Economical alternative to wet processing

Combimix processes (DKXC)

The patented Combimix system transforms the twin-shaft batch mixer (DKX) into a mixer that operates continuously according to the proven three-dimensional mixing principle. This results in a more intense mixing effect and a significantly longer average retention time compared to conventional continuous mixers. The material is extracted at the same rate as the input material is fed into the system.

BHS Combimix process for processing clay-and-rock mixtures in quarries

171012_BHS_Combimix-MSW-DREP2016_ENG_final - Original.mp4
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BHS Combimix process for processing clay-and-rock mixtures in quarries

This nomination video for the German Resources Efficiency Award 2016 introduces the BHS Combimix process for processing clay-and-rock mixtures at the Mönsheim quarry operated by MSW Mineralstoffwerke Südwest

Highlights

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Advantages compared to wet processing

  • No introduction of moisture into the aggregates
  • No wet sieving
  • No sludge processing
  • All materials are recycled, saving landfill space
  • Compact system also available as a semi-mobile version
  • High level of rock reclamation
  • Possible to screen out material smaller than 5 mm

 

Advantages compared to conventional continuous mixers

  • Continuous mixing process with a defined mixing time, which helps to reduce consumption of expensive burnt lime
  • Three-dimensional mixing principle
  • Consistently high mixture homogeneity
  • High throughput rates
  • Low wear

Technical systems

Function

BHS_Grafik_Combimix-System-Lehm.ai

Previously, cost-intensive wet processing was necessary in order to extract valuable rock grade from contaminated input material. Dry processing with the addition of burnt lime is not possible with conventional continuous mixers due to the extremely short retention time and poor mixing effect. The patented BHS Combimix system was developed to offer an economical alternative.

The Combimix system transforms the twin-shaft batch mixer into a mixer that operates continuously according to the proven three-dimensional mixing principle.

This results in a significantly improved mixing effect compared with conventional continuous mixers. The retention time is dependent on the input material and can be varied flexibly from 30 to more than 100 seconds. The filling level is kept constant over the entire production time by means of weight sensing in the mixer. The material is extracted at the same rate as the input material is fed into the system. This procedure enables the recovery of usable rock, while also saving on water, energy and material costs.

Process steps

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1. The raw material is fed in.

2. Pre-separation is performed over a roller screen.

3. The coarse-grain material is transported directly to the jaw crusher and from there to the quarry plant.

4. The clay-and-rock material is fed into the BHS Combimix system and combined with burnt lime.

5. The burnt lime is delivered from the silo by way of volumetric metering into the mixer on a screw conveyor (according to the clay content in the feed material of between 1 and 5%). A weight-based approach is available on request.

6. The mixing material is fed into the screening unit.

7. Materials larger than 5 mm are made available for further processing.

8. Materials smaller than 5 mm can be used as fertilizer, for example, where appropriate.

Technical specifications

Type Throughput 1) Max. particle size Weight 2)
DKXC 1200 85 t/h 42 mm 3.900 kg
DKXC 2600 180 t/h 64 mm 5.900 kg
DKXC 4900 350 t/h 120 mm 10.400 kg
DKXC 7300 520 t/h 120 mm 18.500 kg
DKXC 10800 770 t/h 150 mm 28.000 kg
DKXC 12900 920 t/h 150 mm 37.000 kg

1) 60 s mixing time and density of 1.7 t/m³
2) Weight for standard design without accessories

Performance data for other materials available on request. All specifications apply to the standard design. Technical data for customized designs may differ from the specified data.
All technical data may change due to development. Subject to modification without notice.

Application examples

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Feed material 0 - 40 mm: sticky, loamy, which is considered waste

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Screened material > 5 mm after Combimix mixing process

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Sieved clayey material < 5 mm with quicklime

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Mixed material with quicklime

Solutions

Images

Tests give certainty

Which mixer is the right one for your application? Don’t leave anything to chance. Leave it to our team of process consultants. Working together with you, our specialists will test the material and develop a tailor-made solution for you.

Downloads

“Combimix system (DKXC)” brochure
“Mixing & crushing” overview brochure
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Success stories

Events

bauma CHINA 2020

24.11.-27.11.2020 | Shanghai (China)
Hall E7, booth 538

Intermat Paris 2021

19.04.-24.04.2021 | Paris (France)

bauma 2022

04.04.-10.04.2022 | Munich (Deutschland)

Hillhead 2021

22.06.-24.06.2021 | Hillhead Quarry Buxton (UK)
Booth B36

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