A mineral wool material and a method for producing the same
By optimizing the composition ratio of blast furnace liquid slag and conditioning materials in mineral wool production, a gradient network structure is formed, which solves the problem of unreasonable flux ratio in mineral wool production, improves the cotton sizing ratio and strength, reduces the content of loose cotton and cotton balls, and achieves product quality stability and meets the needs of high-end applications.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- XINJI SINO-AUSTRALIA RENEWABLE RESOURCES RECYCLING CO LTD
- Filing Date
- 2026-03-18
- Publication Date
- 2026-06-09
AI Technical Summary
The current flux ratio in mineral wool production is unreasonable, resulting in poor fiber formability, insufficient bonding strength, difficulty in increasing the cotton-to-sizing ratio, insufficient strength, high content of cotton fibers and cotton balls, poor slag fluidity, unstable product quality, and inability to meet the needs of high-end applications.
An optimized composition ratio of blast furnace liquid slag and conditioning materials, including quartz sand, coal gangue, modified basalt and modified lithium feldspar powder, is adopted. Through modification treatment, a gradient network structure is formed, which improves melt uniformity and fiber strength, and reduces the content of cotton wool and cotton balls.
It achieves simultaneous improvement in mineral wool sizing ratio and strength, reduces the content of cotton wool and cotton balls, improves product quality stability, and meets the needs of high-end applications.
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Abstract
Description
Technical Field
[0001] This invention relates to the field of mineral wool production technology, and in particular to a mineral wool material and its preparation method. Background Technology
[0002] Mineral wool, an inorganic thermal insulation fiber material, is made primarily from blast furnace molten slag, combined with auxiliary flux, through electric furnace temperature and tempering, centrifugal fiber formation, and wool collection. Due to its low thermal conductivity, good flame retardancy, and low cost, it is widely used in building insulation and industrial equipment cooling. The slag-to-slag ratio and mechanical strength are core quality indicators of mineral wool products, while the slag ball content and cotton wool formation rate directly determine the yield and production efficiency of mineral wool. Optimizing and improving these indicators is a key direction for the research and development of mineral wool production processes.
[0003] In existing mineral wool production processes, auxiliary fluxes are mostly made by adding quartz sand alone or by simply mixing quartz sand with coal gangue and potassium feldspar. The batching schemes are largely based on experience. However, due to unreasonable flux ratios, the acidity coefficient of the slag easily deviates from the optimal range for forming the wool. This not only leads to poor fiber formation and insufficient inter-fiber bonding, making it difficult to improve the cotton-to-sizing ratio, but also results in insufficient mechanical strength of the finished wool, failing to meet the quality requirements of high-end applications. Simultaneously, existing fluxes tend to cause excessive iron buildup in the dead iron layer of the electric furnace, affecting slag fluidity and resulting in insufficient slag ball separation during centrifugal fiber forming, leading to persistently high slag ball content. Adding high-melting-point fluxes lowers the slag temperature, causing uneven fiber formation and frequent defects such as uneven or soft fibers. This not only reduces the yield of the finished mineral wool but also increases waste generation, reducing raw material utilization and production efficiency. Furthermore, existing fluxes cannot quickly adapt to fluctuations in slag composition caused by changes in blast furnace conditions, resulting in poor quality stability of mineral wool products. Indicators such as the slag-to-bond ratio and strength fluctuate significantly, hindering the improvement of mineral wool product grades and market competitiveness. Therefore, developing a mineral wool material and its preparation method that can precisely control the slag composition ratio, simultaneously improve the slag-to-bond ratio and strength, and effectively reduce the content of loose cotton and cotton balls has become an urgent technical problem to be solved in this field. Summary of the Invention
[0004] In view of this, the present invention provides a mineral wool material and a method for preparing the same. The mineral wool material provided by the present invention, by optimizing the composition and ratio of its blast furnace liquid slag and conditioning materials, effectively reduces the content of loose cotton and cotton balls, achieving a simultaneous improvement in the mineral wool sizing ratio and strength.
