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Title:
APPARATUS AND METHOD FOR MANUFACTURING MINERAL WOOL AS WELL AS A MINERAL WOOL PRODUCT
Document Type and Number:
WIPO Patent Application WO/2019/043290
Kind Code:
A1
Abstract:
The invention relates to an apparatus for manufacturing mineral wool. The apparatus includes means (1) for producing molten mineral material, at least one fiberizing device (3) for forming fibres, into which fiberizing device the molten mineral material is fed (2) and by which fibres (12) are formed. The fiberizing device (3) comprises, rotationally arranged around a vertical axis (15), at least one fiberizing plate (13) having a vertical peripheral edge, into which are formed numerous small-sized holes (14), through which the molten material is led by centrifugal force to form fibres (12). Into the fiberizing device (3) are arranged elements to produce a vertical flow of blowing medium (16) to be led around the fiberizing plate (13), the flow causing the fibres (12) to turn downwards and, at the same time, to thin. Downstream the fiberizing device (3) is arranged a collection device (6), into which the formed fibres (12) are led and collected into a mat-like material. In connection with said at least one fiberizing plate (13) is arranged a substantially horizontal, relatively narrow channel (5), through which the fibres (12) are brought into the chamber space (7) of the collection device (6). The invention further relates to a method for manufacturing mineral wool and a mineral wool product manufactured by the method

Inventors:
BERGMAN, Niklas (Tiilihaankatu 5, Parainen, 21600, FI)
Application Number:
FI2018/050607
Publication Date:
March 07, 2019
Filing Date:
August 28, 2018
Export Citation:
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Assignee:
PAROC GROUP OY (Energiakuja 3, Helsinki, 00180, FI)
International Classes:
D04H1/4209; C03C13/06; D04H1/4218; D04H1/4226
Domestic Patent References:
WO1987006631A11987-11-05
Foreign References:
US3824086A1974-07-16
US20120074249A12012-03-29
US20140076000A12014-03-20
EP1086054A12001-03-28
US20140364031A12014-12-11
US2991507A1961-07-11
US4759974A1988-07-26
Attorney, Agent or Firm:
LEITZINGER OY (Tammasaarenkatu 1, Helsinki, 00180, FI)
Download PDF:
Claims:
Claims

1. An apparatus for manufacturing mineral wool, the apparatus including means (1) for producing molten mineral material, at least one fiberizing device (3) for forming fibres, into which fiberizing device the molten mineral material is fed (2) and by which fibres (12) are formed, the fiberizing device (3) comprising, rotationally arranged around a vertical axis (15), at least one fiberizing plate (13) having a vertical peripheral edge, into which are formed numerous small-sized holes (14), through which the molten material is led by centrifugal force to form fibres (12), wherein to the fiberizing device (3) are arranged elements to produce a vertical flow of blowing medium (16) to be led around the fiberizing plate (13), the flow causing the fibres (12) to turn downwards and, at the same time, to thin, as well as a collection device (6) arranged downstream the fiberizing device (3), into which the formed fibres (12) are led and collected into a mat-like material, characterized in that the apparatus includes at least two fiberizing devices (3), which are placed at different height levels with each other and/or at different horizontal distance from the collection device (6), and that in connection with said at least one fiberizing plate (13) of each fiberizing device (3) is arranged a conveying device (5), where the fibres (12) are brought before reaching the collection device (6).

2. An apparatus according to claim 1, characterized in that the conveying device comprises a horizontal or inclined channel (5) located between the fiberizing plate (13) and collection device (6). 3. An apparatus according to claim 2, characterized in that the channel (5) is straight or curved.

4. An apparatus according to claim 1, characterized in that the conveying device comprises a belt.

5. An apparatus according to any of claims 1 to 4, characterized in that the conveying device comprises air producing means and/or suction means for transporting fibres to the collection device (6).

6. An apparatus according to any of claims 1 to 5, characterized in that the collection device (6) has a collection chamber (7) and collector elements (8), which comprise a collection drum (9) equipped with a perforated peripheral surface, inside which is a suction box (10), onto which drum the fibres are collected into a primary mat or web.

7. An apparatus according to claim 2 or 3, characterized in that the length of the channel (5) is in the range of 1-10 m. 8. An apparatus according to any one of claims 1 to 7, characterized in that the diameter of the holes (14) on the periphery of the fiberizing plate (13) is in the range of approx. 0.3 mm - approx. 2 mm, preferably approx. 0.5 mm - approx. 1 mm. 9. An apparatus according to any one of claims 1 to 8, characterized in that at least one fiberizing plate (13) has holes (14) of different size in relation to the holes of at least one other fiberizing plate for forming fibres of different thicknesses by different fiberizing plates. 10. An apparatus according to any one of the preceding claims, characterized in that the fiberizing devices (3) are installed in place of an existing fiberizing apparatus in an existing manufacturing line.

11. An apparatus according to any one of claims 1 to 10, characterized in that the fiberizing plates are similar to each other.

