CO-NELE Intensive Mixer solves the industry pain points of uniformity and particle morphology control in ceramic proppant production through the "mixing-granulation integration" technology. Its full-size coverage capacity (1L~7000L) achieves seamless connection from research and development to mass production, significantly reducing the overall production cost. It is especially suitable for the production of high-end ceramic proppants with high strength, low density and small particle size (such as 100 mesh products suitable for ultra-deep shale gas wells). This technology represents the development direction of efficient preparation of modern ceramic powders.

Ceramic proppant Intensive MixerTechnical principle: How to achieve "mixing + granulation" integration?
High shear mixing stage
The equipment exerts strong shear force, impact force and convection on the powder (such as calcined bauxite, additives, binders) through the cooperation of high-speed rotating rotors (blades/blades) and stators.
Key goal: To achieve micro-uniform dispersion of powder and liquid binder within minutes, break agglomerates and form homogeneous plastic materials.
Intensive mixer granulator In-situ granulation stage
Under continuous high shear, the wet material is transformed into a plastic state through mechanical energy-thermal energy conversion, and spontaneously rolls and agglomerates under the extrusion of the rotor and the friction of the container wall.
No additional equipment is required: by adjusting the speed, time, and binder dosage, high spherical wet granules (particle size is usually 0.1-2mm) are directly generated.

Core advantages of Co-Nele Intensive Mixer produces high performance ceramic proppants
Process integration Eliminates the traditional "mixing → transfer → granulation" multiple links, reducing dust pollution, material loss and equipment investment (such as no need for an independent granulator)
Controllable particle size Precisely control the particle size distribution (such as target 20/40 mesh or 40/70 mesh) by adjusting the rotor speed, mixing time, and binder addition rate
High sphericity The particles formed by high shear rolling are close to true spheres (roundness>0.9), which significantly improves the flow conductivity of the proppant
Composition uniformity Eliminates stratification or segregation in traditional processes, ensures that the chemical composition of each particle is consistent, and the strength is uniform after sintering
Scale-up production is feasible From 1L test machine to 7000L industrial machine, the linear amplification of process parameters is achieved by relying on the principles of geometric similarity and dynamic similarity, reducing the risk of pilot production

Intensive Mixer produces high performance ceramic proppants vs Traditional Processes
Reduced energy consumption: eliminating the high-temperature gas consumption of spray drying (accounting for more than 30% of traditional energy consumption)
Space saving: a single device occupies less than 50% of the traditional production line
Improved yield rate: high wet particle strength, transfer crushing rate <0.5% (traditional raw ball crushing rate can reach 5-10%)

Application scenarios and equipment selection