Rock wool building insulation material and its production process

Abstract

The present application belongs to the technical field of thermal insulation materials, and particularly relates to a winding rock wool building thermal insulation material and a production process thereof. The production process comprises the following steps: changing the distribution direction of a cotton layer formed by a pendulum method or a three-dimensional method in a manner of high-pressure gas or fan shaking to generate anisotropic fiber morphology, and obtaining the winding rock wool. The present application solves the problems of low tensile strength of horizontal fiber rock wool board, cracking and falling off in the building thermal insulation system, solves the problem of high thermal conductivity of vertical fiber rock wool board, and the thickness is too large to bring the safety problem of falling off under the condition of meeting the thermal insulation requirement, is energy-saving and environment-friendly, and has good economic benefits.

Description

Technical Field

[0001] The present invention belongs to the technical field of thermal insulation materials, and in particular relates to a wire-wound rock wool building thermal insulation material and a production process thereof. Background Art

[0002] Mineral wool, including glass wool and rock wool, is one of the most common traditional insulation materials. Rock wool, also known as rock wool, is a fluffy, short, fine fiber made from natural rocks and minerals. It is an inorganic fiber produced by melting and fiberizing natural rocks such as basalt, gabbro, dolomite, iron ore, and bauxite at high temperatures. Natural rocks and ores are melted in a cupola or other tank kiln, forced through a pressure of 50 atmospheres, and quenched into fibers. Alternatively, the molten stream is cast onto a multi-stage rotating rotor using centrifugal force to form fibers. Rock wool is widely used in industries such as metallurgy, machinery, building materials, petroleum, and chemicals. Rock wool fibers have excellent thermal insulation properties and are classified as a Class A fireproof material. For wall insulation, rock wool boards can be installed parallel to the wall, or as insulation strips perpendicular to the wall. Rockwool's chemical composition is very stable, making it difficult to volatilize or release harmful gases such as formaldehyde, or to cause mold and pathogens. The product is neutral or slightly alkaline, non-corrosive to the environment and metals, and is an environmentally friendly, safe, and green inorganic fiber. In my country, as the requirements for fire resistance in external insulation systems increase significantly, the use of rockwool, a low-tensile-strength, Class A fireproof inorganic fiber, as an insulation material in engineering projects is gradually increasing.

[0003] Rock wool is mainly divided into horizontal fiber rock wool board (horizontal fiber rock wool board) and vertical fiber rock wool strip (vertical fiber rock wool strip) according to its production process. Among them, horizontal fiber rock wool board is a plate-shaped product made of molten igneous rock as the main raw material, which is blown into fibers, added with appropriate amount of thermoplastic resin adhesive and water repellent, and then pressed, cured and cut. It is mainly produced according to the sedimentation production process. The main production process of the sedimentation process is that the high-temperature melt is centrifugally blown to form rock wool fibers, which are accumulated on the conveyor belt of the sedimentation chamber. After reaching a certain thickness, they pass through the pressure roller and enter the curing furnace. The fibers of the sedimentation rock wool are distributed in a plane. See Figure 1 In Figure A, the uniformity of density and adhesive is poor, which affects the tensile strength and interlayer bonding strength of the board, such as poor peeling strength. Vertical fiber rock wool strips are strip products made by cutting horizontal fiber rock wool boards at a certain interval and flipping them 90 degrees for use. The main fiber layer direction is perpendicular to the surface, see Figure 1Figure B in the drawings, the rock wool board produced according to the pendulum method or the three-dimensional method rock wool production process, the pendulum method is based on the sedimentation method, by improving the cotton collecting method, first by the collection of thin rock wool layer, through the pendulum layer by layer, to a certain number of layers and thickness, then by the pressure roller for pressing, into the curing oven curing, and then cooling, cutting, packaging and other processes to produce finished products. Horizontal wire rock wool and vertical wire rock wool have great differences in fiber distribution, production process, thermal performance and mechanical properties, which are shown in Table 1 below.

[0004] Table 1 Performance of rock wool in the prior art

[0005] Class Fiber distribution Production process Thermal conductivity / W / (m K) Tensile strength / Kpa Vertical rock wool Crested Crested 0.046 100 Crested Horizontal rock wool Layered 0.041 7.5～15

[0006] Comparing the two kinds of rock wool, the following technical problems can be easily found: (1) The horizontal fiber rock wool has a lower thermal conductivity than the vertical fiber rock wool, but its tensile strength and peel strength are low, so when used in building external thermal insulation system, it often has the safety problem of cracking and falling off; (2) The tensile strength of the vertical fiber rock wool is good, but its thermal conductivity is large, so under the same thermal insulation requirement, thicker vertical fiber rock wool strips are needed, which will increase the self-weight of the thermal insulation system and also cause the safety problem of falling off. SUMMARY

[0007] In order to solve the safety technical problems of the horizontal fiber rock wool and the vertical fiber rock wool, the present application provides a winding rock wool building thermal insulation material and its production process, which solves the problem of cracking and falling off of the horizontal fiber rock wool board in the building thermal insulation system, and solves the safety problem of falling off caused by the excessive thickness of the vertical fiber rock wool board under the same thermal insulation requirement.

