30,000 TPA Electric Furnace Rock Wool Production Line

1. Project Background

Under the “Dual Carbon” strategy, the demand for high-performance insulation materials in building energy efficiency, industrial insulation, and transportation sectors is rapidly growing.

Rock wool, produced from natural minerals, is a non-combustible material with excellent fire resistance, thermal insulation, and sound absorption properties, making it highly attractive in global markets.

To meet large-scale continuous production needs, SUNTHERM Group launched the 30,000 TPA Electric Furnace Rock Wool Production Line. By replacing traditional coal/oil melting furnaces with an advanced electric heating process, this line provides customers with a green, low-carbon, and intelligent production solution.

2. Equipment Composition

The production line consists of the following key modules, all of which can be customized:

Ø Raw Material Processing System – automatic crushing, screening, batching, and conveying

Ø Electric Furnace Melting System – electric arc furnace or resistance furnace, precise temperature control, low emissions

Ø Centrifugal Fiberization System – multi-wheel high-speed spinning for fine and uniform fibers

Ø Spraying & Dust Control System – simultaneous spraying of binder and anti-dust oil, eco-friendly and efficient

Ø Fiber Laying & Forming System – multi-stage pendulum, automatic thickness and uniformity control

Ø Curing Oven System – hot-air circulation, intelligent temperature control to ensure product strength and stability

Ø Cooling & Conveying System – air cooling + shaping conveyor, protecting product structure

Ø Cutting System – supports transverse, longitudinal, and edge trimming cuts

Ø Packaging & Palletizing System – fully automatic PE film wrapping, heat shrinking, robotic palletizing

Ø Dust & Emission Control System – bag filters + flue gas condensation tower, compliant with emission standards

Ø Central Control System – PLC + touchscreen, compatible with SCADA/MES integration

3. Technical Parameters

4. Core Advantages

（1）Green Melting, Energy Saving & Emission Reduction
Electric furnace melting reduces CO₂ emissions by more than 50% compared to coal/oil furnaces, with zero SO₂ and NOₓ pollution.

（2）Intelligent Control, Stable High Output
Siemens/Schneider PLC+HMI systems with smart interconnection, stable operation, and quick product switching.

（3）Proven Reliability, Easy Maintenance
Modular design for easy installation and servicing. Key components are from world-renowned brands, ensuring durability and low failure rates.

（4）Automatic Packaging, Higher Efficiency
Automated packaging with film replacement, counting, stacking, and warehousing minimizes labor involvement and error rates.

5. Product Range

ü Rock Wool Boards – for external wall insulation, roofing systems, fire protection

ü Rock Wool Strips – for curtain wall fire barriers

ü Rock Wool Blankets – for steel structure roofs, ducts, industrial insulation

ü High-Density Industrial Rock Wool Boards – for power plants, petrochemical, and marine insulation

ü Custom Rock Wool Products – tailored to client requirements

6. Operational Advantages

Continuous Production – 24/7 automated operation, maximizing throughput.

Flexible Manufacturing – adjustable size, density, and thickness via digital control.

Fast ROI – stable operation with low wear; payback period as short as 2–3 years.

Optimized Workforce – only 15–20 staff required per production line, minimizing labor costs.

7. Environmental & Compliance

l Equipped with bag filters, gas purification towers, and VOC treatment systems

l Meets EU CE and US EPA environmental standards

l Provides environmental impact assessments, technical statements, and energy-saving reports

l Electric-driven process fully aligns with green investment policies along the Belt and Road Initiative

8. Investment & Return

9. Application Fields

External Thermal Insulation Composite Systems (ETICS)

Industrial boilers, pipelines, and pressure vessels

Petrochemical, power, and metallurgical equipment insulation

High-rise building fire barriers and curtain wall firestops

Containers, cold storage, and refrigeration systems

Rail transit, shipbuilding, and airport terminals

10. After-Sales Service & Technical Support

SUNTHERM Group provides one-stop rock wool production solutions, including:

Site selection, energy evaluation, and capacity analysis

Process design, plant layout, and construction guidance

Equipment manufacturing, transport, installation, and commissioning

Complete staff training and operation manuals

Remote diagnostics, spare parts supply, and regular inspections

System upgrades and long-term technical support

We maintain service teams and offices in Russia, Central Asia, Southeast Asia, and Europe, ensuring smooth project implementation and reliable long-term operation.

11. FAQ

Q1: Can this line only use basalt as raw material?
A1: No, it supports multiple raw materials such as basalt, dolomite, and slag. We provide optimized formulas based on local resources to ensure melting performance and product stability.

Q2: Does the line support multiple product specifications? Is switching complicated?
A2: Yes. It can flexibly switch between rock wool boards, strips, and blankets. Parameters such as thickness, density, and length can be set via the control system without major equipment adjustments.

Q3: Is electric furnace operation more expensive than coal furnaces?
A3: Although electricity cost per unit may be slightly higher, energy utilization efficiency is much better. Combined with waste-heat recovery, the overall energy consumption is lower. Additionally, with zero dust emissions and lower maintenance costs, the long-term cost-effectiveness is superior.