The SUNTHERM Group mineral wool production line for coke ovens offers powerful production capacity and can be customized for various scales according to your needs, ranging from small-scale production of a few thousand tons per year to large-scale production of tens of thousands of tons. By employing advanced technologies and equipment, the produced mineral wool exhibits high quality, uniform fiber structure, excellent thermal insulation, sound absorption, noise reduction, and fire-resistant properties. These products are widely used in construction, industry, ships, and other applications.
1. Advanced Technology and Stable Operation
(1) Raw Material Processing:
High-quality ores such as basalt, dolomite, and slag are carefully selected as raw materials. Strict pre-processing such as crushing and screening ensures uniform particle size. Using high-quality coke as fuel, precise electronic dosing, and automatic feeding systems deliver raw materials into the furnace in accurate proportions, establishing a solid foundation for stable production.
(2) High-Temperature Melting:
Coke burns completely in the furnace, reaching temperatures of 1450°C–1600°C, quickly melting the raw ores into a homogeneous melt. Advanced combustion control ensures efficient coke burning, uniform heat transfer, and stable melt quality.
(3) Fine Fiber Formation:
The melt flows into a high-speed centrifuge via a special chute. Under centrifugal force, the melt is instantly transformed into fine fibers of 3–5 microns in diameter. Additives such as phenolic resin, hydrophobic agents, and dust-preventive oils are evenly sprayed to give the fibers superior properties.
(4) Accurate Fiber Collection and Mat Formation:
Fibers enter the accumulation chamber, where the drum uses negative pressure to evenly deposit fibers into a continuous mat. The mat is passed through a pendulum mechanism for uniform layering and then sent to a three-dimensional pleating machine to increase tear strength. After curing in the oven, the binder solidifies, forming a mineral wool board with stable shape and strength.
(5) Post-Processing and Packaging:
Boards are cooled to room temperature, cut according to technical requirements, and packed using automated equipment. Manipulators stack them for safe storage and transportation.
2. Operational Precautions
(1) Before Starting Equipment:
Check all equipment connections, especially the furnace body, pipes, and valves, for looseness or leaks. Verify the electrical system, including control cabinet and motor wiring, ensuring voltage stability and proper grounding. Conduct a trial run of the raw material feed system, checking conveyor alignment and hopper openings. Inspect the cooling water system to ensure normal pressure and even distribution.
(2) During Operation:
Monitor furnace combustion, flame color, and temperature changes. Stabilize the furnace temperature to ensure full ore melting and prevent large fluctuations. Regularly check centrifuge speed and vibration. Monitor glue spray system for uniform additive distribution. Pay attention to sound, temperature, and odor; stop immediately if abnormalities occur.
(3) During Maintenance:
Regularly remove slag from the furnace to maintain combustion efficiency and extend furnace life. Inspect and replace dust collector bags every 2–3 months. Lubricate equipment points as specified in the manual to reduce wear. Perform regular calibration of control systems to ensure accuracy and stability.
3. Environmental Protection and Eco-Friendly Production
(1) Exhaust Gas Treatment:
Use modern desulfurization and selective catalytic reduction (SCR) equipment to remove CO₂, SOx, and NOx.
(2) Dust Collection:
High-performance bag filters capture dust, ensuring proper exhaust and minimizing environmental pollution. Activated carbon units handle trace organic gases.
(3) Wastewater Treatment:
A comprehensive wastewater treatment station collects and treats cooling water and cleaning water. Processes include sedimentation, filtration, oil separation, and neutralization, enabling water reuse and resource conservation.
(4) Waste Recycling:
Furnace slag, collected dust, and other byproducts are reused as raw materials for construction or disposed of in designated landfills following environmental standards.
(5) Noise Control:
Prioritize low-noise equipment. Install noise-reducing devices and sound-absorbing materials in buildings to minimize operator exposure.
4. Professional Team and Dedicated Service
SUNTHERM has an experienced team for production line design, equipment installation, commissioning, maintenance, and technical upgrades. We provide comprehensive support, selecting solutions tailored to your site to ensure efficient, stable production and maximum economic and social benefits.
If you are interested in our mineral wool production line for coke ovens, please feel free to contact us—we are happy to assist you wholeheartedly!
5. FAQ
Q1: What technical specifications of mineral wool products can this production line produce?
A1: The line can produce mineral wool boards, felts, and other products with various densities, thicknesses, and sizes, suitable for applications such as building wall insulation and industrial equipment thermal insulation.
Q2: What key checks are necessary before starting the equipment?
A2: Ensure equipment component connections are reliable, the electrical system voltage and grounding are correct, the raw material feed system works in idle mode, and cooling water pressure and piping are normal.
Q3: How to maintain stable product quality during operation?
A3: Monitor furnace temperature for complete ore melting, stabilize centrifuge operating parameters, and accurately control the glue spray system for uniform additive application.