[0008] The purpose of the present application is to provide a rock wool production process, which changes the distribution direction of the uncured rock wool layer formed by the pendulum method by means of high-pressure gas or fan shaking to produce anisotropic fiber morphology, and obtains winding rock wool.

[0009] The pressure of the high-pressure gas is 5-10 MPa.

[0010] In some embodiments, the flow rate of the high-pressure gas is 5-7 m 3 / min, the frequency is 50-70 times / min, and the interval time is 20-30 milliseconds. For example, the flow rate of the high-pressure gas is 6 m 3 / min, the frequency is 60 times / min, and the total gas flow within one minute is 6 m 3 .

[0011] In some embodiments, the molten raw material for preparing rock wool is processed into a fiber shape to obtain a raw material fiber, which is sent to a rock wool production device. Under the action of the rock wool production device, the raw material fiber forms an uncured rock wool layer.

[0012] The uncured rock wool layer is changed by high-pressure gas to change the distribution direction of the fibers, forming an anisotropic multi-layer folded structure of the cotton felt;

[0013] The cotton felt is cured to obtain the spun rock wool.

[0014] In some embodiments, the rock wool production equipment is a drum-type cotton collector, which comprises a cotton collector drum, a gas pipe is mounted on the drum, the gas pipe comprises an air inlet port and an air outlet port, the air inlet port is used to connect high-pressure gas, a plurality of air jet nozzles are mounted on the air outlet port and the pipe body, and the air jet nozzles blow high-pressure gas to the uncured rock wool layer.

[0015] In some embodiments, the outer diameter of the air jet nozzle is 1-5 mm, such as 1 mm, 2 mm, 3 mm, 4 mm or 5 mm.

[0016] In some embodiments, 1-4 rows of air jet nozzles are mounted on one gas pipe, such as 1 row, 2 rows or 3 rows. The rows of air jet nozzles can be staggered or arranged in parallel.

[0017] In some embodiments, the distance between adjacent air jet nozzles in one row is 8-15 mm, such as 10 mm.

[0018] In some embodiments, the bottom end of the air jet nozzle is 2-3 cm away from the bottom of the uncured rock wool layer, such as 1 cm, 2 cm or 3 cm.

[0019] In some embodiments, the angle between the air jet nozzle and the uncured rock wool layer is 30-60 degrees.

[0020] In some embodiments, the number of gas pipes is two, which are arranged in parallel, the distance between the two gas pipes is 3-5 cm, 3-4 rows of air jet nozzles are arranged on each gas pipe, the two gas pipes have the same width as the cotton collector drum, and are perpendicular to the length direction of the cotton collector drum, and the gas pipes are parallel to the upper surface of the cotton collector drum.

[0021] In some embodiments, phenolic resin and water-repellent agent are sprayed on the raw material fibers before being sent to the rock wool production equipment.

[0022] In some embodiments, the phenolic resin and the water-repellent agent are uniformly sprayed in an amount of 120-140 kg of phenolic resin per ton of raw material fibers and 2-3 kg of water-repellent agent per ton of raw material fibers.

[0023] In some embodiments, the molten raw material is prepared from basalt, blast furnace slag and dolomite.

[0024] The mass ratio of basalt, blast furnace slag and dolomite is 6-7:3-4:0.5-1.

[0025] Preferably, in the above rock wool production process, the mass ratio of basalt, blast furnace slag and dolomite is 6.5:3:0.5.

[0026] Based on the same inventive concept, a rock wool production process is provided, comprising the following steps:

[0027] Mixing basalt, blast furnace slag and dolomite, and crushing them into powder to obtain a mixed raw material;

[0028] melting the mixed raw material to obtain a molten raw material;

[0029] The molten raw material is processed into a fiber shape to obtain raw fiber, and the raw fiber is sent to the rock wool production equipment; during the transportation process, phenolic resin and water repellent are sprayed;

[0030] The raw material fibers form an uncured rock wool layer under the action of the rock wool production equipment;

[0031] The uncured rock wool layer is shaken by high-pressure gas or a fan to change the distribution direction of the fibers, thereby forming an anisotropic multi-layer folded structure wound cotton felt;

[0032] The cotton felt is solidified to obtain wire-wound rock wool.

[0033] Preferably, in the above rock wool production process, the mixed raw material is preheated to 1450-1500° C. and then melted.