[0005] To achieve the above-mentioned objectives, the present invention adopts the following technical solution: A mineral wool material comprising the following raw material components in parts by weight: 60-65 parts of blast furnace liquid slag and 15-25 parts of conditioning material; The blast furnace liquid slag comprises the following chemical composition by mass percentage: SiO2 28%~36%, Al2O3 12%~20%, CaO 32%~45%, MgO 7%~12% and FeO <0.5%; The conditioning material includes 42%~48% quartz sand, 22%~28% coal gangue, 11%~18% modified basalt and 10%~14% modified lithium feldspar powder; The modified basalt is sodium silicate modified basalt; The modified lithium feldspar powder is citric acid-modified calcined lithium feldspar powder.
[0006] The mineral wool material provided by this invention contains abundant SiO2 in the quartz sand, which can stabilize the silicon-oxygen network skeleton in blast furnace liquid slag, improve the fiber continuity and fiber strength of blast furnace liquid slag, and significantly increase the cotton-to-sizing ratio. Coal gangue contains Al2O3 and SiO2, which can supplement the silicon-aluminum components required in the blast furnace liquid slag network, optimize the viscosity and fiber-forming window of the blast furnace liquid slag, and reduce the risk of impurity discoloration through in-situ decarburization. The combination of coal gangue and low-iron blast furnace liquid slag system synergistically improves the cotton-to-sizing ratio of the mineral wool material, while reducing cotton fibers and cotton balls caused by melt inhomogeneity. After modifying basalt with sodium silicate, sodium silicate can significantly reduce the melting temperature of basalt, thereby improving its compatibility with blast furnace liquid slag. The modified basalt forms a uniformly distributed reinforcing silicon-oxygen gel in the melt. The process of calcination can improve the strength and melt flow of mineral wool, thereby increasing the sizing ratio and reducing the content of loose fibers and cotton balls. Calcination can remove the water of crystallization and organic impurities from lithium feldspar powder, avoiding the problem of bubbles in the melt, thus reducing the content of loose fibers and cotton balls in the mineral wool. At the same time, calcination will destroy the crystal structure of lithium feldspar powder, significantly reducing the melting temperature, reducing energy consumption to a certain extent, and also increasing the sizing ratio and strength of mineral wool. When lithium feldspar powder is activated by citric acid, citric acid can further etch the surface of the calcined lithium feldspar powder and remove impurities, reducing the surface energy and interfacial tension of the calcined lithium feldspar powder, while promoting the effective release of active components such as lithium and aluminum, making them more likely to participate in the reconstruction of the silicon-oxygen network, thereby synergistically improving the sizing ratio and strength of mineral wool and reducing the content of loose fibers and cotton balls.
[0007] The modified lithium feldspar powder in the mineral wool material provided by this invention forms a gradient network structure with quartz sand, coal gangue and modified basalt. Under the synergistic effect of the four components, the melt composition is more uniform and the fiber formation is more stable, ultimately achieving a simultaneous increase in cotton sizing ratio and strength, and effectively reducing the content of cotton wool and cotton balls.
[0008] Preferably, the method for preparing the modified basalt includes the following steps: Basalt was added to an acidic sodium silicate aqueous solution, then ground and dried to obtain the modified basalt.
[0009] In the modified basalt preparation method provided by the present invention, a uniform silicate coating layer can be formed on the surface of basalt by grinding. The wet grinding method is simple to operate, mild in conditions, and does not require high-temperature calcination. It can retain the reinforcing properties of basalt itself, and introduce the fluxing and film-forming effects of sodium silicate, effectively reducing the content of cotton wool and cotton balls from the source. At the same time, the sodium silicate modified layer can also participate in the construction of the melt silicon-oxygen network, improve the fiber strength and cotton wool ratio, and achieve a significant improvement in material performance.
[0010] More preferably, the basalt contains 45%~50% SiO2, 10%~15% Al2O3, and <3% FeO.
[0011] More preferably, the mass concentration of sodium silicate in the acidic sodium silicate aqueous solution is 5%~6%, and the mass concentration of hydrochloric acid is 1%~2%.
[0012] More preferably, the mass-to-volume ratio of the basalt and the acidic sodium silicate aqueous solution is 100g:(3~4)mL.
