Development of a Gravity Mixer for Energy-Efficient Mixing of Sapropel and Organic Fertilizers

The high energy consumption of conventional mixers equipped with active mixing elements necessitates the development of more efficient technologies for mixing bulk materials and feed mixtures. This study presents a gravity-driven mixing approach based on the rotation of an inclined cylindrical chamber, eliminating the need for active mixing elements. During chamber rotation, the mixture components move toward both end walls while simultaneously undergoing a circular motion along the inner cylindrical surface. This movement intensifies the mixing process and reduces energy consumption, thereby providing an energy-efficient gravity-based mixing approach that operates without active mixing elements. Laboratory experiments were conducted to determine the key physical and mechanical properties of the sapropel, organic fertilizer, and compound feed (formulation K-60-1). The measured values were as follows: velocity on an inclined steel surface, 0.65–1.21 m/s; coefficient of friction, 0.40–0.91; bulk density, 453–1166 kg/m3; and angle of repose, 36–39°. The experimental results confirmed the validity and adequacy of the developed analytical relationships. A structural and technological design of the gravity mixer was developed, and an experimental prototype was manufactured. Analytical relationships were obtained to determine the critical rotational speed of the chamber, particle movement velocity, and the power required for the mixing process. Under optimal operating conditions, the mixture uniformity reached 95.7% after 4 min of mixing. The mixer productivity was 0.95 t/h, while the specific energy consumption was 0.5 kWh/t, which is 2.5 times lower than that of conventional mixers equipped with active mixing elements. The obtained results confirm the feasibility and effectiveness of the proposed gravity-based mixing method for the preparation of feed and organomineral mixtures under the operating conditions of small-scale farms.