High-Throughput Dust Suppression & High-Frequency Fly Ash Stabilization
The BDSZ Series Humidifying Mixer is a high-capacity, single-shaft dust conditioning system engineered to stabilize bulk fly ash, coal dust, furnace slag, and mineral powders. Utilizing a high-torque single shaft fitted with tungsten carbide-coated paddles alongside a high-frequency anti-adhesion vibration design, it prevents interior material buildup while consuming up to 40% less energy than dual-shaft mixers. Engineered with a multi-zone atomized water injection system and smart PLC control, it achieves 98.7% dust capture efficiency and precise moisture uniformity within ±0.5% across mega-flow processing capacities up to 1,200 tons per hour.
Featured Model Variants
BDSZ-400HM | Mining & Slag Handling Unit
Processing Capacity: 150–400 TPH | Power: 52 kW | Dust Efficiency: 98.7%
Ideal for continuous mineral dust control, aggregate processing, and foundry slag handling.
BDSZ-800HM | Power Station & Material Handling Line
Processing Capacity: 300–800 TPH | Power: 75 kW | Dust Efficiency: 98.8%
Engineered for heavy continuous coal handling systems, thermal power ash yards, and smelting plants.
Key Technical Specifications
Processing Capacity & Moisture Control: Continuous output ranging from 50 to 1,200 TPH (20–180 m³/h) with an adjustable output moisture range of 8–12%.
Drive Assembly & Shaft Speeds: Driven by 7.5 kW to 90 kW motors with high-torque gear reducers operating at steady mixing speeds of 18–65 rpm.
Construction & Housing Ratings: Fabricated from 316L stainless steel or Q235/Q345 carbon steel with Viton/labyrinth seals, IP65 protection, and quiet operation (≤ 78 dB(A)).
Why Choose BDSZ Humidifying Mixer
Choosing the right dust control system is critical for productivity, safety and environmental compliance. The BDSZ Humidifying Mixer stands out for several reasons , these are:
Efficient Dust Suppression: For Efficient Dust Suppression it Achieves up to 98.7% dust capture efficiency and exceeding the industry average of 85–90%.
Energy Saving Design: This system also can operates with 40% less power than conventional dual shaft mixers (averaging only 78 kW).
Superior -Durability: For a lifetime support it is built with 316L stainless steel and wear resistant coatings for a 15+ year service life.
Precision -Engineering: Also this humidifying mixer can delivers ±0.5% accuracy in moisture control under varying temperature and humidity conditions.
Certified -Quality: In quality issues it is Fully ISO 9001:2015 and CE Marking certified and also meeting international quality and safety standards.
High ROI: This system have a average payback period of only 14 months through reduced material loss and lower maintenance costs.
Why Leading Plants Choose SENOTAY BDSZ Humidifying Mixer
Factory-Direct Pricing. Certified Quality. Dedicated Support.
Best Price Guarantee
Certified & Compliant
Fast, Reliable Delivery
BDSZ Humidifying Mixer – Type & Performance Analysis
Type No. | Model | Processing Capacity (TPH) | Power (kW) | Moisture Control Accuracy (±%) | Dust Efficiency (%) | Application Area |
1 | BDSZ-200HM | 50–200 | 35 | 0.5 | 98.5 | Fly Ash Conditioning |
2 | BDSZ-300HM | 100–300 | 48 | 0.5 | 98.6 | Cement Dust Control |
3 | BDSZ-400HM | 150–400 | 52 | 0.5 | 98.7 | Mining Dust Systems |
4 | BDSZ-500HM | 200–500 | 60 | 0.5 | 98.7 | Slag Handling |
5 | BDSZ-600HM | 250–600 | 70 | 0.5 | 98.7 | Coal Conveying Systems |
6 | BDSZ-800HM | 300–800 | 75 | 0.5 | 98.8 | Material Handling Units |
7 | BDSZ-1000HM | 400–1000 | 85 | 0.5 | 98.7 | Power Plants |
8 | BDSZ-1200HM | 500–1200 | 90 | 0.5 | 98.7 | Cement Kilns |
9 | BDSZ-Custom | 100–1000 | Custom | 0.4 | 99.0 | Special Custom Applications |
10 | BDSZ-Mobile | 50–300 | 40 | 0.6 | 98.5 | Portable Ash Systems |
BDSZ Humidifying Mixer – Technical Specification Table
Physical Dimensions | Performance Ratings | Material & Construction | Operational Data | Certifications & Lifecycle |
Overall Length: 1,800–3,600 mm | Moisture Range: 8–12% | Q235 / Q345 Steel | 7.5–30 kW | 8–12 years |
Width: 520–1,000 mm | Mixing Capacity: 20–180 m³/h | Wear-resistant Alloy (Cr-Mo) | 40–65 rpm | 18,000–25,000 hrs |
Height: 650–1,350 mm | Operating Pressure: 0.3–0.6 Bar | NM360 / NM400 | 0.2–0.4 MPa | ISO 9001:2015 / CE |
Inlet Diameter: Ø160–Ø400 mm | Max Pressure: 1.0 Bar | Single-shaft, welded | 0.2–1.2 m³/h | JB/T 6779 |
Outlet Diameter: Ø200–Ø450 mm | Operating Temp: –10 to 120 °C | Rubber + Labyrinth Seal | 280–1,050 Nm | 600–1,000 hrs |
Flange BCD: Ø190–Ø520 mm | Max Temp: 150 °C | SS304 / SS316 | 0–15° | 4,000–6,000 cycles |
Hopper Volume: 0.15–0.60 m³ | Dust Suppression Efficiency: > 90% | Grade 8.8 / 10.9 | 520–2,450 kg | EN 60204-1
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Product Description and Material Properties
The BDSZ Humidifying Mixer integrates advanced single shaft mixing technology with a multi-zone atomized water injection system to achieve consistent moisture distribution and efficient particle agglomeration. Its core material construction is engineered for high-strength performance in harsh industrial environments.
