Holcim, the global leader in cement manufacturing, encountered a significant challenge in their liquid blending operations while striving to innovate and enhance their production processes. The aggressive and abrasive nature of liquid cement components necessitated a specialized solution that traditional dynamic mixers were unable to provide.
Problem
Traditional dynamic mixers were found to be unsuitable for Holcim’s production processes due to their inability to effectively handle the abrasive nature of cement. Additionally, these mixers introduced complications in terms of maintenance and efficiency. Holcim required a more robust and reliable solution; a specially designed static mixer that would ensure the efficient blending of liquids within the pipes.
Solution
Zetamix technology was selected to explore an innovative approach to address this challenge. The proposed solution involved creating static mixer components through 3D printing, a technology ideally suited for designing complex, small-volume parts tailored to the specific requirements of Holcim’s production process. Alumina was the material of choice due to its exceptional resistance to abrasion and aggressive chemicals.
The picture: The Alumina 3D printed parts being mounted on the rod of a static mixer
Implementation and Testing
The Zetamix team provided the prototype pieces that were directly mounted on the rod of a static mixer used for producing insulating mineral foams. Simple to install and without requiring any major modifications to the infrastructure, these mixers were directly inserted into the existing piping system. Allowing the liquid cement to blend progressively as it moved through the pipes. The static mixer performed as expected and operated without significant fouling, This test proved the potential of ceramic 3D printing with Zetamix filament for high wear-resistant static mixers.
Pictures below: The Alumina 3D printed parts
This test with Zetamix technology provided valuable insights into the potential of 3D-printed static mixers for abrasive and aggressive liquid blending applications and Holcim remains open to explore further innovations and improvements that align with their operational requirements and criteria.
