Evaluating the Effectiveness of Lancaster Products K-Series High Shear Counter-Current Mixers in Ceramic Processing
In typical ceramic processing applications, mixing / milling is performed using processes such as ball milling, which is a lengthy and energy-intensive process, often requiring processing times as long as 12 – 24 hours.
Could you achieve similar mixing in far less time?
A Simple Study
- Mix the components of a solid state reaction system and evaluate phase composition, particle size, and homogeneity (not shown here) of the heat treated powders (calcium carbonate and titanium dioxide.)
- Compare ball milling at set increments (3,6,12, and 24 hours) with powder sampled from the K-series mixer at shorter times (30 min. or less.)
Comparable mix quality and reduction in particle size in 10 to 20 minutes of mixing in a high shear, counter-current mixer yielded similar results as 3 to 6 hours of ball milling time.
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Lancaster Products is dedicated to optimizing our customers’ mixing processes and recipes. This 3 part video series will focus on our on-site lab and testing capabilities. In this first video, we demonstrate proof of concept testing with a chicken litter material for a fertilizer product.
We use our K1 lab mixer during these initial tests. We load the K1 mixer with the test material and then program the steps and feeds. After the mixer begins, we add a liquid binder to it to allow the material to agglomerate into granules or larger pellets.
Rotary table feeders act as a critical piece of equipment in Lancaster Mixers continuous batch processing lines. They provide a mechanical conduit to continuously meter and feed materials from each batch of material processed to the next process in line. The cone and cylinder over the table is used as a surge hopper to temporarily store the material batch while the table feeder continuously discharges the material. Their role may seem simple compared to the processing equipment they’re connected to, but is significant to maintaining continuous throughput and ensuring overall system performance.
Lancaster Products’ high shear mixers process materials in batches which allows for tight control over the physical properties of the end product and thus, higher on-size, homogeneous yields. Most batches are processed completely and ready for discharge in a matter of minutes. By positioning a Lancaster rotary table feeder under the mixer’s discharge chute and feeding product downstream to the next piece of equipment, the batch processing is converted to a continuous process.