How do you manufacture Rockwool?
About Rock Wool Production Line
Rock wool is a common thermal insulation and sound insulation material. Its manufacturing process mainly revolves around the melting, fiberization and subsequent processing of raw materials such as rocks. The following are detailed manufacturing steps and related instructions:
I. Raw material preparation
Main raw materials: basalt, dolomite, limestone and other rocks (accounting for about 80%-90%), supplemented with a small amount of soda ash (sodium carbonate), borax and other fluxes (used to reduce the melting temperature).
Raw material processing: The rock is broken into small pieces with a diameter of about 5-10 cm, and after removing impurities, it is mixed evenly with the flux in proportion.
II. Melting stage
Melting equipment: High-temperature equipment such as cupolas and pool kilns are used.
Melting process: The mixed raw materials are put into the furnace and heated to 1400-1600℃ to melt them into liquid magma.
Control the melting temperature and time to ensure that the raw materials are fully melted and avoid the generation of unmelted particles.
III. Fiberization molding
Fiberization method: Centrifugal method or blowing method is commonly used to convert liquid magma into fiber.
Centrifugal method:
Molten magma flows out from the bottom of the furnace and enters a high-speed rotating centrifuge (such as a drum or turntable) through a chute.
The centrifugal force throws the magma into a thin stream, and at the same time, it is blown and pulled by a high-speed airflow (such as air or steam, with a temperature of about 200-300℃) to further refine it into fibers with a diameter of 1-5 microns.
Blowing method:
Liquid magma is ejected through a nozzle and is blown by high-pressure air or steam (pressure of about 0.5-1.0MPa) to break it into fibers.
The key to fiber formation: Control the air flow speed, temperature and magma flow rate to ensure that the fiber thickness is uniform and there is no adhesion.
IV. Applying binder
Binder type: Thermosetting resins such as phenolic resin and polyester resin, sometimes with additives such as waterproofing agent and water repellent agent.
Application method: During the fiber forming process, the binder solution is evenly sprayed on the fiber through a spray device, and the amount used is about 2%-5% of the fiber weight.
Function: Make the fibers bond to each other and improve the strength and formability of rock wool.
V. Curing and molding
Curing process:
The fibers sprayed with binder are collected on the molding mesh belt to form fluffy fiber felt.
The fiber felt is sent to the curing furnace and heated at 180-250℃ for 10-30 minutes to cure the binder and shape the fiber felt into products such as rock wool board, rock wool felt or rock wool tube.
Molding control: Adjust the mesh belt speed, curing temperature and time to control the density (usually 80-200kg/m³) and thickness of the product.
VI. Cutting and processing
According to the needs, the cured rock wool products are cut into plates, felt rolls or pipes of different specifications.
Some products need surface treatment, such as aluminum foil coating, mesh cloth, etc., to enhance waterproofness, aesthetics or installation convenience.
VII. Quality Inspection and Packaging
Inspection items: fiber diameter, density, thermal conductivity, compressive strength, water absorption, combustion performance (rock wool is usually a non-combustible material that meets Class A fire protection standards), etc.
Packaging: Qualified products are packaged in plastic film or woven bags and stored in a dry environment to prevent moisture.
Key Technical Points
Raw Material Ratio: The amount of flux affects the melting temperature and fiber quality and needs to be precisely controlled.
Fiberization process: Air flow parameters (speed, temperature) directly determine the thickness and uniformity of the fiber, which in turn affects the thermal insulation and sound insulation properties of rock wool.
Binder curing: Insufficient temperature and time will lead to weak bonding, while excessive temperature may increase the brittleness of the product.
Extension of rock wool applications
Due to its excellent thermal insulation, fireproof and sound insulation properties, it is widely used in building exterior wall insulation, roof insulation, pipeline insulation, industrial equipment sound insulation and other fields.
Through the above process, raw materials such as rocks are converted into rock wool products with specific properties to meet the use requirements of different scenarios.
