Mixing systems and methods including disk assemblies
Mixing systems and methods that include a mixer housing and one or more disk assemblies for mixing and processing materials is disclosed. The disks rotate to mix an additive into the material and to carry agglomerated solids toward a discharge of the mixing system. The disks may have a plurality of fingers or lobes which extend from a central portion of the disks.
1. A method for aggregating a slurry in a mixing system, the mixing system comprising a mixer housing having a front wall, a mixer housing discharge opposite the front wall, a floor that extends from the front wall to the mixer housing discharge, and an additive feed system including a feed vessel for holding a solidifying additive and an additive discharge connecting the feed vessel to the mixer housing, the method comprising:
adding a slurry to the mixer housing;
adding, by the additive feed system, the solidifying additive to the mixer housing; and
rotating a plurality of disks disposed in the mixer housing to mix the solidifying additive with the slurry, the disks having at least one of fingers and lobes, the at least one of fingers and lobes extending radially outward from a central axis of the disk, the solidifying additive causing the slurry to aggregate into particles, wherein the disks cause a portion of the aggregated particles to be propelled toward the mixer housing discharge and at least a portion of the slurry to be propelled toward the front wall.
2. The method as set forth in claim 1 wherein the mixer housing is divided into a first section and a second section, the second section being angled relative to the first section, the method comprising:
rotating a first plurality of the disks disposed in the first section to mix the solidifying additive with the slurry;
conveying at least a portion of the slurry and aggregated particles to the second section of the mixing system; and
rotating a second plurality of the disks disposed in the second section, wherein at least a portion of the particles in the slurry are conveyed by the second plurality of the disks to the mixer housing discharge and at least a portion of the slurry falls through the second plurality of the disks to a second section floor, the portion that falls to the second section floor traveling down the second section floor and returning to the first section.
3. The method as set forth in claim 1 wherein the solidifying additive is cement.
4. The method as set forth in claim 1 wherein no material is discharged from the mixer housing through an outlet other than the mixer housing discharge.
5. The method as set forth in claim 1 wherein the mixing system includes a slurry feed system including a slurry discharge, the slurry being added to the mixer housing at the slurry discharge, and wherein the additive discharge is upstream of the slurry discharge in the direction of flow of the aggregated slurry toward the mixer housing discharge.
6. The method as set forth in claim 1 further comprising:
controlling an adjustable floor assembly to adjust a distance between the floor and the plurality of disks.
7. The method as set forth in claim 1 wherein the mixer housing is divided into a first section and a second section oriented at an angle relative to the orientation of the first section, the method comprising:
conveying, by a conveyor assembly, the slurry from the first section to the second section.
8. The method as set forth in claim 1 , further comprising:
distributing, by a distribution assembly, the solidifying additive across a width of the mixer housing.
9. The method as set forth in claim 8 , wherein the distribution assembly includes a screw auger.
10. The method as set forth in claim 1 , wherein the mixer housing further includes a plurality of shafts, each disk of the plurality of disks being connected to a shaft of the plurality of shafts so that the disks are movable with the shaft, wherein the rotating the plurality of disks comprises rotating the plurality of shafts.
11. The method as set forth in claim 1 , wherein each disk comprises a rim defining two or more lobes.
12. The method as set forth as set forth in claim 11 wherein:
the rims each define two lobes and the disks have an oval profile; or
the rims each define three lobes and the disks are each shaped as a Reuleaux triangle.
13. The method as set forth in claim 1 , wherein the at least one of fingers and lobes of at least some disks of the plurality of disks are angularly offset relative to the at least one of fingers and lobes of adjacent disks of the plurality of disks.
14. The method as set forth in claim 1 , wherein the mixer housing includes a conveyor assembly having a belt, the method further including actuating the conveyor assembly to move the slurry to the mixer housing discharge.
15. The method of claim 14 , wherein the conveyor assembly is pivotably connected to the mixer housing, and wherein the method further includes pivoting the conveyor assembly to discharge at least a portion of the slurry from the mixer housing.
16. The method of claim 15 , wherein the mixer housing includes a flange that contacts and at least partially seals against the belt.
17. The method of claim 1 , wherein the floor is formed from a flexibly resilient material and is releasably attached to the mixer housing.
18. The method of claim 17 , wherein at least one clamp is attached to the mixer housing, the at least one clamp being configured to apply tension to the floor and secure the floor to the mixer housing.
19. The method of claim 17 , wherein the floor includes at least one rib that contacts one of a first sidewall and a second sidewall of the mixer housing.