[0013] This invention limits the composition of the sodium silicate aqueous solution and the ratio of basalt to sodium silicate aqueous solution, so that moderate surface etching and uniform coating of basalt can be achieved under mild conditions, which ensures sufficient modification and avoids agglomeration due to excessive concentration or insufficient modification due to insufficient concentration, thereby improving melt homogeneity and improving the overall performance of mineral wool.
[0014] More preferably, the ball-to-material ratio in the grinding process is (6~7):1.
[0015] More preferably, the grinding speed is 300~350 r / min.
[0016] More preferably, the grinding time is 30-40 minutes.
[0017] Preferably, the preparation method of the modified lithium feldspar powder includes the following steps: S1. Calcining lithium feldspar powder at 650~680℃ to obtain calcined lithium feldspar powder; S2. The calcined lithium feldspar powder is impregnated in an alcoholic solution of citric acid to obtain the modified lithium feldspar powder.
[0018] In the preparation method of modified lithium feldspar powder provided by the present invention, a specific calcination temperature can effectively destroy the crystal structure of lithium feldspar powder, remove water of crystallization and impurities, improve the reactivity, and reduce the melting temperature. The calcined lithium feldspar powder is impregnated with citric acid, which can further improve the dispersibility and reaction uniformity of lithium feldspar powder in mineral wool melt, thereby synergistically improving the cotton sizing ratio and mechanical strength of mineral wool, reducing defects such as cotton wool and cotton balls, and the modification effect is stable.
[0019] Preferably, in S1, the calcination time is 2.5 to 3 hours.
[0020] Preferably, in S1, a programmed temperature rise method is used, with the temperature rising to 650~680℃ at a rate of 5~6℃ / min.
[0021] Preferably, in S2, the mass ratio of citric acid, anhydrous ethanol and water in the citric acid alcohol solution is (1~2):1:(7~8).
[0022] Preferably, in step S2, the impregnation temperature is 60~65°C.
[0023] The optimal impregnation time can further improve the modification effect.
[0024] Preferably, in step S2, the immersion time is 40-50 minutes.
[0025] Preferably, in S2, the stirring rate during impregnation is 450~500 r / min.
[0026] Preferably, the particle size of the quartz sand is 80-100 mesh.
[0027] Preferably, the particle size of the coal gangue is 110-130 mesh.
[0028] Preferably, the modified basalt has a particle size of 150-200 mesh.
[0029] Preferably, the modified lithium feldspar powder has a particle size of 220-250 mesh.
[0030] This invention provides a method for preparing the above-mentioned mineral wool material, comprising the following steps: Step 1: Weigh each component according to the mass ratio, add the weighed blast furnace liquid slag and conditioning material to the electric furnace, stir and homogenize to obtain a mixed melt; Step 2: Centrifuge and cool the mixed melt, collect the wool, and obtain mineral wool material.
[0031] Preferably, in step 1, the stirring is electromagnetic stirring.
[0032] Preferably, in step 1, the temperature of the electric furnace during stirring is 1350~1380℃, the stirring rate is 180~200rpm, and the stirring time is 25~35min.
[0033] Preferably, in step 1, the homogenization temperature is 1380~1410℃, and the homogenization time is 15~25min.
[0034] Preferably, in step 2, the centrifugation and cooling are carried out in a four-roll centrifuge with a rotation speed of 1500~2000 rpm, an outlet flow rate of 8~12 kg / min, a cooling air temperature of 25~35℃, and a cooling air velocity of 10~15 m / s.
[0035] This invention optimizes the centrifuge speed and cooling parameters to avoid fiber agglomeration and fiber breakage caused by untimely fiber cooling, improves fiber uniformity, and lays the foundation for subsequent improvement of cotton-spunbond ratio and finished product strength. Detailed Implementation
[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.
[0037] In this invention, the quartz sand was purchased from Qingdao Zhiyuan Filter Material Co., Ltd., the coal gangue was purchased from Lingshou County Cailin Mineral Products Processing Plant, and the lithium feldspar powder was purchased from Lingshou County Suda Mineral Products Processing Plant. The basalt contains 45%–50% SiO2, 10%–15% Al2O3, and <3% FeO.
[0038] Unless otherwise specified, the raw materials and reagents used in this invention are all conventional commercially available products; unless otherwise specified, the methods used in this invention are all conventional methods in the field.