[0034] The present invention also provides a wire-wound rock wool building insulation material prepared by the above process. The thermal conductivity of the insulation material is lower than that of the vertical wire rock wool and horizontal wire rock wool in the prior art, and the tensile strength is higher than that of the horizontal wire rock wool in the prior art.

[0035] Compared with the prior art, the present invention has the following beneficial effects:

[0036] This invention changes the distribution direction of the uncured rock wool layer to produce anisotropic fiber morphology, and develops a new rock wool product - wire-wound rock wool. The thermal conductivity of wire-wound rock wool is 20% lower than that of rock wool strips (vertical wire rock wool), and the tensile strength, compressive strength, shear modulus and other parameters are more than 4 times higher than those of rock wool boards (horizontal wire rock wool). This achieves the goal of meeting the mechanical properties of the material while reducing the insulation thickness by more than 20%. It solves the problem of cracking and shedding of horizontal fiber rock wool boards that often occur in building insulation systems.

[0037] In terms of economic benefits, the superior performance of wire-wound rock wool reduces the amount of material used by 20% compared to vertical fiber rock wool. Using the wire-wound rock wool of this invention in housing construction increases the homebuyer's housing acquisition rate by 1%. Assuming 90% of homes use rock wool as exterior wall insulation, the wire-wound rock wool exterior wall insulation system reduces the average exterior wall thickness by 20 mm, resulting in an annual carbon reduction of 189,000 tCO2. This solves the safety issue of vertical fiber rock wool panels falling off due to excessive thickness while meeting insulation requirements. The process of this invention is energy-efficient, environmentally friendly, and economically beneficial. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Sedimentation method It is a cross-sectional view of the prior art horizontal fiber rock wool (A) and vertical fiber rock wool (B).

[0039] Figure 1 This is a schematic diagram of fiber distribution when no high-pressure gas is applied, that is, a top view of the positional relationship between rock wool fibers, cotton collecting drum, and air pipe.

[0040] Figure 2 It is a cross-sectional view of the prior art corrugated fiber rock wool.

[0041] Figure 3 Schematic diagram of fiber distribution after high-pressure gas is applied.

[0042] Figure 4 This is the production process flow chart of wire-wound rock wool. DETAILED DESCRIPTION

[0043] In order to enable those skilled in the art to better understand and implement the technical solution of the present invention, the present invention is further described below with reference to specific embodiments and drawings.

[0044] In the description of the present invention, unless otherwise specified, all reagents used are commercially available and all methods used are conventional techniques in the art.

[0045] In the following examples and experiments, some raw materials were obtained from the following sources:

[0046] Basalt is a basic extrusive rock, formed by volcanic magma that solidifies after cooling at the surface. It has a dense or foamy structure and is classified as an igneous rock. It is primarily composed of a mixture of calcium-iron-magnesium silicates (pyroxene) and calcium- and sodium-rich feldspars (plagioclase). Purchased from the Guohong Stone Processing Factory in Baitaizi Town, Linghai City, it is black in color and has a porosity of 1%.

[0047] Blast furnace slag: Also known as slag, it is a byproduct of the blast furnace ironmaking process and contains components such as silica and alumina. Purchased from Hebei Leijiang New Materials Technology Co., Ltd.

[0048] Dolomite: Its chemical composition is CaMg(CO₃)₂. Its crystals are trigonal carbonate minerals. Its crystal structure is similar to that of calcite, with rhombohedral crystals often curved into saddle-shaped faces. Synthetic twinning is common, and it often occurs in massive or granular aggregates. Pure dolomite is white, but can sometimes appear gray-green, gray-yellow, or pink depending on other elements and impurities. It has a vitreous luster. Purchased from the Anda Mineral Powder Factory in Lingshou County.

[0049] In the present invention, the phenolic resin is suitable for the production of rock wool, such as the brown-red liquid with CAS number 9003-35-4, and the phenolic resin for rock wool and glass wool for inorganic fiber (Shandong Baofeng New Materials Co., Ltd.).

[0050] In the present invention, the water repellent is a water repellent suitable for rock wool production, such as rock wool water repellent (Hebei Kesiduoju Trading Co., Ltd.).

[0051] In the present invention, the rock wool collector is a conventional rock wool collector for rock wool production, such as the rock wool drum collector provided by Zibo Jinyue Machinery Manufacturing Co., Ltd. The drum collector includes an exhaust system, a collection belt, a rock wool lifting system, and a pendulum system. The rock wool is sucked by the exhaust system and evenly deposited on the collecting drum 3 of the drum collector to form a primary rock wool layer. The primary rock wool layer is then fed into the pendulum system through the rock wool lifting system.

[0052] The inventive concept of the present invention is to change the distribution direction of the uncured rock wool layer formed by the pendulum method to produce anisotropic fiber morphology, and develop a new type of rock wool product - wire-wound rock wool.

