/Catalogue-2018/Exhibitor-List 386385 386655 2186856

BHS-Sonthofen GmbH

BHS-Sonthofen GmbH - Concrete industry, other machinery and equipment (WOC Europe)

An der Eisenschmelze 47
87527 Sonthofen
GERMANY

Description

BHS-Sonthofen is a highly experienced manufacturer of mixers for the concrete industry and of crushers for the aggregate industry. There are many thousands installations of BHS machines worldwide.

Additional entity

  • Subsidiary

    BHS-Sonthofen (France) 49 boulevard du Collet 13008 Marseille FRANCE Contact

Press releases

  • BHS-Sonthofen: Creating value from overburden

    20 April 2018

    The dry Combimix process developed by BHS-Sonthofen removes clay adhesions from screen waste produced in quarries and gravel pits. Operators report that they are able to convert more than 90% of contaminated feed material into salable rock grade using the Combimix system. At the same time, the dry process significantly reduces water, energy and material costs. Many quarries contain large quantities of material contaminated with clay that has not been possible to be processed economically up to now. Frequently, the material has to be dumped at considerable expense as mining overburden. However, wet treatment is one method that allows this material to be used. Washing and subsequent water treatment as well as sludge disposal is extremely costly. The process often fails because many quarries lack access to the volumes of water required. Dry processing in conventional continuous mixers using quick lime is also been problematic because the retention times of the material in the mixer are so short that the clay cannot blend adequately with the lime. The solution: Variable retention time The patented BHS Combimix system developed by BHS-Sonthofen offers an economical alternative and its practical suitability has already been proven in several quarries. The basic principle has been known for years but it has not been possible to implement the system due to various limitations in mixing technology: Mixing clay with quick lime changes the properties of the clay, which can then be reliably separated from the rock. For the first time, twin-shaft continuous mixers of type DKXC allow regulation of the retention time of the material in the mixer within broad limits. The clay has enough time to mix intensively with the lime and detach from the rock. The intensive movement of material during the mixing process also assists the cleaning process. After screening, the feed material is so clean that it is no longer classed as waste and can be sold. Grains greater than 5 mm in diameter that are largely free of clay can now be further processed in the gravel quarry. Grains less than 5 mm in diameter form a lime/clay mixture that can be sold to the agriculture industry, for example. Combination of batch and continuous mixers The Combimix process is based on the combination of twin-shaft batch and continuous mixers manufactured by BHS-Sonthofen. Unlike traditional continuous mixers, the retention time of the mixture in the Combimix system can be regulated within broad limits – from less than 30 to more than 100 seconds. BHS regulates the retention time via a gate on the underside of the mixing trough. The company is the only manufacturer that offers a trough with this design. Extracted material is replaced with an equivalent volume of feed material. Continuous measurements are taken during this process to monitor the weight of the mixer. The quick lime is metered by a screw conveyor inside the mixer according to the clay content in the feed material in a range of less than one or a maximum of five percent of the feed quantity. Together with the long retention time, the established three-dimensional mixing principle of the BHS-Sonthofen twin-shaft mixer makes an important contribution to achieving good results: The lime is mixed intensively with the clay so that the treated clay reliably separates from the rock. Costs for supplying water, reslurrying, filtering and disposing of the slurry are no longer incurred because the material is treated dry. BHS-Sonthofen manufactures different versions of mixer for throughputs between 85 and 1000 t/h. The grain size of the feed material can range up to 150 mm, depending on the mixer size. Practical experience BHS has installed the Combimix system in several quarries. One facility has been operating extremely successfully for several years in a quarry owned by the company Cemex based in France. Before the system was installed, more than 100,000 t of rock/clay mixtu

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  • BHS-Sonthofen presented with the German Resources Efficiency Award