[0039] Example 1 This embodiment provides a mineral wool material, comprising the following raw material components in parts by weight: 60 parts of blast furnace liquid slag and 25 parts of conditioning material; The blast furnace liquid slag comprises the following chemical components by mass percentage: SiO2 34.5%, Al2O3 18.3%, CaO 37.7%, MgO 9.3%, and FeO 0.2%; The conditioning material comprises 45% quartz sand of 80-100 mesh, 25% coal gangue of 110-130 mesh, 16% modified basalt of 150-200 mesh, and 14% modified lithium feldspar powder of 220-250 mesh. The preparation method of modified basalt includes the following steps: Basalt was added to a sodium silicate aqueous solution, the ball-to-material ratio was controlled at 6:1, and the mixture was ground at a rate of 300 r / min for 40 min. After drying, modified basalt was obtained. The sodium silicate aqueous solution contains 6% sodium silicate by mass and 1% hydrochloric acid by mass. The mass-to-volume ratio of basalt and sodium silicate aqueous solution is 100g:3mL; The preparation method of modified lithium feldspar powder includes the following steps: S1. The lithium feldspar powder is calcined at a rate of 5℃ / min to 650℃ for 2.5h to obtain calcined lithium feldspar powder. S2. Add calcined lithium feldspar powder to an alcoholic solution of citric acid, and impregnate at 65°C for 50 min. Stir at a rate of 500 r / min during impregnation to obtain modified lithium feldspar powder. In an alcoholic solution of citric acid, the mass ratio of citric acid, anhydrous ethanol, and water is 1:1:7.
[0040] This embodiment provides a method for preparing the above-mentioned mineral wool material, including the following steps: Step 1: Weigh each component according to the mass ratio, add the blast furnace liquid slag and conditioning material into the electric furnace, stir at 180 rpm for 35 min at 1350℃, and homogenize at 1390℃ for 25 min to obtain a mixed melt. Step 2: Centrifuge and cool the mixed melt, collect the wool, and obtain mineral wool material; Centrifugation and cooling are carried out in a four-roll centrifuge at a speed of 2000 rpm, a flow rate of 10 kg / min, a cooling air temperature of 30℃, and a cooling air velocity of 15 m / s.
[0041] Example 2 This embodiment provides a mineral wool material, comprising the following raw material components in parts by weight: 62 parts of blast furnace liquid slag and 20 parts of conditioning material; The blast furnace liquid slag comprises the following chemical components by mass percentage: SiO2 34%, Al2O3 16%, CaO 38%, MgO 11.5%, and FeO 0.5%; The conditioning material comprises 42% quartz sand of 80-100 mesh, 27% coal gangue of 110-130 mesh, 17% modified basalt of 150-200 mesh, and 14% modified lithium feldspar powder of 220-250 mesh. The preparation method of modified basalt includes the following steps: Basalt was added to a sodium silicate aqueous solution, the ball-to-material ratio was controlled at 7:1, and it was ground at a rate of 350 r / min for 30 min. After drying, modified basalt was obtained. The sodium silicate aqueous solution contains 5% sodium silicate by mass and 2% hydrochloric acid by mass. The mass-to-volume ratio of basalt and sodium silicate aqueous solution is 100g:4mL; The preparation method of modified lithium feldspar powder includes the following steps: S1. The lithium feldspar powder was calcined at a rate of 6℃ / min to 650℃ for 3 hours to obtain calcined lithium feldspar powder. S2. Add calcined lithium feldspar powder to an alcoholic solution of citric acid and impregnate at 60°C for 40 min, stirring at a rate of 450 r / min during impregnation to obtain modified lithium feldspar powder. In an alcoholic solution of citric acid, the mass ratio of citric acid, anhydrous ethanol, and water is 2:1:8.
[0042] This embodiment provides a method for preparing the above-mentioned mineral wool material, including the following steps: Step 1: Weigh each component according to the mass ratio, add the blast furnace liquid slag and conditioning material into the electric furnace, stir at 200 rpm for 30 min at 1370℃, and homogenize at 1400℃ for 20 min to obtain a mixed melt. Step 2: Centrifuge and cool the mixed melt, collect the wool, and obtain mineral wool material; Centrifugation and cooling are carried out in a four-roll centrifuge at a speed of 1500 rpm, a flow rate of 8 kg / min, a cooling air temperature of 35℃, and a cooling air velocity of 10 m / s.
