High efficiency and excellent quality
SUNTHERM Group's coke oven rock wool production line has a strong production capacity and can be customized to different scales according to your needs, ranging from small-scale annual production of thousands of tons to large-scale production of tens of thousands of tons. With advanced technology and equipment, the rock wool products produced are of high quality, uniform fiber, excellent thermal insulation, sound absorption and noise reduction, and fire retardant properties, and are widely used in construction, industry, ships and other fields.
1. Mature process, stable operation
(1) Raw material processing: Carefully select high-quality ores such as basalt, dolomite, slag, etc. as the main raw materials, and undergo strict pre-treatment processes such as crushing and screening to ensure that the raw material particle size is uniform. With high-quality coke as fuel, the raw materials are transported to the cupola in precise proportions through a precise electronic metering fully automatic feeding system, laying a solid foundation for stable production.
(2) High-temperature melting: In the cupola, the coke is fully burned, releasing high temperatures of up to 1450℃ - 1600℃, causing the ore raw materials to quickly melt into a uniform melt. In this process, advanced combustion control technology ensures efficient combustion of coke, uniform heat transfer, and stable melt quality.
(3) Fine fiberization: The melt flows out of the cupola and is accurately transported to the high-speed centrifuge through a special chute. Under the strong centrifugal force of the centrifuge, the melt is instantly thrown into fine fibers with a diameter of only 3-5 microns. At the same time, through the precise glue spraying system, phenolic resin, water repellent, dust-proof oil and other additives are evenly sprayed to give the rock wool fiber excellent properties.
(4) Precise cotton collection and molding: After the fiber filaments with additives are blown out of the centrifugal blower wind system, they quickly enter the cotton accumulation chamber. The cotton accumulation drum in the cotton accumulation chamber uses the negative pressure formed by the induced draft system to evenly adsorb the fibers on its surface to form rubber cotton. Subsequently, the rubber cotton is conveyed to the pendulum through a belt, and the pendulum swings precisely to spread the cotton, and the rock wool fibers are evenly laid on the conveyor belt. After reaching a certain number of layers, it is sent to a three-dimensional wrinkling machine, and the tensile strength of the rock wool board is greatly improved by pressurized pleating. Then, it enters the curing furnace. Under appropriate temperature and time conditions, the adhesive is cured, so that the rock wool fibers are tightly bonded together to form a rock wool board with stable shape and strength.
(5) Post-processing and packaging: The rock wool board coming out of the curing furnace is quickly cooled to room temperature through the cooling system, and then accurately cut longitudinally and transversely according to different specifications and uses through high-precision cutting equipment. After the cutting is completed, the rock wool products are strictly inspected and packaged by automated packaging equipment. Finally, they are neatly stacked into stacks by robots for easy storage and transportation.
2. Operation precautions
(1) Before starting the equipment: Check the connections of all equipment components to see if they are firm, especially the furnace body, pipes, valves, etc. of the cupola to ensure that there is no looseness or leakage. Carefully check the electrical system, including the control cabinet and motor wiring, to confirm that the voltage is stable and meets the equipment requirements, and the grounding protection device is intact. Perform a no-load test run on the raw material conveying system to check whether the belt is running off track and whether the discharge ports of each silo are unobstructed. At the same time, check the cooling water system to ensure that the water pressure is normal, the pipes are not blocked, and the water flow at each cooling point is evenly distributed.
(2) During equipment operation: Pay close attention to the combustion of the cupola, including the combustion state of the coke, the color of the flame and the temperature change. Maintaining a stable furnace temperature is the key to ensuring that the ore is fully melted and avoiding large temperature fluctuations. Regularly check the operating parameters of the centrifuge, such as speed, vibration, etc., to ensure its stable operation. If the centrifuge is found to have abnormal noise or increased vibration, it should be stopped immediately for inspection. Strictly monitor the pressure and flow of the glue spraying system to ensure that the additives are sprayed evenly and stably on the fiber filaments to prevent uneven glue spraying from affecting the quality of rock wool products. During the operation of the production line, always pay attention to the operating sound, temperature, odor, etc. of each equipment. If there is any abnormality, the equipment should be stopped and processed in time.