[0053] See also Figure 5 An air pipe 1 is installed on a drum-type cotton collector, such as the pendulum system of the drum-type cotton collector. The air pipe 1 includes an air inlet port and an air outlet port. The air inlet port is used to connect to high-pressure gas. The air outlet port and the pipe body are provided with multiple air nozzles 2, which blow high-pressure gas into the uncured rock wool layer. The air nozzle 2 has an outer diameter of 1-5 mm and multiple air outlet holes. The inner diameter of the air outlet holes is 1-5 μm. The air nozzle 2 blows high-pressure gas into the uncured rock wool layer, causing the fibers to twist and form an S-shape. Because the air nozzle 2 is arranged around the wall of the air pipe 1, the air pipe 1 is parallel to the upper surface of the cotton collecting drum 3, the rock wool fibers are parallel to the length of the cotton collecting drum 3, and the air pipe 1 is perpendicular to the length of the cotton collecting drum. Therefore, the high-pressure gas can twist different fibers in different directions. The cured rock wool is cut along the extension direction of the fiber, forming a winding, thereby reducing the thermal conductivity. A low thermal conductivity improves thermal insulation performance.

[0054] In addition, the fibers in the uncured rock wool layer can be twisted in different directions by mechanical means of fan shaking. The cured rock wool is cut along the extension direction of the fiber filaments to form windings, thereby reducing the thermal conductivity and improving the thermal insulation performance.

[0055] Preferably, an angle of 30-60 degrees is formed between the air pipe 1 and the uncured rock wool layer. Since the uncured rock wool layer is laid on the cotton collecting drum 3, an angle of 30-60 degrees is formed between the air jet nozzle 2 and the upper surface of the cotton collecting drum 3, that is, the air jet nozzle 2 is at an angle of 30-60 degrees relative to the vertical direction. In this way, the high-pressure air blown out from the air jet nozzle 2 and the fibers of the uncured rock wool layer are also staggered and not perpendicular, which is conducive to the winding of the fibers.

[0056] It should be noted that there are some three-dimensional rock wool structures in the existing technology, but they are just pleating the rock wool fibers in the transverse direction after the rock wool is solidified. The transverse direction does not change, and there is no effect between the rock wool layers. Figure 2 The connection between rock wool layers is not strong.

[0057] The rock wool made in this application is wound wire, not simply "pleated". The winding of the present invention is similar to twisting, and the fibers of each layer are interwoven before the rock wool is solidified. And because the air jet nozzle 2 is multi-directional, "winding" in multiple directions will be produced, and the interweaving is tighter. Figure 3 In the process, the fibers are originally distributed in the transverse direction, but after the process of the present invention, the fibers become wound yarns, such as Figure 2 It should be noted that Figure 4 and Figure 2 It is a line diagram drawn to help readers understand the inventive concept of the invention.

[0058] The present invention provides a rock wool production process, referring to Figure 4 , including the following steps:

[0059] First, basalt, blast furnace slag and dolomite are mixed in a ratio of 6-7:3-4:0.5-1, and then put into a crusher to be crushed into 100-150 mesh powder to obtain a mixed raw material.

[0060] Second, the mixed raw materials are preheated to 1450-1500° C. and then put into an electric furnace for melting to obtain molten raw materials.

[0061] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120-140 kg per ton of raw fiber and 2-3 kg per ton of raw fiber. The phenolic resin and water repellent can be mixed first and then sprayed, allowing for immediate use. Alternatively, the phenolic resin can be sprayed first, followed by the water repellent.

[0062] Fourth, the raw fibers form a primary cotton layer under the action of the cotton collector. The primary cotton layer with a thickness of 1-2 cm is collected by the collecting belt and stacked layer by layer by the pendulum to 15-20 layers, with a thickness of 30-50 cm, forming an uncured rock wool layer.

[0063] Fifth, the above-mentioned uncured rock wool layer is mechanically changed in fiber distribution direction by using 5-10 MPa high-pressure gas or fan shaking (such as fan shaking of the cotton collector exhaust system) to form an anisotropic multi-layer wire-wound folded structure of cotton felt on the conveyor belt of the cotton collector.

[0064] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180-230° C. to obtain wire-wound rock wool.

[0065] The above method is to crush and melt basalt, dolomite, and blast furnace slag, then centrifuge them into fibers and blow them into a cotton wool collector. At the same time, phenolic resin and water repellent are evenly sprayed on them. The cotton wool collector forms a primary cotton layer, which is then stacked layer by layer using a pendulum machine to obtain an uncured rock wool layer. High-pressure gas or fan-driven mechanical shaking methods are then added to form an anisotropic multi-layer folded cotton felt structure. Finally, the material is shaped at high temperature or under high pressure to obtain wire-wound rock wool. Wire-wound rock wool greatly improves the tensile strength of the material, ensuring that it will not crack or fall off, while also reducing its thermal conductivity. Thinner wire-wound rock wool can meet insulation requirements.