[0043] Example 3 This embodiment provides a mineral wool material, comprising the following raw material components in parts by weight: 65 parts of blast furnace liquid slag and 18 parts of conditioning material; The blast furnace liquid slag comprises the following chemical components by mass percentage: SiO2 32%, Al2O3 18%, CaO 37.6%, MgO 12%, and FeO 0.4%; The conditioning material comprises 44% quartz sand of 80-100 mesh, 25% coal gangue of 110-130 mesh, 17% modified basalt of 150-200 mesh, and 14% modified lithium feldspar powder of 220-250 mesh. The preparation method of modified basalt includes the following steps: Basalt was added to an aqueous solution of sodium silicate, the ball-to-material ratio was controlled at 7:1, and the mixture was ground at a rate of 320 r / min for 35 min. After drying, modified basalt was obtained. The sodium silicate aqueous solution contains 5% sodium silicate by mass and 2% hydrochloric acid by mass. The mass-to-volume ratio of basalt and sodium silicate aqueous solution is 100g:4mL; The preparation method of modified lithium feldspar powder includes the following steps: S1. The lithium feldspar powder was calcined at a rate of 6℃ / min to 680℃ for 3 hours to obtain calcined lithium feldspar powder. S2. Add calcined lithium feldspar powder to an alcoholic solution of citric acid and impregnate at 60°C for 45 min, stirring at a rate of 450 r / min during impregnation to obtain modified lithium feldspar powder. In an alcoholic solution of citric acid, the mass ratio of citric acid, anhydrous ethanol, and water is 1:1:8.
[0044] This embodiment provides a method for preparing the above-mentioned mineral wool material, including the following steps: Step 1: Weigh each component according to the mass ratio, add the blast furnace liquid slag and conditioning material into the electric furnace, stir at 200 rpm for 35 min at 1360℃, and homogenize at 1390℃ for 25 min to obtain a mixed melt. Step 2: Centrifuge and cool the mixed melt, collect the wool, and obtain mineral wool material; Centrifugation and cooling were carried out in a four-roll centrifuge at a speed of 1500 rpm, a flow rate of 12 kg / min, a cooling air temperature of 30℃, and a cooling air velocity of 12 m / s.
[0045] Comparative Example 1 This comparative example provides a mineral wool material, which differs from Example 1 in that the modified basalt is silica-modified basalt; Specifically, the preparation method of modified basalt includes the following steps: Basalt was added to a silica dispersion, the ball-to-material ratio was controlled at 6:1, and the mixture was ground at a rate of 300 r / min for 40 min. After drying, modified basalt was obtained. The silica dispersion contains 6% silica by mass and 1% hydrochloric acid by mass. The mass-to-volume ratio of basalt and silica dispersion is 100g:3mL; The other components and preparation methods remain unchanged, and will not be repeated here.
[0046] Comparative Example 2 The mineral wool material provided in this comparative example differs from that in Example 1 in that the modified lithium feldspar powder is tartaric acid-modified calcined lithium feldspar powder. Specifically, the preparation method of modified lithium feldspar powder includes the following steps: S1. The lithium feldspar powder is calcined at a rate of 5℃ / min to 650℃ for 2.5h to obtain calcined lithium feldspar powder. S2. Add calcined lithium feldspar powder to an alcoholic solution of tartaric acid and impregnate at 65°C for 50 min, stirring at a rate of 500 r / min during impregnation to obtain modified lithium feldspar powder. The mass ratio of tartaric acid, anhydrous ethanol, and water in the alcoholic solution of tartaric acid is 1:1:7. The other components and preparation methods remain unchanged, and will not be repeated here.
[0047] Example of effect The performance of the mineral wool materials provided in the examples and comparative examples was tested, and the specific test results are shown in Table 1.
[0048] Test method for cotton sizing ratio: (1) Calculate the amount of resin glue used (t / h, the glue tank has an automatic metering display); (2) Calculate the amount of water added to the resin glue based on the water flow meter, the amount of water used, and the water ratio; (3) Automatically record the hourly output of finished cotton (t / h), and the computer automatically calculates the cotton sizing ratio.
