is fed in by means of the inlet 3.3. A centering panel 10, preferably made of rubber, which is attached to the shaft of the vertical mixing device 3.1, is disposed above the inlet of the screw conveyor 2.1 and serves along with centering of the shaft to keep dust of the used formulation away from the plug-in connector for the motor shaft 3.2.1, which is preferably located within the mixer housing. The motor 3.2 can together with the lid 3.2.2 of the mixer housing be pivoted away for example with a hinged joint and the mixing device 3.1 can be removed vertically from the mixer housing for cleaning. The upper area of the vertical mixer 3 has on its lower end a funnel-shaped area. The stirring element 3.1 has a wiping element 11, which wipes the conical section of the upper area, so that solids and solids that have already come into contact with liquid cannot adhere. The wiping element 11 can be attached as shown by means of a spiral-shaped element to the vertical mixing device 3.1. In the lower area of the vertical mixer 3, a pipe insert 12 made of plastic is used, which can be removed from the housing of the mixer 3. This pipe insert 12 has the advantages that materials adhere less easily to plastic as they do to steel and that after removing the pipe insert this can be quickly cleaned of adhering material by dusting off and the associated elastic deformation. The mixing device 3.1 is designed as a whisk. At the bottom of the vertical mixer 3, the progressive cavity pump 4 is disposed, whose rotor 4.1 is preferably detachably connected with the bottom end of the whisk. The housing of the progressive cavity pump 4 is mounted in the insert 4.4.

The internal shell surface of the horizontal mixer 5 is formed by means of a plastic pipe 13, which is advantageous for the reasons stated about the pipe insert 12. To absorb or transfer the forces and torques occurring in the horizontal mixer 5, the plastic pipe 13 is housed in a preferably three-part housing 15. The housing 15 has a front section 15.1 having an opening for the insert 4.4, a bearing for the horizontal mixing device and an opening for the foam inlet. The housing 15 has a back section 15.2 having a bearing as shown in Fig. 10 for the horizontal mixing device. To transfer forces and torques between the two described sections 15.1 and 15.2, the housing 15 has a central section 15.3, to which the two sections 15.1 and 15.2 preferably detachably connect. The section 15.3 is preferably formed by a strut, for example three bars spread over the scope of the plastic pipe 13. The section 15.3 can preferably have a trough-shaped support for the plastic pipe 13, in order to prevent slight sagging of the same. On the back section 15.2, a conically widening rubber joint 16 preferably connects, which leads into a not shown material container of a filling installation or to which a not shown hose line is connected. The horizontal mixing device 5.1 is formed by a square element 14, on which flexible mixing elements 14.1 and 14.2 are attached. The square element 14 has on both ends a shaft extension for mounting in the sections 15.1 and 15.3 of the housing 15. The mixing elements 14.1, 14.2 are preferably formed of an elastic sheet, particularly spring steel, and have respectively two shanks attached at a distance to the square element, said shanks being connected at their outer end by a support. The mixing elements 14.1 and 14.2 are different in that the supports of the mixing element 14.1 are aligned parallel to the square element 14 and the supports of the mixing element 14.2 are aligned obliquely thereto. This is achieved in that the shanks of a mixing element 14.1 are attached to the same lateral face of the square element 14 and the shanks of a mixing element 14.2 are attached to opposite lateral surfaces of the square element 14. The inclination of the mixing elements 14.2 is selected such that a conveying effect in the direction of the rubber joint 16 occurs when the mixing device is rotated. The rigidity of the mixing elements 14.1 or 14.2 can be adjusted by forming these as multiple layers in the area of the shanks, the shanks of the mixing elements 14.1 are thereby formed of two layers of sheet steel, the mixing elements 14.2 from a single layer of sheet steel. Two mixing elements 14.1 positioned successively in the longitudinal direction of the mixer are preferably fastened to opposing lateral surfaces of the square element 14. It is particularly advantageous to the embodiment variation of Fig. 12 that all areas of the continuous mixing apparatus through to the outlet 5.3.3, which come into contact with self-hardening slurry, are constantly swept by rotating parts. In addition, it is advantageous that the internal shell surfaces of the mixer 3, 5 ad progressive cavity pump 4, which come into contact with self-hardening slurry, are formed of plastic, which reduces the consolidation of hardened slurry and facilitates cleaning by means of dusting off. It is particularly advantageous to the system described according to Fig. 12 that the cleaning can rapidly occur in a purely mechanical manner and therefore the introduction of cleaning fluid at high pressure can be omitted, thus no nozzles 8 are necessary and a shut-off element beneath the solid inlet in the vertical mixer can be omitted.