[0066] The following describes embodiments of the present invention.

[0067] Example 1

[0068] A rock wool production process comprises the following steps:

[0069] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0070] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0071] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 2 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0072] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0073] Fifth, see Figure 5 , two air pipes 1 are installed on the cotton collecting drum 3 of the drum-type cotton collecting machine. The two air pipes 1 are the same width as the cotton collecting drum 3 and are perpendicular to the length direction of the cotton collecting drum 3. The distance between the two air pipes 1 is 3 cm. The two air pipes 1 are arranged parallel to the upper surface of the cotton collecting drum 3. The air pipe 1 includes an air inlet port and an air outlet port. The air inlet port is used to connect high-pressure gas. A plurality of air jet nozzles 2 are provided at the air outlet port and the tube body. Each air pipe 1 is provided with 3 rows of air jet nozzles 2. The outer diameter of the air jet nozzle 2 is 2 mm. The air jet nozzle 2 has a plurality of air outlet holes. The inner diameter of the air outlet hole is 1 μm. Figure 2 In the top view shown, the three rows of air jet nozzles 2 form angles of 30, 45, and 60 degrees with the uncured rock wool fibers, respectively. The lowest end of the air jet nozzles 2 is 2 cm from the bottom of the uncured rock wool layer. Within a row of air jet nozzles 2, the spacing between adjacent nozzles 2 is 10 mm.

[0074] The air jet nozzle 2 blows high-pressure gas to the uncured rock wool layer, and the high-pressure gas pressure is 5MPa, forming an anisotropic multi-layer winding folded structure of cotton felt. The flow rate of the high-pressure gas is 6m 3 / min, the frequency is 60 times / min, and the total gas flow rate in one minute is 6m 3 .

[0075] The air jet nozzle 2 blows high-pressure gas into the uncured rock wool layer, causing the fibers to twist and form an S shape. Since the air jet nozzle 2 is circumferentially arranged around the wall of the air pipe 1, the high-pressure gas can twist different fibers in different directions. The cured rock wool is cut along the extension direction of the fiber filaments to form a winding.

[0076] Since the uncured rock wool layer is laid on the cotton collecting drum 3, angles of 30, 45, and 60 degrees are formed between the air jet nozzle 2 and the cotton collecting drum 3. In this way, the high-pressure air blown out from the air jet nozzle 2 and the fibers of the uncured rock wool layer are also staggered and not perpendicular, which is conducive to the winding of the fibers.

[0077] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0078] Example 2

[0079] A rock wool production process comprises the following steps:

[0080] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:1, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0081] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0082] Thirdly, the molten raw material is treated into fibrous form by centrifuge to obtain raw material fibers, and is blown to a cotton collector; in the process of blowing, phenolic resin and hydrophobic agent are uniformly sprayed according to the amount of 120 kg of phenolic resin per ton of raw material fibers and 2 kg of hydrophobic agent per ton of raw material fibers. The phenolic resin and the hydrophobic agent are mixed first and then sprayed, and are mixed and used immediately.

[0083] Fourthly, the raw material fibers form a primary cotton layer under the action of the cotton collector, and a 2 cm-thick primary cotton layer is collected by a capture belt and is stacked by a pendulum to 15 layers, with a thickness of 30 cm, to form a non-cured rock wool layer.

[0084] Fifthly, the operation is the same as the fifth step of Example 1.

[0085] Sixthly, the cotton felt is sent into a curing furnace to be shaped at a high temperature environment of 180℃ to obtain the spun rock wool.

[0086] Example 3

[0087] A rock wool production process comprises the following steps:

[0088] Firstly, basalt, blast furnace slag and dolomite are mixed in a ratio of 6.5:4:0.5 and then are put into a pulverizer to be pulverized into 100-mesh powder to obtain mixed raw materials.

[0089] Secondly, the mixed raw materials are preheated to 1450℃ and then are put into an electric furnace to be melted to obtain molten raw materials.

[0090] Thirdly, the molten raw materials are treated into fibrous form by a centrifuge to obtain raw material fibers, and are blown to a cotton collector; in the process of blowing, phenolic resin and hydrophobic agent are uniformly sprayed according to the amount of 120 kg of phenolic resin per ton of raw material fibers and 2 kg of hydrophobic agent per ton of raw material fibers. The phenolic resin and the hydrophobic agent are mixed first and then sprayed, and are mixed and used immediately.

[0091] Fourthly, the raw material fibers form a primary cotton layer under the action of the cotton collector, and a 2 cm-thick primary cotton layer is collected by a capture belt and is stacked by a pendulum to 15 layers, with a thickness of 30 cm, to form a non-cured rock wool layer.

