Natural gas furnace rock wool production line
The natural gas furnace rock wool production line is a modern production system designed for high-efficiency rock wool products. It uses basalt, dolomite and other main raw materials. Through the high melting point of natural gas (1450-1500℃), high-speed centrifugal fiberization and intelligent curing molding process, it produces flame-retardant (A1 grade), thermal insulation (thermal conductivity ≤ 0.040 W/m-K), sound absorption (noise reduction coefficient NRC ≥ 0.9) rock wool boards/blankets/pipe sleeves and other products, which are widely used in construction, petrochemical, shipbuilding and other fields.
1. Production line process
(1) Raw material pretreatment
- Intelligent proportioning: basalt (60-80%), slag (20-40%), binder (phenolic resin ≤3%).
- Automatic crushing and screening: 0.5-5mm particle size control to ensure uniform melting.
(2) Natural gas melting system
- Double heat storage combustion technology: melting furnace temperature is stable ±10℃, energy consumption ≤120m³ natural gas/ton rock wool.
- Low nitrogen oxide emissions: nitrogen oxides <100mg/m3 (exceeding the national ultra-low emission standard).
(3) Centrifugal fiberization
- Four-roll centrifuge: fiber diameter 3-7 μm, slag bead content <10% (national standard ≤15%).
- Negative pressure cotton collection system: fiber distribution uniformity error ≤5%.
(4) Curing and molding
- Intelligent pendulum laying: multi-layer staggered laying technology, tensile strength increased by 20%.
- High temperature curing oven: temperature gradient control (200-250℃), curing time shortened to 10-15 minutes.
(5) Cutting and packaging
- Laser positioning cutting: dimensional accuracy ±1mm, support customized specifications (plate thickness 30-200mm, width ≤1200mm).
- Automatic palletizing and packaging: daily output can reach 10-30 tons (depending on production line configuration).
2. Comparison of technical parameters
|
Item |
Traditional natural gas furnace rock wool production line |
SUNTHERM natural gas furnace rock wool production line |
|
Electricity costs |
800-1000 Yuan/ton |
500-600 Yuan/ton |
|
Carbon emissions |
1.8 tons of CO₂/ton |
0.9 tons of CO₂/ton |
|
Fiber uniformity |
Slag ball content 10-15% |
Slag ball content <10% |
|
Degree of automation |
Semi-automated (with lots of human intervention) |
Fully automatic (unmanned operation) |
3. Six Major Advantages
l Energy-saving and economical: Natural gas has high calorific value, and the total cost is 25-30% lower than that of electric furnace.
l Environmental protection: Equipped with SCR denitrification system + bag dust removal, dust emission <10mg/m3.
l High yield rate: Online quality control system, finished product qualification rate ≥99.5%.
l Flexible adaptability: One-click switching of production mode (plate/pipe/shell/accessories).
l Durable and stable: The service life of the main equipment is greater than 100,000 hours (the service life of the refractory furnace is ≥5 years).
l Intelligent operation and maintenance: Remote diagnosis + predictive maintenance, fault response time <2 hours.
4. Applications
(1) Building insulation
- Rock wool board for exterior wall insulation (water repellency ≥ 98%, tensile strength ≥ 15 kPa).
- Fire barrier (fire resistance ≥ 2 hours).
(2) Industrial insulation
- Pipe insulation sleeve (operating temperature from -200℃ to 700℃).
- Tank insulation layer (thermal conductivity 0.035-0.042 W/m-K).
(3) Special cases
- Fireproof wool for ship bulkheads (in accordance with IMO A60 standard).
- Agricultural greenhouse insulation wool (moisture permeability ≥ 85%).
5. Service support
Turnkey project: process design → equipment installation → personnel training → production acceptance of the entire process.
Customized modernization: optional explosion-proof system (chemical scenario), ultra-explosion-proof water treatment (humid environment).
Global after-sales service network: 48-hour emergency response, lifetime supply of spare parts.
6. FAQ
Q1: What is the capacity of the natural gas furnace rock wool production line?
A1: It can produce 4-15 tons of rock wool products per hour, which can meet most industrial requirements.
Q2: Does the natural gas furnace rock wool production line consume a lot of natural gas?
A2: Due to the energy-saving design, the natural gas consumption is reduced by 15% compared with similar equipment.
Q3: Is the quality of rock wool produced by the natural gas furnace rock wool production line stable?
A3: Equipped with advanced quality control system, the product quality is stable, and all indicators meet international standards.
