At the Maco Group Headquarter in Beijing, China, installation work is currently underway at full speed for a dry mortar production plant planned by EIRICH for more than 100 raw materials in two production lines. Commissioning is scheduled for early 2015.
Plants and mixers for the production of dry mortar are supplied by a wide range of manufacturers all over the world. EIRICH, however, is the company which has been in the market the longest, having supplied mixers for making plaster as early as 1906. Over the last few decades it has equipped more than 250 plants with state-of-the-art mixing technology and systems engineering. In addition to turn-key systems, EIRICH also supplies mixers for the optimization of existing systems or for new systems from other systems engineering companies. EIRICH is flexible enough to accommodate the specific wishes and requirements of each potential customer and implement them to perfection. This was the reason why MACO awarded EIRICH the contract for the engineering and the delivery of the key components of the new plant (mixers, batching systems, scales, control systems). One of the two lines will be ATEX-conform.
The core element and at the same time quality-critical component of a dry mortar plant is the mixing system. In essence there are two different mixing systems used around the world, most of which are batch process-based. One of the systems is the single-shaft axial mixer, also known as the plowshare mixer or named after its working principle, which runs within the Froude number range of < 10. The other system is the
EIRICH intensive mixer. The Froude number, which describes the ratio of the impact of centrifugal forces relative to gravitational forces in the mixing process, can for the latter be many times that of the plowshare mixer, depending on requirements.
The requirements to be met by the mixing process are high. The mortar can contain up to 20 different components, often with fibers, pigments and organic additives in small amounts as well. In addition to the mechanical mixing of the components, other critical factors are the disintegration of fines, disagglomeration, and the separation of fibers. Single-shaft mixers are therefore equipped with additional choppers which are run at speeds of up to 3,000 rpm. The two EIRICH RV24 (2 x 3,000 l) intensive mixers used at MACO require no choppers for system-related reasons: the disintegration of the fines is achieved thanks to the high Froude numbers of the mixing tool.
In order to meet requirements in terms of the high quality standards and the diversity of the large and small components, today´s dry mortar production plants are almost completely automated. For the MACO project this means that more than 100 components have to be batched via over 30 scales, some of which are accurate to within +/- 5 g.
Other inherent advantages of EIRICH mixing technology which MACO can count on include: The efficiency of the mixer is not dependent on the arrangement of the product inlets; liquids such as, e.g. dust bonding oil, do not have to be injected but can often be simply poured in instead; the tool is subject to less wear, resulting in above average operational reliability and therefore system availability
EIRICH anticipates that more major orders from China will follow.