[0092] Fifthly, the operation is the same as the fifth step of Example 1.

[0093] Sixthly, the cotton felt is sent into a curing furnace to be shaped at a high temperature environment of 180℃ to obtain the spun rock wool.

[0094] Example 4

[0095] A rock wool production process comprises the following steps:

[0096] First, basalt, blast furnace slag, dolomite are mixed in a ratio of 6:3:0.5, then put into a pulverizer to be crushed into 100-mesh powder to obtain mixed raw materials.

[0097] Second, the mixed raw materials are preheated to 1450℃, then put into an electric furnace to be melted to obtain molten raw materials.

[0098] Third, the molten raw materials are centrifuged by a centrifuge to be processed into fibrous form to obtain raw material fibers, and are blown to a cotton collector; in the process of blowing, phenolic resin and water-repellent agent are uniformly sprayed in an amount of 120 kg of phenolic resin per ton of raw material fibers and 2 kg of water-repellent agent per ton of raw material fibers. The phenolic resin and the water-repellent agent are mixed first and then sprayed, and are mixed and used immediately.

[0099] Fourth, the raw material fibers form a primary cotton layer under the action of the cotton collector, and the primary cotton layer with a thickness of 2 cm is collected by a capture belt and is stacked layer by layer by a pendulum to 15 layers with a thickness of 30 cm to form a non-solidified rock wool layer.

[0100] Fifth, the operation is the same as the fifth step of Example 1.

[0101] Sixth, the cotton felt is sent into a curing furnace to be shaped in a high-temperature environment of 180℃ to obtain spun rock wool.

[0102] Example 5

[0103] A rock wool production process, comprising the following steps:

[0104] First, basalt, blast furnace slag, dolomite are mixed in a ratio of 6:3:0.5, then put into a pulverizer to be crushed into 100-mesh powder to obtain mixed raw materials.

[0105] Second, the mixed raw materials are preheated to 1450℃, then put into an electric furnace to be melted to obtain molten raw materials.

[0106] Third, the molten raw materials are centrifuged by a centrifuge to be processed into fibrous form to obtain raw material fibers, and are blown to a cotton collector; in the process of blowing, phenolic resin and water-repellent agent are uniformly sprayed in an amount of 120 kg of phenolic resin per ton of raw material fibers and 2 kg of water-repellent agent per ton of raw material fibers. The phenolic resin and the water-repellent agent are mixed first and then sprayed, and are mixed and used immediately.

[0107] Fourth, the raw material fibers form a primary cotton layer under the action of the cotton collector, and the primary cotton layer with a thickness of 2 cm is collected by a capture belt and is stacked layer by layer by a pendulum to 15 layers with a thickness of 30 cm to form a non-solidified rock wool layer.

[0108] Fifth, the operation is the same as the fifth step of Example 1.

[0109] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0110] Example 6

[0111] A rock wool production process comprises the following steps:

[0112] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0113] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0114] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 2 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0115] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0116] Fifth, the uncured rock wool layer is shaken by a fan (the fan of the cotton collector exhaust system is shaken) to change the distribution direction of the cotton layer fibers, and a cotton felt with an anisotropic multi-layer wire winding and folding structure is formed on the conveyor belt of the conveyor.

[0117] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0118] Example 7

[0119] A rock wool production process comprises the following steps:

[0120] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 150-mesh powder to obtain a mixed raw material.

[0121] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0122] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 2 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0123] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0124] Fifth, the operation is the same as the fifth step of Example 1.

[0125] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0126] Example 8

[0127] A rock wool production process comprises the following steps:

[0128] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0129] Second, the mixed raw material is preheated to 1500° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0130] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 2 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0131] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0132] Fifth, the operation is the same as the fifth step of Example 1.

[0133] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0134] Example 9

[0135] A rock wool production process comprises the following steps:

[0136] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0137] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0138] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 3 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0139] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0140] Fifth, the operation is the same as the fifth step of Example 1.

[0141] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0142] Example 10

[0143] A rock wool production process comprises the following steps:

[0144] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0145] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0146] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 140 kg per ton of raw fiber and 3 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0147] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0148] Fifth, the operation is the same as the fifth step of Example 1.

[0149] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0150] Example 11

[0151] A rock wool production process comprises the following steps:

[0152] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0153] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0154] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 2 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0155] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 1.5cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until 20 layers are formed, with a thickness of 30cm, forming an uncured rock wool layer.

[0156] Fifth, the operation is the same as the fifth step of Example 1.

[0157] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0158] Example 12

[0159] A rock wool production process comprises the following steps:

[0160] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0161] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0162] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 2 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0163] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0164] Fifth, the operation is the same as the fifth step of Example 1.

[0165] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 200° C. to obtain wire-wound rock wool.