(3) During equipment maintenance: Regularly clean the slag in the cupola to prevent excessive slag from affecting the combustion efficiency and the life of the furnace. Generally, according to the production situation, thorough slag cleaning is carried out once a week or every two weeks. Regularly check and replace the bags of the bag filter. Usually check the damage of the bags every 2-3 months. If there is any damage, replace it in time to ensure the dust removal effect. Regularly lubricate the lubrication points of each equipment. According to the cycle specified in the equipment manual, add appropriate lubricating oil or grease to the motor, reducer, bearing and other parts to reduce equipment wear. Regularly maintain and calibrate the control system of the production line, such as calibration of the electronic metering system, calibration of temperature sensors and pressure sensors, etc., to ensure the accuracy and stability of the system operation.
3. Environmental protection first, green production
(1) Waste gas purification: Equipped with advanced desulfurization and denitrification equipment, using mature limestone-gypsum wet desulfurization and selective catalytic reduction (SCR) denitrification processes, effectively removing harmful gases such as sulfur dioxide and nitrogen oxides produced by coke combustion. At the same time, high-performance bag dust collectors are installed at the air outlets of each dust-producing equipment to effectively intercept and collect dust, ensure that waste gas emissions meet standards, and reduce pollution to the atmospheric environment. In addition, for the small amount of organic waste gas generated during the production process, an activated carbon adsorption device is installed to achieve comprehensive purification.
(2) Wastewater recycling: Build a complete sewage treatment station to centrally collect and treat cooling water, equipment cleaning water, etc. in the production process. Through a series of processes such as sedimentation, filtration, oil separation, and neutralization, impurities such as suspended matter, oil pollution, and chemical agents in the wastewater are removed, so that the treated water meets the reuse standards and is reused in the production process, realizing the recycling of water resources and reducing water resource consumption and wastewater discharge.
(3) Comprehensive utilization of waste slag: Waste slag generated by the production line, such as cupola slag and dust collected by dust collectors, is comprehensively utilized as a resource. Slag can be used as a raw material for building materials, such as cement, bricks, road base materials, etc.; collected dust can be reused in production as a raw material or additive for rock wool. For a small amount of waste slag that cannot be comprehensively utilized, it shall be transported to a designated waste slag landfill for standardized landfill in strict accordance with environmental protection requirements to prevent soil and groundwater pollution.
(4) Noise control: When selecting equipment, low-noise crushers, fans, centrifuges and other production equipment are preferred, and the equipment noise provided by the equipment supplier is required to meet national standards. At the same time, noise reduction devices such as shock-absorbing bases and mufflers are installed on noise-generating equipment, and sound-absorbing materials are used for decoration on the walls and roofs of the workshop to effectively reduce the noise intensity in the workshop and reduce the impact on the surrounding environment and operators.
4. Professional team, considerate service
We have an experienced and skilled professional team, from production line design and planning, equipment installation and commissioning, to later maintenance and technical upgrades, to provide you with comprehensive, one-stop considerate services. We will tailor the most suitable coke oven rock wool production line solution for you according to your actual needs and site conditions, ensure the efficient and stable operation of the production line, and create the greatest economic and social benefits for you.
If you are interested in our coke oven rock wool production line, please feel free to contact us, we will serve you wholeheartedly!
5. FAQ
Q1: What specifications of rock wool products can the coke oven rock wool production line produce?
A1: It can produce rock wool boards, rock wool felts and other products of different densities, thicknesses and sizes, which can meet the needs of various scenarios such as building exterior wall insulation and industrial equipment insulation.
Q2: What key inspections should be done before the equipment is started?
A2: It is necessary to check whether the equipment components are firmly connected, whether the voltage and grounding of the electrical system are normal, the no-load operation of the raw material conveying system, and the water pressure and pipeline conditions of the cooling water system.
Q3: How to ensure stable product quality during operation?
A3: Closely monitor the cupola temperature to ensure that the ore is fully melted; stabilize the centrifuge operating parameters; accurately control the glue spraying system to ensure uniform spraying of additives.
