Pellet quality starts with homogeneous mixing. Uneven blending of iron concentrate, bentonite, return fines and additives is a common headache for pellet plants. It leads to unstable green pellet strength, high breakage rate, excessive return material and higher binder consumption, which negatively affects the induration process and raises the cost per ton of pellets.As the key pre-treatment equipment before pelletizing, the intensive mixer for pelletizing adopts the counter-current high-shear mixing principle to solve typical defects of traditional drum mixers such as material segregation and dead mixing zones. It lays a solid foundation for stable pellet production.
Intensive Mixer for Pelletizing
The intensive mixer features an inclined rotating drum combined with an adjustable high-speed rotor. Materials undergo tumbling, convection and shearing movements inside the chamber to form a 3D turbulent state. Microscopic uniform dispersion can be achieved within tens of seconds to a few minutes. Binders and moisture evenly coat iron ore particles to eliminate segregation, delivering far better mixing uniformity than conventional drum mixers.Key Advantages-Improved green pellet performance & reduced return finesSufficient mixing ensures even distribution of bentonite and binders. Under the same formula, green pellet compressive strength and drop strength are greatly improved. Fewer green pellets break, finished pellets show consistent metallurgical properties. It works well with grate-kiln and straight grate pellet processes.-Lower binder dosage & reduced operating costPowerful high-shear dispersion helps cut bentonite consumption. Uniform mixing optimizes heat utilization during firing and reduces overall energy consumption, bringing remarkable long-term economic benefits.-Heavy-duty wear-resistant design for harsh metallurgical conditionsWear-resistant liners and mixing blades are installed at material contact areas to resist abrasion from ore powder. Fully enclosed structure minimizes dust emission and improves workshop environment. Modular design facilitates inspection and spare part replacement, suitable for 7×24 continuous industrial operation.-Intelligent control & wide material adaptabilityEquipped with PLC control system. Water addition, rotor speed and mixing time can be precisely adjusted. It handles iron concentrate, oxide pellet feed, metallurgical sludge, dust ash and other blended materials. Custom models are available for new pellet lines and revamping projects with compact footprint for easy layout.-Integrated mixing and pre-agglomerationIt completes homogenization and pre-granulation at the same time, lowering the load of subsequent disc pelletizers. Pellet size distribution becomes more stable and reduces fluctuation in the pelletizing section.
Intensive Mixer for Pelletizing
Our intensive mixers have been successfully applied in pilot lines and large-scale pellet plants with millions of tons annual capacity. For existing production lines, retrofitting with this mixer requires limited civil modification and achieves quality upgrade with low investment. For new projects, it stabilizes the whole production chain from the raw material stage.Under the trend of cost reduction, carbon reduction and quality upgrading in the metallurgical industry, upgrading the mixing section is a preferred route for pellet process optimization. A reliable pellet intensive mixer acts as the stabilizer of your whole pelletizing line.We welcome inquiries from pellet producers, engineering institutes and plant revamping contractors. Material testing, process design, capacity selection and customized on-site solutions are available. Trial runs can be arranged to verify mixing performance.