12. An apparatus according to any one of claims 1 to 10, characterized in that the fiberizing plates are different from each other. 13. A method for manufacturing mineral wool, the method using an apparatus, which includes means (1) for producing molten mineral material, at least one fiberizing device (3) for forming fibres, into which fiberizing device the molten mineral material is fed and by which fibres (12) are formed, the fiberizing device (3) comprising, rotationally arranged around a vertical axis (15), at least one fiberizing plate (13) having a vertical peripheral edge, into which are formed numerous small- sized holes (14), through which the molten material is led by centrifugal force to form fibres (12), wherein into the fiberizing device (3) are arranged elements to produce an annular flow of blowing medium (16) directed vertically downwards around the fiberizing plate (13), the flow causing the fibres (12) to turn downwards and to thin, as well as a collection device (6) arranged downstream the fiberizing device (3), into which the formed fibres (12) are led and collected into a mat-like material, characterized in that, in the method, at least two fiberizing devices (3) are arranged to feed fibres into a common collection device (6), the fiberizing devices (3) being placed at different height levels with each other and/or at different horizontal distance from the collection device (6), and that in connection with the fiberizing plate (13) of each fiberizing device (3) is arranged a conveying device (5) where the fibres (12) are brought and by means of which the fibres are conveyed into the collection device (6) to form a primary fibre mat or web.

14. A method according to claim 13, characterized in that with different fiberizing plates (13) are used different fiberizing parameters and/or holes of different size (14) to vary in a desired manner the characteristics of the intermediate product and/or final product to be manufactured by the apparatus.

15. A method according to claim 13, characterized in that blowing medium is used to transport the fibres with the conveying means into the collection device (6).

Description:
Apparatus and method for manufacturing mineral wool as well as a mineral wool product

The present invention relates to an apparatus for manufacturing mineral wool according to the preamble of independent claim 1. The invention further relates to a method for manufacturing mineral wool according to the preamble of independent claim 13.

Such mineral wool manufacturing lines are implemented with various configurations. In order to manufacture mineral wool (rock wool and glass wool), the raw material is melted in a melting furnace and led into a fiberizing device, from which it is brought into the collecting apparatus. The manufacture of rock wool typically includes a collection chamber for the fibres formed, and means for collecting the fibres into a fibre mat or web. Such a fibre mat or web, which is often called a primary mat, is then brought into the pendulum apparatus, in which is formed a secondary mat of the desired thickness.

In the manufacture of glass wool, the fiberizing apparatus is typically a plate rotationally arranged around an axis, to the peripheral edge of which plate are arranged numerous small-diameter holes. The number of holes can be even tens of thousands and their diagonal can be, for example, in the range of 0.5 mm - 1 mm. The molten material led onto the plate pushes through the holes under the influence of centrifugal force, forming fibres. Around the plate is led a blowing medium, oriented substantially parallel with the axis of rotation from above to below, which can be, for example, heated air. This blowing causes the fibres to orientate downwards and to stretch, thus thinning them. The fibres are led by the blowing medium to a transportation base passing the blowing medium through, onto which base the fibres are settled into a mat-like or a web-like product to be brought for further processing. Such a fiberizing plate is typically used in the manufacture of glass wool. Such a fiberizing plate is presented, for example, in US2991507.

In the manufacture of rock wool are typically used, arranged rotationally around a horizontal axis, a group of spinner discs (fiberization ring/spinner disc), in which material spins under the influence of centrifugal force and forms fibres. Around the spinner discs is led horizontally-oriented blowing medium to stretch and orient the fibres horizontally towards the collection chamber, into which are arranged collector elements to collect the fibres into a mat or web. Such an arrangement is known, for example, from WO87/06631.

A disadvantage, especially when using spinner discs, is a significantly great amount of non-fiberized material (shot), which can be as much as 40% by weight from the weight of the source material. There are various solutions for separating the shot from the fibres, but nonetheless a significant amount of them ends up in the final product, weakening its quality and increasing its weight.

The object of the present invention is to provide a solution, with which the creation of this shot can be effectively prevented and, at the same time, to provide an adequately high production output as well as high-grade and homogenous product quality.

In order to achieve this object, the apparatus according to the invention is characterized by the features presented in the characterizing part of independent claim 1. The method according to the invention is, in turn, characterized by the features presented in the characterizing part of independent claim 13.

In the following, the invention is described in more detail with reference to the accompanying figures, in which:

Fig. 1 shows a schematic principle illustration of an apparatus according to the invention,

Fig. 2 shows a schematic principle illustration viewed from above of one possible placement of fiberizing devices with their channels, and

Fig. 3 shows a schematic principle illustration of one placement of the

channels in the mouth of the collection device, the channels being connected to the fiberizing devices. Reference numeral 1 in Fig. 1 denotes a melting furnace, from which the molten material is led along a trough 2 into a fiberizing device 3. The fiberizing device 3 is equipped with a blower 4, which produces a flow 17 of blowing air, which transports the fibres 12 formed by the fiberizing device into the channel 5 and further into the collection device 6. The collection device 6 has a collection chamber 7 and collector elements 8, which, in this embodiment, comprise a collection drum 9 equipped with a perforated peripheral surface, inside which is a suction box 10. The blowing air moves through the holes of the drum 9 into the suction box and further away from the collection apparatus. This contributes to the collecting of the fibres 12 onto the surface of the drum 9 to form a primary fibre mat or web, which is then

transported, for example, by a conveyor 11, to the pendulum device (not shown), in which it is formed into a secondary mat, which is then brought for further processing, for example, hardening. The collection chamber can as such be according to known art, or it can differ from known art. The feeding of binder is not shown in the figure. For example, the collection device can be a foraminous or perforated belt conveyor having suction boxes inside the belt loop.

