Vertical shaft high-shear mixer for de-agglomeration, and associated methods and systems

A method comprising:

• rotating a downwardly facing mixing assembly within a mixing chamber having an upper end and a lower end opposite the upper end, wherein the mixing assembly includes a rotating mixer shaft having mixing tools attached thereto;
• dropping a pre-moistening masonry mixture downwardly through the mixing chamber past the mixing tools;
• processing the pre-moistening masonry mixture with the mixing tools to produce a product formula;
• and
• collecting the product formula as the product formula exits the lower end of the mixing chamber.
• wherein the processing includes:
• breaking apart agglomerations in the moistened partially mixed formula;
• pulverizing the moistened partially mixed formula;
• enhancing dispersion of the moistened partially mixed formula;
• and
• enhancing homogeneity of the moistened partially mixed formula.

A mixing system, comprising:

• a first mixer configured for premixing constituents to produce a pre-moistened compressible masonry formula;
• a transport assembly configured for transporting the pre-moistened compressible masonry formula from the first mixer;
• and
• a second mixer for receiving the pre-moistened compressible masonry formula from the transport assembly;
• wherein the second mixer includes
• a mixing chamber extending from an upper end to a lower end, wherein the mixing chamber includes an inlet at the upper end and an outlet at the lower end;
• a mixer shaft extending downward from a first end to a second end;
• one or more tools attached to the shaft between the first end and the second end;
• a rotation mechanism coupled to the first end of the mixer shaft;
• wherein the rotation mechanism is configured to rotate the shaft and the attached tools;
• wherein the mixer is configured to
• receive the moistened partially mixed formula through the inlet from the transport assembly;
• and
• process the moistened partially mixed formula as the moistened partially mixed formula falls toward the outlet, wherein the processing includes:
• breaking apart agglomerations in the moistened partially mixed formula;
• pulverizing the moistened partially mixed formula;
• enhancing dispersion of the moistened partially mixed formula;
• and
• enhancing homogeneity of the moistened partially mixed formula.

A masonry product formula, wherein a moistened masonry formula that includes fines, concrete, and water is processed to produce the masonry product formula by a method comprising:

• rotating a downwardly facing mixing assembly within a mixing chamber having an upper end and a lower end opposite the upper end, wherein the mixing assembly includes a rotating mixer shaft having mixing tools attached thereto;
• dropping the moistened masonry formula downwardly through the mixing chamber past the mixing tools;
• processing the moistened masonry formula with the mixing tools to produce a product formula;
• and
• collecting the product formula as the product formula exits the lower end of the mixing chamber;
• . wherein the processing includes any of:
• breaking apart agglomerations in the moistened masonry formula;
• pulverizing the moistened masonry formula;
• enhancing dispersion of the moistened masonry formula;
• and
• enhancing homogeneity of the moistened masonry formula.