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Kneader Reactors

Kneader reactor is a special machine which speciallize in mixing & kneading high viscousity materials. In the food stuff or the chemical industries, there are many materials need to be fine coumpounding together.E.g. the chewing gum is made up of the sugar, gum rubber & some other materials.

Description

1.Horizontal mixing machine with 2 Sigma or Z type blades.
2.There are 2 different gears connect drive the 2 blades, 1 shaft is about 1.5 speed than another blades.
3.Kneader reactor usually has a W type barrel & a heating jacket outside.
4.With 1 Powerful Motor & Speed reducer to drive the 2 blades.
5.With Hydraulic tilt turnning the W type barrel.
6.With Hydraulic Cover Opening system.
7.The Kneader Reactor could design a Vacuum system to remove the gas from the material.
8.The machine could be designed by 2 PT-100 sensor to test the jacket oil temperature & the material temperature.

Usage

High & Very high Viscousity material like:Chewing gum,dough,toffee;Plasticine,Rubber,Silicone,Adhesive,Resin,etc.
Those material has a viscousity at about 1,000,000cps.The reactants are liquids, Powder, solid.ie. slurry, and the reaction mass does not undergo a physical phase change while the reaction takes place.

How to select

1.NHZ-5Lt--1.5KW Motor--Tilt Discharge--Heating--Vacuum(-0.096Mpa);
2.NHZ-20Lt--3KW Motor--Tilt Discharge--Heaging--Vacuum(-0.096Mpa);
3.NHZ-50Lt--4KW Motor--Tilt Discharge--Heating--Vacuum(-0.096Mpa);
4.NHZ-200Lt--11KW Motor--Hydraulic Tilt Discharge--Heating--Vacuum(-0.096Mpa);
5.NHZ-300Lt--15KW Motor--Hydraulic Tilt Discharge--Heating--Vacuum(-0.096Mpa);
6.NHZ-500Lt--22KW Motor--Hydraulic Tilt Discharge--Heating--Vacuum(-0.096Mpa);
7.NHZ-1000Lt--45KW Motor--Hydraulic Tilt Discharge--Heating--Vacuum(-0.096Mpa);
8.NHZ-2000Lt--75KW Motor--Hydraulic Tilt Discharge--Heating--Vacuum(-0.096Mpa);
9.NHZ-3000Lt--90KW Motor--Bottom pump Discharge--Heating--Vacuum(-0.096Mpa).

If however phase changes occur during processing, the conventional technology requires the use of diluents. Diluents, or solvents decrease the viscosity of the reaction mass enabling mixing in the reactor, and controlling the reaction temperature.

More recently, manufacturers have been looking for technological solutions that allow synthesis in the concentrated phase, minimizing or eliminating the use of solvents, and intensifying the process itself. This “dry” process is possible in a kneader reactor or Continuous Processor.

Single Shaft Kneader Reactor

History

Developed by Heinz List, a pioneer of modern industrial processing technology, the kneader reactor technology is just starting to become popular in the processing industry.

In 1966, Heinz List said, “Processes in the concentrated phase are considerably more efficient than processes in the diluted phase and therefore also significantly more economical”. He recognized that processing in the concentrated phase, meaning solvent lean or even solvent-free, can maximize process yield per unit volume. In order to process in the concentrated phase, in itself a very complex and challenging task, new technology was required. He began the development of reliable process technology capable of handling phase changes during processing in the concentrated phase, otherwise known as “dry processing”.

Technology advantages

The relatively new Kneader Reactor Technology was introduced with the following competitive technological characteristics:

Excellent mixing and kneading performance during wet, pasty and viscous phases
Large working volume reactors efficiently handling large product volumes
Large heat-exchange surface areas yielding highest possible surface-to-volume ratio
Maximum self-cleaning
Narrow residence-time distribution for plug flow operation
Adaptive for a wide range of residence times
Closed design for cleaner production environment
Robust design for high viscosity processing
Compact design maximizing process yield per performance volume and minimizing space requirement

LIST Continuous Bulk Polymerizer, 100 Liter Unit

LIST Continuous Bulk Polymerizer, 100 Liter Unit

Equipment

Today, kneader reactor technology comprises the well-known twin shaft AP (1969) and single shaft DISCOTHERM B (1974), the versatile twin shaft ORP (1990), CRP (1990), CKR (2000), the unique single shaft LCD (List Continuous Dissolver, 1992) the new generation single shaft CBP (Continuous Bulk Polymerizer, 2003), single shaft CME (Continuous Main Evaporator, 2002) and TSF (Twin Shaft Finisher, 2002).

Kneader reactor technology has long been used for what today is known as “Process Intensification”, where multiple processing steps are performed in the same unit. Such units are characterized by high yield per performance volume and also have the flexibility to produce different grades and/or products.

Other types of equipment used to process high viscosity products continuously include the twin screw Continuous Processor. On a Continuous Procesor, the mixing elements are stacked up on the machines twin shafts, allowing for an infinate range of mixing intensities. The same machine can be used to continuously mix/process sensative, shear thinning materials, or mix products such as rubber where very high shear is needed.