Mixing, storage and weighing of raw materials for rock wool production line. The raw material storage, mixing and weighing system is located at the beginning of the rock wool production line. From the melting of mixed raw materials (mainly basalt and dolomite), rock wool fibers with a suitable fiberization system can be obtained. They can add several types of slag (such as blast furnace, copper) to the mixture, various additives to obtain fibers, and properly treated production waste. The raw material storage, mixing and weighing system includes: a series for storing and stacking raw materials (various basalt, dolomite, slag, coal briquettes, coke), through weighing, extraction and mixing systems, transporting the mixture to the feeding system of the melting furnace.
Melting furnace in rock wool production process. The melting furnace used by rock wool board manufacturers can melt raw materials. And the melting furnace can be selected: cupola (coke) and electric melting machine cupola. The melting furnace uses the combustion of coke and hot air to melt raw materials and mixtures, converting them into melt. The furnace body of this melting furnace is mainly composed of high-temperature resistant special steel ("boiler steel"), which can not melt at high temperatures, and the furnace body is water-cooled. The circulation of cooling liquid adopts a natural circulation system, without the help of pumps, even in the case of power outages, the system has inherent safety. No emergency power generation system is required. Some components are coated with special refractory materials. The main advantages of the cupola are: can be closed/opened in a short time, low cost, easy maintenance, can recycle production line waste, convert it, high operational flexibility. Electric melting furnace. The main advantage of the electric melting machine for rock wool production line is using electricity instead of coke, can recycle all types of waste and turn them into coal briquettes, low energy consumption compared to the same period, higher melting process efficiency.
Smoke and dust filtration system for rock wool production line. The smoke and dust filtration system ensures compliance with current regulatory emission limits and recovers most of the thermal energy in the exhaust gas. It has a great impact on the environment, so it is equipped with a smoke and dust filtration system first.
Incinerator for rock wool line. The incineration system installed to treat exhaust gas aims to: through high-temperature oxidation combustion, at appropriate residence time, organic pollutants (CO, H2S, VOC, C etc.). Recover the thermal energy of combustion gas to heat process air.
Fiber forming machine, spinning machine for rock wool production line. The fiber forming machine or spinning machine is the technical core of the system, which can convert melt into fibers. In traditional spinning machines used to produce rock wool, the number of discs may vary from 2 to 4 (according to the required production capacity), and the motion is transmitted from the motor to the spindle through a special belt. Traditional spinning machines, depending on the number of disks, are very suitable for small and medium capacities, ensuring high reliability and easy maintenance and reducing costs. And if using a high-performance aerodynamic spinning machine (or fiber forming machine), the efficiency will be much higher. Its purpose is to achieve high capacity and very high quality fibers (length, diameter, elasticity, compressibility...). The capacity of the pneumatic spinning machine is 7.5 tons/hour, and due to the high-reliability mechanical solution, the machine enables us to obtain ultra-light products, making the density reach 25 kg/cubic meter.
Forming chamber: It is part of the production downstream of the spinning machine, where fibers are collected to form a material termed "primary felt". Fibers are blown away from the spinning machine and separated from heavy components (pellets), sprayed with adhesive (phenolic resin, acrylic resin or ecological resin), and then deposited on a special conveyor belt through vacuum action. Debugging the shape and aerodynamics of this part (using the spinning machine) is very important to ensure high process efficiency and uniform distribution of fibers in the primary felt, which guarantees high product quality. In fact, there are different primary felt layers (distributed on the main line by a pendulum), constituting the product according to the required density.
Crimping machine: It is a special device for fiber orientation, installed before the curing oven. By acting on the orientation of fibers, crimping improves the mechanical properties of the product. Vertical fiber orientation leads to high mechanical compressive strength and delamination strength. The tensile strength in the thickness direction increases from 5 times to 10 times, which is a very important feature for boards used outside buildings/construction. It can provide two types of crimping: conventional crimping using rollers, belt crimping and pre-crimping. Crimping with rollers or belts
Roller crimping consists of a double roller conveyor, the lower part of the machine is fixed, and the upper height is adjustable.
Curing oven for rock wool production line. The curing oven is used to polymerize the adhesive contained in the felt through hot air, so that the product has density and shape. The main features of the curing oven are suitable for processing products with a width of up to 2500mm (net width after trimming).
The maintenance opening space between conveyor belts is 500mm. The working thickness is 300mm.
Heating roller for rock wool production line. The heating roller is a device used to combine rock wool products with different facing materials (such as kraft paper, aluminum and glass fiber veil), these facing materials are used as barriers for steam and dust. According to the facing material used (with or without pre-coupled plastic film), use electric heating rollers for bonding, melting the plastic film, or it can be carried out at lower temperatures, but add acrylic adhesive or glue in water according to. Facing can only be done on the bottom or both sides of the product.
Cutting device for rock wool production line. The cutting unit is used to complete the production process, cutting the product into required sizes. The hob group usually includes the following groups: cutting and trimming side edges, longitudinal slitting unit, thickness band saw, cross-cutting unit. The hob groups all use "dust-free" type hob blades rotating at extremely low speed. This ensures precise and clean cutting, no irregularities, higher production line productivity (no waste of cutting material), and no need for any type of dust collection system and related filtration.
Edge trimming unit. The trimming unit is used to cut rock wool boards. After passing through the curing oven and cooling, both sides reach the width and have smooth sides. The machine is designed to grind the cut scraps, and the ground product is sent to the forming chamber to mix with new fibers.
This material does not pass through the fan, so they have high durability. Appropriately designed conveyor belts can also be used for transportation.
Longitudinal slitting unit. The longitudinal slitting unit is used for material slitting to obtain products with required sizes. Cross-cutting unit and/or high-speed chopper. The cross-cutting unit is used to cut the product into required lengths. Panels of any density are usually cut with a rotary blade saw with one or two cutting heads, cutting cleanly, no dust or irregularities. Cutting is used for light or non-resin felts, the production line speed is fast, and the indentation quality of cutting is not a problem. Use a band saw to produce two-layer or multi-layer panels from one felt, cutting its thickness. The advantage of this procedure is reducing the running speed of the production line and obtaining lower thickness and density.
Stacker for rock wool production line. The stacker is a production unit installed in the rock wool factory before packaging. Once cut to size, the panels can be stacked and packaged. Main features of the stacker: high performance (stacking speed and packaging height), high degree of automation, low maintenance. Stacking of different widths and lengths, without any intervention for adjustment or setting, using a special forking device to stack from the bottom (one layer inserted under other layers). The number of layers and stacking height can be adjusted through the control system.
Winder for rock wool production line. The designed and manufactured paper winding machine can automatically wind up mattresses or felts. The operator can select a compression ratio suitable for the production type, so the software ensures perfect uniformity, compressibility and roundness of the rolls. The "packaging" machine automatically wraps the roll from the outside with plastic film or paper. A special heat shrink system seals the roll at its ends. Depending on the type of plastic film, the covering can be partial or full.
Packaging unit for rock wool production line. The packaging unit is the end part of the mineral wool production line. The production process ends with the packaging of the material. When the stacker unloads, the package is automatically wrapped in polyethylene and heat shrunk. During packaging, the package can be compressed according to density, reducing its volume, thereby reducing transportation costs. After packaging is completed, they can be automatically stacked on pallets by anthropomorphic robots. Due to or extended film packaging machine, it can also complete the packaging of the package. This packaging unit can also be completed together with a cover machine or stretch film wrapping machine.
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