[0166] Example 13

[0167] A rock wool production process comprises the following steps:

[0168] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0169] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0170] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 2 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0171] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0172] Fifth, the operation is the same as the fifth step of Example 1.

[0173] Sixth, the cotton felt is sent into a curing furnace and shaped in a high temperature environment of 230° C. to obtain wire-wound rock wool.

[0174] Example 14

[0175] A rock wool production process comprises the following steps:

[0176] First, basalt, blast furnace slag, and dolomite are mixed in a ratio of 6.5:3:0.5, and then put into a crusher to be crushed into 100-mesh powder to obtain a mixed raw material.

[0177] Second, the mixed raw material is preheated to 1450° C. and then placed in an electric furnace for melting to obtain a molten raw material.

[0178] Third, the molten raw material is centrifuged into fibers to obtain raw fiber, which is then blown to a cotton collector. During the blowing process, phenolic resin and water repellent are evenly sprayed at a rate of 120 kg per ton of raw fiber and 2 kg per ton of raw fiber. The phenolic resin and water repellent are mixed first and then sprayed, ensuring immediate use.

[0179] Fourth, the raw fibers are formed into a primary cotton layer under the action of the cotton collector. The 2cm thick primary cotton layer is collected by the collection belt and stacked layer by layer by the pendulum until it reaches 15 layers and a thickness of 30cm, forming an uncured rock wool layer.

[0180] Fifth, two air pipes 1 are installed on the cotton collecting drum 3 of the drum-type cotton collecting machine. The two air pipes 1 are of the same width as the cotton collecting drum 3 and are perpendicular to the length direction of the cotton collecting drum 3. The distance between the two air pipes 1 is 5 cm. The air pipe 1 includes an air inlet port and an air outlet port. The air inlet port is used to connect high-pressure gas. The air outlet port and the pipe body are provided with multiple air jet nozzles 2. Each air pipe 1 is provided with 3 rows of air jet nozzles 2. The outer diameter of the air jet nozzle 2 is 3mm. The air jet nozzle 2 has multiple air outlet holes. The inner diameter of the air outlet hole is 5μm. Figure 2 Figure 2 In the top view shown, the three rows of air jet nozzles 2 form angles of 30, 45, and 60 degrees with the uncured rock wool fibers, respectively. The lowest end of the air jet nozzles 2 is 3 cm from the bottom of the uncured rock wool layer. Within a row of air jet nozzles 2, the spacing between adjacent nozzles 2 is 12 mm.

[0181] The air jet nozzle 2 blows high-pressure gas to the uncured rock wool layer, and the high-pressure gas pressure is 5MPa to form an anisotropic multi-layer winding folded structure of cotton felt. The flow rate of the high-pressure gas is 6m 3 / min, the frequency is 60 times / min, and the total gas flow rate in this minute is 6m 3 .

[0182] The air jet nozzle 2 blows high-pressure gas into the uncured rock wool layer, causing the fibers to twist and form an S shape. Since the air jet nozzle 2 is circumferentially arranged around the wall of the air pipe 1, the high-pressure gas can twist different fibers in different directions. The cured rock wool is cut along the extension direction of the fiber filaments to form a winding.

[0183] Since the uncured rock wool layer is laid on the cotton collecting drum 3, angles of 30, 45, and 60 degrees are formed between the air jet nozzle 2 and the cotton collecting drum 3. In this way, the high-pressure air blown out from the air jet nozzle 2 and the fibers of the uncured rock wool layer are also staggered and not perpendicular, which is conducive to the winding of the fibers.

[0184] Sixth, the cotton felt is sent into a curing furnace and pressurized and shaped in a high temperature environment of 180° C. to obtain wire-wound rock wool.

[0185] Direct benefit analysis: according to the existing experimental detection, the rock wool insulation board prepared by example 1-14 has a bulk density of 110 kg / m 3 The thermal conductivity is 0.35-0.37 W / (m·K), which is 20% lower than the thermal conductivity of the commonly used vertical fiber (vertical fiber) rock wool board (Chengdu Jinliushun Building Material Co., Ltd.). Since the thermal conductivity can directly affect the thickness of the thermal insulation material layer, the thickness of the rock wool of the present application is about 20% less than that of the vertical fiber rock wool under the same bulk density.

[0186] Compared with the same bulk density of horizontal fiber rock wool (rock wool board, Zhengye Building Material (Langfang) Co., Ltd.), the rock wool insulation board prepared by example 1-14 has a bulk density of 110 kg / m 3 , and the tensile strength is increased by at least 4 times. For specific results, refer to Table 2.

