Twin-shaft mixer-extruder, front-screen mixer-extruder, and hydraulic fine-crushing roller mill: what are the specific differences in their effects on brick and tile raw material processing?
■ All three devices are manufactured by our company. In a nutshell, here's how their functions are positioned:
1. Hydraulic Fine Crushing Double Roller Machine：Controls material particle size (fine crushing)、 extrusion mixing (extrusion into sheets)、Differential kneading and plasticizing.
2. Pre-screen mesh paddle extruder：water addition, filtration、 mixing (extruding fine clay strips into rod form)、 fine extrusion kneading and plasticizing.
3. Twin-shaft powerful mixing extruder：water addition、 mixing (extrusion and chopping, forming large lumps)、 coarse extrusion and kneading plasticizing.
■ The three are interchangeable in some functions, but their core goals are entirely different.
The particulars are as follows:
1. Hydraulic Fine Crushing Roller Machine [Material Size Control (Fine Crushing), Extrusion Mixing (Sheet Forming), Differential Speed Kneading & Plasticizing].
(1) Fineness adjustment function:
Generally placed after aging and before main machine forming, the primary purpose is to control raw material fineness (achieved by adjusting different roller gaps via hydraulic movable rollers, while regulating roller gaps based on forming effect, surface roughness, and fired product quality to meet production needs).
(2) Extrusion mixing function:
For wet and dry materials that are difficult to mix uniformly with twin-shaft stirring and prone to granulation, roll pressing mixing effectively compresses them into sheets for strong blending. Then, through differential-speed rollers, the sheets are torn and crushed, achieving extrusion mixing. Due to thin-layer mixing, it delivers better results than twin-shaft stirring. If installed in the forming section, it can eliminate the need for subsequent twin-shaft mixers (mixing function).
(3) Differential kneading and plasticizing function:
Two rollers have differential speed, with a speed difference.10%–20%After adjusting the gap between the two rollers (to control material particle size), differential speed enables crushing particles into powder while compressing the material, reducing particle ratio, increasing powder ratio, altering particle distribution, improving raw material plasticity, and enhancing product quality.
2. Pre-screen mesh paddle extruder [water addition, filtration, mixing (extruding fine clay strips, forming strips), fine extrusion kneading and plastification].
(1) Add water function:
Add atomized water to the material through piping, and mix evenly via stirring and extrusion.
(2) Filter function:
Material passes through the extrusion section, enters the mesh, and the shrinkage ratio can reach50%, higher than powerful stirring. As material passes through the mesh, grass roots and woven fibers attach to it and are filtered out. The mesh plate is then replaced hydraulically to maintain debris filtration.
(3) Mixing (extruding fine clay strips into strip form), fine extrusion and kneading for plasticization:
Material passes through the extrusion section, enters the mesh, and through the mesh achieves strong mixing and separation of the material, with a shrinkage ratio of up to50%, higher than powerful stirring.
3. Twin-shaft powerful stirring extruder [water addition, mixing (extrusion and shredding into large lumps), coarse extrusion kneading and plasticizing].
(1) Add water function:
Add atomized water to the material through piping, then mix and extrude for uniform blending.
(2) Mixing Function:
The material is extruded through the extrusion section into a large ring, shrinks, and is then cut into large chunks by the cutting blade. The shrinkage ratio reaches80%During this process, grassroots and woven materials will not be filtered out.
(3) Kneading and plasticizing:
The material passes through the extrusion section, is compressed into a round cake ring, and then shredded. The whole process is a large-block extrusion and shredding process, with average plasticizing effect.
■ Summary:
If we're talking about the lifting and firming function.
Hydraulic double-roll crusher≥Pre-screen mesh paddle extruder≥Powerful Blender.
Hydraulic ultra-fine double roller crusher, ratioThe powerful blender is significantly stronger, as it can directly alter particle size ratio and, through its kneading function, achieve pre-extrusion molding, greatly enhancing raw material properties. Two projects can illustrate this point.
(1) Fujian Fuding Project:
Sandy material, the raw material contains some quartz sand. The entire raw material line has a hydraulic double-roll crusher (Zhongyuan) and a powerful mixer, but once making void ratio35%Porous bricks, cannot be stacked for palletizing.
Later, a set of ultra-fine hydraulic roller crushers was added before forming, with a roller gap (GS1210）Adjust to1.8mmDifferential15%, the plasticity of raw materials has been addressed, and palletizing is also fine.
(2) Suqian coal gangue brick-making:
Crushed coal gangue as main material, hammer crusher.The material from the screen is mostly granular, lacks plasticity, and cannot be used for perforated bricks. The production line has multiple roller crushers and a powerful mixer.
The final solution is to add a hydraulic ultra-fine double-roll crusher before the forming process.GS1210, design roll gap1.8MM, differential, after installation, the plasticity of the perforated brick raw material has improved, and stacking is no problem.