In Fig. 13, the system described in Fig. 12 is shown in a disassembled state. With the vertical mixer 3, the motor (3.2) with the lid 3.2.2 is first pivoted away and the vertical mixing device 3.1 is removed. Then at least one part of the housing of the lower area of the vertical mixer 3 and the pipe insert 11 is removed, wherein the housing part can also be pivoted away using a hinged joint. The horizontal mixer is initially pivoted downwards away from the progressive cavity pump 4, such that the insert 4.4 can be removed. The section 15.2 or just the bearing plate 5.4 of the section 15.2 is removed or pivoted away together with the rubber joint 16. Thereafter the horizontal mixing device 5.1 and the plastic pipe 13 can be removed from the device. In the dismantled state, the mixing devices 3.1, 5.1 and the pipes 11,13 can be particularly rapidly cleaned of adhesions by dusting off. The motor 5.2 can also be mounted such that it can be removed or pivoted away in order to be able to knock out the horizontal mixing device 5.1 on its shaft pin protruding from the mixer housing from the mixer housing, should this become stuck.

The use of the system in question is particularly advantageous when processing mineral slurry that hardens extremely quickly without autoclaving, as this adheres particularly rapidly to surfaces in the mixer and hardens there due to these properties. Through the constant wiping of the surfaces, the duration of the cleaning interval is maximised, this amounts to a few hours with the formulations typically processed with the system designed according to Fig. 12, which makes the advantage of rapid disassembly and rapid cleaning of the elements particularly apparent. The formulation being processed is preferably Geolyth of Geolyth Mineral Technologie GmbH or comparable mineral formulations, as are described in WO 2011044604 A1 or WO 2011106816 A1, among others.

As many detailed improvements according to the invention are specifically described in the figure description, reference is made in conclusion once again to the basic solution according to the invention, consisting of the conveying of a flowable slurry with a progressive cavity pump 4 connecting at the bottom of a vertical mixer 3 directly into the initial area of a horizontal mixer 5, wherein the foam of a foam gun is also pumped into the initial area of the horizontal mixer 5 and the foam and the slurry are mixed on the way through the horizontal mixer 5 to its outlet 5.3.3 by means of the rotating horizontal mixing device 5.1.

Claims

Sekventielt gennemløbsblandeanlæg

1. Gennemløbsblandeanlæg til fremstilling af en skummet slurry, hvor der i en vertikal blander (3) blandes faste stoffer og blandevæske til en flydedygtig slurry, og hvor der ved den nederste ende af den vertikale blander (3) befinder sig en vertikalt placeret excentersnekkepumpe (4), hvor - excentersnekkepumpen (4) på udgangssiden munder tryktæt direkte ud i den første, forreste ende af huset (5.3) på en horisontal blander (5), - blanderen (5) ved sin anden, bageste ende er forsynet med en udløbsåbning (5.3.3), kendetegnet ved, at - huset (5.3) ved den første, forreste ende er forsynet med en skumindløbsåbning (5.3.2), ved hvilken ledningen fra en skumkanon er tilsluttet tryktæt, - der i blanderen (5) er placeret et roterbart horisontalt blandeværktøj 85.1).

2. Gennemløbsblandeanlæg ifølge krav 1, kendetegnet ved, at den vertikale blander (3) indeholder et øverste og et nederste område, hvor en transportanordning (2) til transport af de faste bestanddele i slurryen fra en forrådsbeholder (1) munder ud i det øverste område på den vertikale blander (3), hvor transportanordningen (2) fortrinsvis er en snekketransportør, og hvor en tilslutning (3.3) til tilførsel af væske fører ind i blandekammeret i det nederste område af den vertikale blander.

3. Gennemløbsblandeanlæg ifølge krav 2, kendetegnet ved, at det øverste område af den vertikale blander (3) tilspidses konisk i forhold til det nederste område af den vertikale blander (3), hvor et afstrygerelement (11), der roterer sammen med det vertikale blandeværktøj (3.1) i det mindste tilnærmelsesvist ligger op til den konvekse flade af det koniske område, og at det vertikale blandeværktøj (3.1) i det nederste område af den vertikale blander (3) er udformet som et piskeris, der har mindst to ben, der i det mindste tilnærmelsesvist ligger op til den konvekse flade på den vertikale blander (3).

4. Gennemløbsblandeanlæg ifølge et af kravene 1 til 3, kendetegnet ved, at der i den vertikale blander (3) eller i det nederste område af den vertikale blander (3) er indsat en udtagelig indsats i form af et rør, der danner den indvendige konvekse flade af blanderhuset.