Property | Material Specification | Mechanical Characteristics |
Mixer Housing | 316L Stainless Steel | Corrosion-resistant, high tensile strength |
Mixing Shaft | Hardened Alloy Steel (42CrMo4) | Long service life, high wear resistance |
Paddle Coating | Tungsten Carbide | Prevents erosion during high-abrasion mixing |
Seals & Gaskets | Viton® Fluorocarbon Rubber | Excellent chemical and thermal resistance |
Wear Surfaces | Ceramic-Coated Steel | Reduces friction and extends component life |
Protective Rating | IP65 | Resistant to dust ingress and water jets |
BDSZ Humidifying Mixer Work process
Material Input: In very first stage here dry materials such as fly ash, cement or coal dust enter the mixing chamber through the feed port.
Rotational Mixing: In this mixing process the single shaft equipped with 36 tungsten carbide-coated paddles rotates at 18–22 RPM that ensuring complete tumbling and turnover.
Multi-Zone Humidification: By this Humidification process A 7-zone water distribution system sprays micron sized droplets (10–50µm) at controlled pressures (30–50 bar) through 84 stainless-steel nozzles.
Precise Moisture Regulation: The PLC based monitoring system continuously measures 18 critical parameters and auto-adjusts the water flow to maintain target humidity.
Homogenized Output: Uniformly humidified material exits through the discharge port, ready for safe transport or disposal which minimizing airborne dust contamination.
Key Features
Global Performance: Installed in 217+ industrial facilities across 28 countries since 2009.
Processing Capacity: Handles 50–1,200 tons per hour (TPH).
Smart Moisture Control: ±0.5% precision using real-time feedback sensors.
Safety Compliance: ISO 13857:2019 safety standards with interlocks.
Smart Control System: Siemens S7-1500 PLC and 10.4” touchscreen HMI with automatic calibration.
Noise Reduction: Acoustic housing maintains low 78 dB(A) sound levels at 1 meter.
Core Components
Single Shaft Mixing Assembly – It have High durability alloy shaft with 36 tungsten carbide paddles.
Multi-Zone Spray System – Also it contain 7 independent moisture control zones with 84 precision nozzles.
Advanced Control Interface – Smart PLC automation with NIR moisture sensors.
Dust Containment Housing – Insulated and acoustically dampened double-wall enclosure.
Structural Frame – Modular, heavy-duty frame for easy maintenance and scalability.
Installation Method
Foundation Preparation: Ensure the equipment is installed on a flat, vibration-free surface with adequate structural load support.
Connection and Alignment: Connect inlet/outlet ducts and secure the main shaft alignment per Senotay specifications.
Electrical and Water Systems: Integrate with the existing 380V, 3-phase power supply and water pipelines.
Control Setup: Calibrate the PLC system and moisture sensors.
Trial Operations: Conduct dry and wet test runs before full-scale commissioning.
Technical Advantages in Senotay Manufacturing
Senotay’s R&D-driven production sets the BDSZ apart:
In-house precision machining and strict QC at every stage.
Application of 316L stainless steel fabrication for superior corrosion resistance.
Custom-build flexibility for different materials,temperature ranges, and capacities.
Real-world performance validated by 10,000+ operational hours field tests.
Integration of advanced AI-driven control algorithms for moisture adjustment.
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FAQs
Q1: What capacity range does the BDSZ Humidifying Mixer cover?
Answers: It ranges from 5 to 1,200 TPH, suitable for small and large-scale operations.
Q2: What type of materials can it process?
Answers: Compatible with fly ash, cement, coal dust, ore and aggregates.
Q3: Is it suitable for high-temperature environments?
Answers: Yes, it operates reliably from -20°C to +50°C and up to 95% humidity.
Q4: How often does it require maintenance?
Answers: Regular maintenance is recommended every 6,000 hours of operation.
Q5: Does it comply with international safety standards?
Answers: Absolutely. It carries ISO 9001:2015 and CE Marking certifications.