[0049] WT Value Test: A granular cotton (WT value) strength tester was used. The outer cylinder inner diameter was 93.6 mm, the inner cylinder outer diameter was 92.8 mm, and 3380 kg of filler material was added. The height of both the inner and outer cylinders was 230 mm. Test Procedure: Weigh 50 g of sample, disperse any large clumps of cotton by hand, and place them in the test chamber. Add 2500 mL of room temperature tap water and mix thoroughly. Quickly pour the sample into the outer cylinder within 20 seconds. When the liquid level drops to the point where the fibers are exposed above the water surface, gently place the sample into the inner cylinder. After 1 minute, use a vernier caliper to measure the height difference between the inner and outer cylinders at three equidistant points along the edge of the outer cylinder. The reading should be accurate to 0.1 mm, which is the WT strength value.
[0050] Table 1
[0051] As shown in Table 1, the total content of cotton wool and cotton balls in the mineral wool materials provided in Examples 1-3 of the present invention can be reduced to below 27%, the cotton-to-spun cotton ratio can be increased to above 8.8, and the strength (WT value) can be increased to above 59 cN / tex. The overall performance of the products is far superior to that of the prior art.
[0052] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A mineral wool material, characterized in that, The raw material components include the following parts by weight: 60-65 parts of blast furnace liquid slag and 15-25 parts of conditioning material; The blast furnace liquid slag comprises the following chemical composition by mass percentage: SiO2 28%~36%, Al2O3 12%~20%, CaO 32%~45%, MgO 7%~12% and FeO <0.5%; The conditioning material includes 42%~48% quartz sand, 22%~28% coal gangue, 11%~18% modified basalt and 10%~14% modified lithium feldspar powder; The modified basalt is sodium silicate modified basalt; The modified lithium feldspar powder is citric acid-modified calcined lithium feldspar powder.
2. The mineral wool material as described in claim 1, characterized in that, The method for preparing the modified basalt includes the following steps: Basalt was added to an acidic sodium silicate aqueous solution, ground, and dried to obtain the modified basalt.
3. The mineral wool material as described in claim 2, characterized in that, The basalt contains 45%–50% SiO2, 10%–15% Al2O3, and <3% FeO.
4. The mineral wool material as described in claim 2, characterized in that, The acidic sodium silicate aqueous solution contains 5% to 6% sodium silicate by mass and 1% to 2% hydrochloric acid by mass.
5. The mineral wool material as described in claim 2, characterized in that, The mass-to-volume ratio of the basalt and the acidic sodium silicate aqueous solution is 100 g: (3~4) mL.
6. The mineral wool material as described in claim 1, characterized in that, The preparation method of the modified lithium feldspar powder includes the following steps: S1. Calcining lithium feldspar powder at 650~680℃ to obtain calcined lithium feldspar powder; S2. The calcined lithium feldspar powder is impregnated in an alcoholic solution of citric acid to obtain the modified lithium feldspar powder.
7. The mineral wool material as described in claim 6, characterized in that, In S1, the calcination time is 2.5~3 hours; In S1, a programmed temperature rise method is used to raise the temperature to 650~680℃ at a rate of 5~6℃ / min.
8. The mineral wool material as described in claim 6, characterized in that, In S2, the mass ratio of citric acid, anhydrous ethanol and water in the citric acid alcohol solution is (1~2):1:(7~8). In S2, the impregnation temperature is 60~65℃; In S2, the immersion time is 40-50 minutes.
9. The mineral wool material as described in claim 1, characterized in that, The particle size of the quartz sand is 80~100 mesh; The particle size of the coal gangue is 110~130 mesh; The modified basalt has a grain size of 150-200 mesh; The modified lithium feldspar powder has a particle size of 220-250 mesh.
10. A method for preparing the mineral wool material according to any one of claims 1 to 9, characterized in that, Includes the following steps: Step 1: Weigh each component according to the mass ratio, add the weighed blast furnace liquid slag and conditioning material to the electric furnace, stir and homogenize to obtain a mixed melt; Step 2: Centrifuge and cool the mixed melt, collect the wool, and obtain mineral wool material.