5. Gennemløbsblandeanlæg ifølge et af kravene 1 til 4, kendetegnet ved, at den vertikale blander (3) i området mellem transportanordningens (2) udmundingsåbning og tilslutningen (3.3) er forsynet med en skilleplade (3.4), der deler den vertikale blander (3) i to delområder og indeholder i det mindste en åbning til gennemløb af de faste stoffer og drivakslen på det vertikale blandeværktøj (3.1).

6. Gennemløbsblandeanlæg ifølge et af kravene 1 til 5, kendetegnet ved, at det vertikale blandeværktøj (3.1) inden for huset i den vertikale blander (3) via en stikkobling er forbundet med drivakslen (3.2.1) på en motor (3.2), der er anbragt øverst på blanderhuset, og at motoren (3.2) kan fjernes sammen med dækslet (3.2.2) på den vertikale blander (3.2), således at det vertikale blandeværktøj (3.1) kan fjernes fra huset i vertikal retning.

7. Gennemløbsblandeanlæg ifølge et af kravene 1 til 6, kendetegnet ved, at huset (5.3) på den horisontale blander (5) i eller på slurryindløbsåbningen (5.3.1) haren lejeflade til vertikal afstøtning af rotoren (4.1) til excentersnekkepumpen (4), eller at der mellem den horisontale blander (5) og excentersnekkepumpen (4) er anbragt en lejeplade (4.2), der indeholder en lejeflade til rotoren (4.1).

8. Gennemløbsblandeanlæg ifølge et af kravene 1 til 7, kendetegnet ved, at der i huset (5.3) på en horisontale blander (5) er indsat en indsats (4.4), der indeholder slurryindløbsåbningen (5.3.1) og danner en lejeflade til vertikal afstøtning af huset til excentersnekkepumpen (4).

9. Gennemløbsblandeanlæg ifølge et af kravene 1 til 8, kendetegnet ved, at den nederste ende af rotoren (4.1) rager ind i slurryindløbsåbningen (5.3.1), idet den fortrinsvis cylindriske ende ligger excentrisk i forhold til det vertikale blandeværktøjs (3.1) omdrejningsakse, og omløbsbanen af det yderste omfangsområde af rotorens (4.1) ende ligger på eller tæt på slurryindløbsåbningens (5.3.1) diameter.

10. Gennemløbsblandeanlæg ifølge et af kravene 1 til 9, kendetegnet ved, at motoren (5.2), der driver det horisontale blandeværktøj (5.1), er anbragt ved den forreste ende af huset (5.3), og at huset (5.3) er udført som en hulcylinder, der er lukket på den ene side, idet den bageste ende af huset (5.3) i det mindste for en stor dels vedkommende er åben.

11. Gennemløbsblandeanlæg ifølge et af kravene 1 til 10, kendetegnet ved, at beklædningen til den horisontale blander (5) er dannet af et plastrør (13), der i det mindste ved sine to ender er optaget i et hus (15).

12. Gennemløbsblandeanlæg ifølge et af kravene 1 til 11, kendetegnet ved, at det roterbare horisontale blandeværktøj (5.1) består af en aksel, på hvilken der er fastgjort fjederelastiske blandeelementer (5.1.1, 14.1, 14.2).

13. Gennemløbsblandeanlæg ifølge et af kravene 1 til 12, kendetegnet ved, at det i det mindste ene blandeelement (5.1.1, 14.1, 14.2) er forbundet med det horisontale blandeværktøjs (5.1) aksel via i det mindste to ben i en indbyrdes afstand, der er forbundet ved hjælp af et forbindelsesstykke, der forløber parallelt med akslen.

14. Gennemløbsblandeanlæg ifølge et af kravene 12 til 13, kendetegnet ved, at indersiden af beklædningen til det horisontale blanderhus (5.3) over sin samlede længde er i berøring med en eller flere blandeelementer (5.1.1, 14.1, 14.2).

15. Fremgangsmåde til drift af et gennemløbsblandeanlæg ifølge et af kravene 1 til 14, kendetegnet ved, at - de faste stoffer og blandevæsken forblandes i den vertikale blander (3) og i form af en flydedygtig slurry pumpes direkte ind i den forreste ende på en horisontal blander (5) ved hjælp af en excentersnekkepumpe (4), - der pumpes skum ind i den forreste ende på den horisontale blander (5) ved hjælp af en skumkanon, - slurryen og skummet transporteres gennem den horisontale blander (5) hen til dennes bageste ende og dermed til udløbsåbningen (5.3.3), hvor transportvirkningen bevirkes af skummets høje volumenstrøm, - skummet vendes i slurryen i den horisontale blander (5) ved hjælp af et horisontalt blandeværktøj (5.1).