How do you manufacture Rockwool?
About Rock Wool Production Line
Rock wool is a common thermal insulation and sound insulation material. Its manufacturing process mainly revolves around the melting, fiberization and subsequent processing of raw materials such as rocks. The following are detailed manufacturing steps and related instructions:
I. Raw material preparation
Main raw materials: basalt, dolomite, limestone and other rocks (accounting for about 80%-90%), supplemented with a small amount of soda ash (sodium carbonate), borax and other fluxes (used to reduce the melting temperature).
Raw material processing: The rock is broken into small pieces with a diameter of about 5-10 cm, and after removing impurities, it is mixed evenly with the flux in proportion.
II. Melting stage
Melting equipment: High-temperature equipment such as cupolas and pool kilns are used.
Melting process: The mixed raw materials are put into the furnace and heated to 1400-1600℃ to melt them into liquid magma.
Control the melting temperature and time to ensure that the raw materials are fully melted and avoid the generation of unmelted particles.
III. Fiberization molding
Fiberization method: Centrifugal method or blowing method is commonly used to convert liquid magma into fiber.
Centrifugal method:
Molten magma flows out from the bottom of the furnace and enters a high-speed rotating centrifuge (such as a drum or turntable) through a chute.
The centrifugal force throws the magma into a thin stream, and at the same time, it is blown and pulled by a high-speed airflow (such as air or steam, with a temperature of about 200-300℃) to further refine it into fibers with a diameter of 1-5 microns.
Blowing method:
Liquid magma is ejected through a nozzle and is blown by high-pressure air or steam (pressure of about 0.5-1.0MPa) to break it into fibers.
The key to fiber formation: Control the air flow speed, temperature and magma flow rate to ensure that the fiber thickness is uniform and there is no adhesion.
IV. Applying binder
Binder type: Thermosetting resins such as phenolic resin and polyester resin, sometimes with additives such as waterproofing agent and water repellent agent.
Application method: During the fiber forming process, the binder solution is evenly sprayed on the fiber through a spray device, and the amount used is about 2%-5% of the fiber weight.
Function: Make the fibers bond to each other and improve the strength and formability of rock wool.
V. Curing and molding
Curing process:
The fibers sprayed with binder are collected on the molding mesh belt to form fluffy fiber felt.
The fiber felt is sent to the curing furnace and heated at 180-250℃ for 10-30 minutes to cure the binder and shape the fiber felt into products such as rock wool board, rock wool felt or rock wool tube.
Molding control: Adjust the mesh belt speed, curing temperature and time to control the density (usually 80-200kg/m³) and thickness of the product.
VI. Cutting and processing
According to the needs, the cured rock wool products are cut into plates, felt rolls or pipes of different specifications.
Some products need surface treatment, such as aluminum foil coating, mesh cloth, etc., to enhance waterproofness, aesthetics or installation convenience.
VII. Quality Inspection and Packaging
Inspection items: fiber diameter, density, thermal conductivity, compressive strength, water absorption, combustion performance (rock wool is usually a non-combustible material that meets Class A fire protection standards), etc.
Packaging: Qualified products are packaged in plastic film or woven bags and stored in a dry environment to prevent moisture.
Key Technical Points
Raw Material Ratio: The amount of flux affects the melting temperature and fiber quality and needs to be precisely controlled.
Fiberization process: Air flow parameters (speed, temperature) directly determine the thickness and uniformity of the fiber, which in turn affects the thermal insulation and sound insulation properties of rock wool.
Binder curing: Insufficient temperature and time will lead to weak bonding, while excessive temperature may increase the brittleness of the product.
Extension of rock wool applications
Due to its excellent thermal insulation, fireproof and sound insulation properties, it is widely used in building exterior wall insulation, roof insulation, pipeline insulation, industrial equipment sound insulation and other fields.
Through the above process, raw materials such as rocks are converted into rock wool products with specific properties to meet the use requirements of different scenarios.
