B&P’s CK-CP continuous kneader delivers high output, strong performance, and excellent value. It can operate continuously at a capacity of 10–55 tons per hour. By improving green density, baked density, electrical resistance, and porosity, it helps reduce electricity consumption and waste generation.
For example, using B&P’s CK-CP continuous kneader can reduce coke generation in anode paste from 60 tons to 15 tons per ton of carbon product. In addition, according to reports from the aluminum industry, the CK-CP continuous kneader produced by B&P can continuously supply the coke required in a 320 kA aluminum reduction line, while keeping coke consumption below 400 kg per ton of carbon product.
1. Preassembled Industrial Base
- The kneader uses a preassembled industrial base, with the gearbox, drive motor, lubrication system, and discharge system all installed on a single base.
- The overall design ensures good factory alignment, making installation and maintenance easier.
- The equipment is shipped with all required pipelines and wiring already connected to the base.
- Because the load is evenly distributed across the entire machine base, the system runs more smoothly and eliminates much of the field work required for support foundations, reducing installation, commissioning, and total equipment costs.
2. Advanced Control and Display System
- The control system uses multi-point linked control and can be configured to provide data acquisition and processing functions based on customer requirements. A PLC-based control system is also available upon request.
- The display system uses a touchscreen or button-type interface and is independently installed both at the machine and in the main control room. For convenience in China, B&P also offers a color display with Chinese/English switching, and the control cabinet is clearly labeled in both Chinese and English so that operators and B&P commissioning staff can work efficiently.
3. Kneading Screw and Kneading Chamber
- The kneading screw uses an insert-type segmented design, which improves structural precision and adds forward pushing force to the material. Special wear-resistant materials are used to extend service life.
- Because of the segmented screw design, worn sections can be partially replaced during maintenance, extending the replacement cycle of components and making maintenance simpler and more convenient. This reduces labor and maintenance costs significantly.
- The segmented chamber liner is made from wear-resistant cast components. Its segmented design allows individual replacement, simplifying maintenance without repeated welding or machining, which reduces maintenance cost and downtime.
- B&P has also optimized the screw diameter and length according to the characteristics of domestic materials and production in China. The length-to-diameter ratio of the kneading chamber has been increased to 11.76:1, extending material residence time and further improving kneading quality. Localization of kneading screws, fixed gears, and wear-resistant liners is progressing smoothly, and after commissioning, these improvements will further reduce user operating costs.
4.Drive System
- The main drive motor is maintenance-free and does not require a forced cooling system, helping reduce maintenance and operating costs.
- An input torque limiter protects the gearbox and other components from overload, reducing maintenance costs and downtime.
- A robust screw coupling eliminates the need for support bearings and brackets, improves screw shaft alignment, and further reduces maintenance costs and service time.
- Compact helical gear reducer：
⑴ Equipped with a heavy-duty drive mechanism.
⑵ At screw speeds of up to 100 RPM, output power can reach 1000 kW.
⑶ The gearbox can handle torque up to 15 kN·m.
⑷ The gearbox features a fully enclosed external forced lubrication system mounted on a common base.
⑸ The gearbox includes an automatic torque limiter, providing full protection under overload conditions.
5. Automatic Feed Control
- The hydraulically controlled discharge gate can be automatically adjusted to ensure a constant feed rate. By reducing overfeeding and supporting the wet mixing and shaping process, it provides excellent control of paste quality.
- The discharge gate is operated primarily by automatic hydraulic control, but manual operation is also available.
- It can maintain the wet mix inventory above 7.0 tons per ton of paste, helping achieve stable paste quality.
- The interior is fitted with replaceable high-wear liners.
- The discharge gate is automatically controlled through feedback from motor load generated during wet mixing, keeping the system in optimal operating condition.
6. Major Design Improvements
B&P has focused on reducing both capital investment and operating costs for low-cost paste production lines. Based on actual operating conditions in China and a comprehensive analysis of nine kneaders currently running in the domestic market, B&P has introduced the following improvements to better suit local requirements.
- The graphite gasket has been replaced with a graphite spool arrangement, solving the oil leakage problem.
- Lubrication is handled in two sections: one for the universal joint and one for the shaft.
- The lubrication station is mounted on the integrated base.
- The new gearbox delivers significantly higher output power.
- The discharge gate has been converted from a rigid linkage system to hydraulic control.
- The integrated base has a compact structure and reduced height, making installation and maintenance easier.
- The length has been increased, extending material residence time and improving wet mixing quality.
- The metal hose routing has been improved so the hose is less likely to break.
- The effective mixing section has been extended by about 1.2 meters, increasing material residence time and improving mixing performance.
| No. | User | Model | Qty. | Capacity (mtph) | Location |
| 1 | Alcoa | KE-400 | 3 | 10 | USA |
| 2 | Alcan | KE-400 | 4 | 8 | Canada |
| 3 | Pechiney | KE-400 | 4 | 7 | USA |
| 4 | Carborundum | UK-400 | 1 | 8 | USA |
| 5 | Intalco | UKE-500 | 4 | 18 | USA |
| 6 | Alcoa | UKE-500 | 2 | 30 | USA |
| 7 | Revere | UKE-500 | 1 | 20 | USA |
| 8 | Superior Graphite | UKE-400 | 1 | 8 | USA |
| 9 | Alcoa | UKE-500 | 2 | 35 | USA |
| 10 | Aluminerie EsPanol | UKE-600 | 1 | 23 | Spain |
| 11 | Aluminium Bahrain | UKE-500 | 2 | 26 | Bahrain |
| 12 | Alcan | UKE-500 | 2 | 28 | Canada |
| 13 | Alcoa | UKE-500 | 1 | 32 | USA |
| 14 | Boyne Smelters | UKE-500 | 2 | 35 | Australia |
| 15 | Slovalco | UKE-500 | 1 | 25 | Slovakia |
| 16 | Alcoa | UKE-500 | 1 | 32 | Canada |
| 17 | Yunnan Aluminum | UKE-600 | 1 | 35 | China |
| 18 | Xingan Aluminum | UKE-500 | 1 | 25 | China |
| 19 | Lanzhou Aluminum | CK600 CP | 1 | 35 | China |
| 20 | Guizhou Aluminum | CK500 CP | 1 | 25 | China |
| 21 | Yichuan Aluminum | CK600 CP | 1 | 35 | China |
| 22 | Qian’an Aluminum | CK500 CP | 1 | 25 | China |
| 23 | Zhongfu Aluminum | CK600 CP | 1 | 40 | China |
| 24 | Guangyuan Star Aluminum | CK500 CP | 1 | 30 | China |
| 25 | Baotou Aluminum | CK600 CP? | 1 | 40 | China |
| 26 | Shenhuo Aluminum | CK500 CP | 1 | 20 | China |
| 27 | Xingan Aluminum (Phase II) | CK600 CP | 1 | 40 | China |
| 28 | Alcoa,Norway | CK700 CP | 1 | 60 | Norway |