    20 April 2018

    One ton of lime is all it takes to turn 100 tons of rock into a valuable building material. BHS-Sonthofen and MSW Mineralstoffwerke Südwest received the German Resources Efficiency Award 2016 on 16 February 2017. The prestigious prize was awarded by the German Federal Minister for Economic Affairs and Energy to the two companies to commend the development and successful implementation of the Combimix process. This process turns a previously worthless mining by-product accumulated in quarries into a valuable building resource. BHS developed the Combimix process based on their twin-shaft batch mixers and implemented it together with MSW at their quarry in Mönsheim. This marked the first German project of this kind. It helped to increase raw material efficiency from the previous level of 65-70% to around 93%. In quarries and gravel pits, the Combimix process takes clay-and-rock mixtures – which previously had to be refilled or disposed at a landfill – and turns them into a marketable building material. Furthermore, this means that millions of tons of material previously considered worthless and dumped can now be reactivated. BHS has also installed the Combimix system in several quarries in France using continuous mixers. Before the system was installed, in one facility more than 100,000 t of rock/clay mixture from the quarry had to be dumped every year. More than 90 % of contaminated feed material is now sold as rock grade thanks to the Combimix system. The plant manager is extremely pleased about the significant reduction in costs: "Before the mixer was installed, we had to break down 400,000 t of rock each year to obtain 300,000 t of salable material. The new procedure means we only require 330,000 t to achieve the same delivery quantity." The German Federal Ministry for Economic Affairs and Energy (Bundesministerium für Wirtschaft und Energie) awards the German Resources Efficiency Award to exemplary products that efficiently use raw materials and other materials, processes or services, as well as application-oriented research results. A jury comprising 14 members screened over 40 submissions to select four winners in the ‘Companies’ category and a single winner in the ‘Research Facilities’ category. Andre Däschlein, Director of International Sales for Mixing & Crushing Technology at BHS, and Benedikt Fahrland, Managing Director of MSW Mineralstoffwerke Südwest GmbH & Co. KG, accepted the award presented by Uwe Beckmeyer, Parliamentary State Secretary of the Federal Minister for Economic Affairs and Energy at the ‘Efficient use of raw materials – Market success’ symposium. A happy moment for Däschlein: “This award demonstrates yet again that deep industry know-how and close ties to their customers allow mid-sized companies, in particular, to create innovative processes and solutions that deliver true efficiency gains.” Excerpt from the laudation of State Secretary Beckmeyer: “The sparing and efficient use of natural resources is a key skill needed to create a sustainable society. This year’s winning projects serve as role models of innovative and competitive industrial entrepreneurship in Germany. They furthermore pave our way to becoming less dependent on resource imports.” MSW introduced the process at their Mönsheim quarry in the summer of 2016. It allowed the company to increase their repository’s yield by 25%. To produce the same volume of the final product, it was previously necessary to extract about 620,000 tons of limestone annually. Now the total is around 188,000 tons less, which corresponds to a relative reduction of around 30%. It helped to increase raw material efficiency from the previous level of 65–70% to around 93%. Dennis Kemmann, the Managing Director of BHS-Sonthofen GmbH, is already thinking ahead: “Our Combimix process holds a vast potential as it enables companies across the globe and throughout various industries to utilize resources more effici

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  • BHS-Sonthofen: Mixers from Bavaria on the roof of the world

    20 April 2018

    Six twin-shaft batch mixers of type DKX 6.0 delivered by BHS-Sonthofen are producing the concrete needed to build the main embankment of the Dagu hydro dam undergoing construction near the Tibetan city of Zangmu. The construction site is located 3,700 m above sea level, making this the most elevated site ever for employing mixers from BHS. BHS-Sonthofen specially modified the mixers to meet the challenges they are facing at this extreme altitude. The first two mixers of type DKX 6.0 started producing the first batches of concrete on 12 July 2017. Two months later, Sinohydro No. 9 Engineering Company commissioned four more units. The mixers will produce approximately three million tons of roller compacted concrete (RCC) over the course of the dam’s construction, which is scheduled for completion in 2019. The complete facility, which comprises six mixers, is dimensioned to produce 160,000 m³ of hardened concrete per month. The mixers are equipped with a coarse-grain mixing unit for processing grain sizes up to 160 mm, as is typical in hydro dam construction. This mixer type has proven its worth in numerous installations across the globe. About 6 m³ of hardened concrete are discharged per batch at a rate of up to 48 cycles per hour, resulting in a total yield of up to 288 m³ of hardened concrete in one hour. The cycle times are short due to the intensive mixing of the concrete and the extra-large rotary valves at the underside of the mixing trough, which significantly speed up the discharge process. Given the vast amount of concrete that needs to be processed, BHS-Sonthofen reinforced the mixing troughs with a tougher version of its 28-mm ‘Optilong’ wear tiles. The service life of these tiles is nearly twice as long as the diamond-shaped tiles commonly used in construction projects. The variable hardness of the individual tile rows ensures uniform abrasion across all wear zones. BHS-Sonthofen even accounted for the remote location of the construction site: In order to prepare the machines for a potentially unstable grid, the company used special motor couplings. The hydrodynamic turbo couplings reduce mechanical as well as electrical load peaks. Thanks to this property, they have proven ideal for use in locations with critical grid fluctuations. Also, since high-altitude air does not extract as much heat from the electric motors, BHS-Sonthofen equipped the mixers with special motors that feature type ‘H’ insulation. The sheer remoteness of the construction site posed yet another challenge. The construction site in Tibet is nearly 4,000 km from Tianjin near Beijing, which is where BHS-Sonthofen’s Chinese subsidiary is situated. It took 20 days to transport the mixers across this distance. The project: Once completed, the Dagu dam will be 126 m tall with a dam crest measuring 385 m. The power plant will generate 640 MW of hydro energy. The dam is part of a major project undertaken by the Chinese government to provide the eastern parts of the Tibetan Autonomous Region with electricity, all the way to remote villages. Multiple hydro dams are damming up the Yarlung Tsangpo, the Earth’s highest river. It crosses Tibet from west to east and continues through India, where it is called Brahmaputra.

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  • Mixer increases quarry yield by 25 percent

    20 April 2018

    At the quarry in Mönsheim, Germany, which is operated by MSW Mineralstoffwerke Südwest, a BHS-Sonthofen twin-shaft mixer is adding quicklime to clay-contaminated pre-screened material. This makes it possible for the clay to be completely separated from the rock, most of which can then be further processed. As a result of this dry process, 70 percent of the material that was previously being dumped at a landfill has become usable.

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