The fiberizing device 3 comprises, rotating around a vertical axis 15, a cup-like plate 13, on the periphery of which are numerous small holes 14, through which the molten mass moves under the influence of centrifugal force forming fibres 12, which are stretched around the plate by vertically led blowing air 16, annularly

surrounding the plate. In connection with the feeding of blowing air and the stretching of the fibres, binder and other necessary chemicals can be fed. Such a fiberizing plate and the production of blowing air, surrounding it annularly, in the manufacture of glass wool is prior known to the skilled person in the art, for example, from US4759974. The advantage in using such a fiberizing plate is that the majority of the mass can be fiberized. The disadvantage is that through one fiberizing device can be fed only approx. 400-500 kg molten mass per hour, which is significantly less than in solutions implemented with spinner discs, in which the fed amount of molten mass can be, for example, 5000-7000 kg per hour. In the solution according to the invention, in connection with the fiberizing device 3, preferably below it, is arranged a relatively small-diameter, horizontal channel 5 leading to the collection device, the length of which channel can be several metres, for example, in the range of approx. 1 m - approx. 10 m. In connection with the channel 5 is arranged a blower 4, which creates a horizontal air flow in the channel 5 directing the fibres 12, oriented downwards by the vertical blowing air 16 in the fiberizing device, horizontally along the channel 5 towards the collection device 6. By means of this channel solution, it is possible to place several fiberizing devices 3 to feed one collection device 6, wherein the production output can be increased to a desired level. The fiberizing devices can be placed at different height levels with each other and at different horizontal distance from the collection device 6, wherein only the channels 5 need to be adapted to the inlet port of the collection device. The channels 5 do not need to all be the same shape or size, and their location in relation to the collection apparatus can also be modified.

Fig. 2 shows as a schematic illustration viewed from above of one placement of the fiberizing devices 3 in relation to each other, as well as in relation to the collection chamber 7 and the collector elements 8. Fig. 3 shows schematically an example of one manner of placing the channels 5 in the mouth of the collection device 6 as viewed from the direction of the collection drum 9.

Fig. 4 shows a schematic illustration of the apparatus wherein the conveying device comprises a belt 20 on which the fibres are deposited. The belt can be provided with suction boxes inside the belt loop to assist depositing of the fibres on the certain portion of upper run of the belt. For releasing the fibres into a collection device the belt is preferably without any suction means in the discharging area of the belt loop or there can be blower means for directing an air flow from inside the belt loop through the belt in the discharging area of the belt 20 to assist releasing of the fibres.

Fig. 5 shows a schematic illustration of the apparatus wherein the conveying device 5 comprises a curved channel 5 through which the fibres are transported from a fiberizing device 3 to a collection device 6 by means of the blowing air directed vertically downwards around the fiberizing plate and/or by means of suction means arranged in the channel in the vicinity of the collection device. Fig. 6 shows a schematic illustration of the apparatus wherein the conveying device 5 comprises an inclined channel 5 through which the fibres are transported from a fiberizing device 3 to a collection device by means of the blowing air directed vertically downwards around the fiberizing plate and/or by means of suction means arranged in the channel in the vicinity of the collection device.

One or more fiberizing plates can be equipped with perforations of different size in relation to the other fiberizing plates, wherein different fiberizing plates can be used to produce fibres of different size. Furthermore, different fiberizing plates can be used to produce different fiberizing parameters, such as, for example, the rotation speed of the plate, the feeding rate of the molten material and/or the flow rate of the vertical blowing air, to vary in a desired manner the characteristics of the intermediate product and/or final product to be manufactured by the apparatus. In the solution according to the invention, the fiberizing plates can be similar to or different from each other, i.e. their dimensions, such as, for example, the diameters of the fiberizing plates may differ from each other, and the fiberizing plates may also differ in their design (for example, the height and shape of the edges of the fiberizing plate).

By using the method according to the invention, it is possible to create a mineral wool product having a fibre content in excess of 90%, preferably in excess of 95%, based on the following standards or specifications: 1) Eurima 5 (10.5.1967), Determination of the content of non-fibrous material in mineral wool

2) BS 2972:1975, Method of test for inorganic thermal insulating material, Section 14

3) ASTM C 612-83, Annex, Shot content of unorganic fibrous thermal insulation 4) JIS A 9504-1984, Heat insulation made of Rockwool.

The method according to the invention enables the manufacture of a mineral wool product having the desired tensile strength characteristics, i.e. the transverse tensile strength of which is greater than the linear tensile strength.