[0187] Table 2 rock wool performance test results

[0188]

[0189]

[0190] Economic benefit analysis: as a thermal insulation material, the thickness of rock wool not only affects the building energy consumption, but also has a great influence on the practical area of the building. If the bulk density of the rock wool board is 110 kg / m 3 , the house rate will increase by 1% for every 1 cm decrease in the thickness of the rock wool board, and the practical area of the building will increase by about 1m 2 . Due to the superior performance of the rock wool material, the amount of rock wool material is reduced by 20% compared with the vertical fiber rock wool material, and the current residential price in Shaanxi Province is about 10,000 yuan / m 2 -20,000 yuan / m 2 , so for the home buyers, the actual housing cost of using the rock wool outer wall external thermal insulation system can be saved by 2-4 million yuan / house.

[0191] Energy saving benefit analysis: according to the total production capacity of domestic rock wool, the rock wool industry digests more than 10 million tons of industrial waste slag per year; in terms of energy saving, the whole life cycle energy consumption level (from raw material mining to finished product manufacturing) of rock wool and polystyrene organic insulation board is about 400-500 kg of standard coal per ton of product, while the energy consumption of polystyrene organic insulation board is 8660 kg of standard coal per ton of product. It is not difficult to find that the use of rock wool insulation material can reduce the energy consumption of 94.23% per ton compared with other organic insulation materials. At present, according to the two-star energy saving requirement of green building, the thickness of rock wool insulation material is about 120 mm, and the bulk density is 110 kg / m 3 , the 1m 2The rock wool board is about 13.2kg, of which 1m 2 The rock wool board is 13.2kg, so per m 2 The energy consumption of rock wool board is about 5.94kg standard coal. The carbon emission factor of rock wool in the "Building Carbon Emission Calculation Standard" GB / T51366-2019 is 1980kgCO2 / t. The amount of wire-wound rock wool is 20% less than that of vertical wire rock wool board. According to the completion area of ​​residential buildings in Shaanxi Province in 2020, it will reach 48.33 million m 2 , as 90% of the houses use rock wool as the exterior wall insulation material, the wire-wound rock wool exterior wall insulation system reduces the thickness of the exterior wall by an average of 20mm, and its annual carbon reduction reaches 189,000 tCO2.

[0192] It should be noted that when numerical ranges are mentioned in the present invention, it should be understood that both endpoints of each numerical range and any value between the two endpoints may be selected. Since the steps and methods used are the same as those in the embodiments, in order to avoid redundancy, the present invention describes preferred embodiments. Although preferred embodiments of the present invention have been described, those skilled in the art may make additional changes and modifications to these embodiments once they understand the basic inventive concepts. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0193] Obviously, those skilled in the art may make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if such changes and modifications fall within the scope of the claims and their equivalents, the present invention is intended to include such changes and modifications.

Claims

1. A rock wool production process, characterized in that: The molten raw material for preparing rock wool is processed into fibers to obtain raw fibers, which are then sent to the rock wool production equipment. The raw fibers form an uncured rock wool layer under the action of the rock wool production equipment; The uncured rock wool layer is subjected to high-pressure gas to change the distribution direction of the fibers to form an anisotropic multi-layer folded structure wound cotton felt; curing the cotton felt to obtain wire-wound rock wool; Wherein, the pressure of the high-pressure gas is 5-10MPa; The flow rate of high pressure gas is 5-7m 3 / min, the frequency is 50-70 times / min, and the interval time is 20-30 milliseconds.

2. The rock wool production process according to claim 1, characterized in that: The rock wool production equipment comprises a cotton collecting drum, an air pipe (1) is installed on the cotton collecting drum, the air pipe (1) comprises an air inlet port and an air outlet port, the air inlet port is used to connect high-pressure gas, and a plurality of air jet nozzles (2) are installed on the air outlet port and the pipe body, and the air jet nozzles (2) blow high-pressure gas to the uncured rock wool layer.

3. The rock wool production process according to claim 2, characterized in that: The diameter of the air jet nozzle (2) is 1-5 mm.

4. The rock wool production process according to claim 3, characterized in that: One air pipe (1) is provided with 1 to 4 rows of air jet nozzles (2).

5. The rock wool production process according to claim 4, characterized in that: In a row of the air jet nozzles (2), the spacing between adjacent air jet nozzles (2) is 8-15 mm.

6. The rock wool production process according to claim 3, characterized in that: The bottom end of the air jet nozzle (2) is 2-3 cm away from the bottom of the uncured rock wool layer.

7. The rock wool production process according to claim 6, characterized in that: The air jet nozzle (2) forms an angle of 30-60 degrees with the uncured rock wool layer.

8. The rock wool production process according to claim 3, characterized in that: There are two air pipes (1) arranged in parallel, with a distance of 3-5 cm between the two air pipes (1). The two air pipes (1) have the same width as the cotton collecting drum and are perpendicular to the length direction of the cotton collecting drum. The air pipes (1) are parallel to the upper surface of the cotton collecting drum.

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