Method for manufacturing mineral wool composite material

Abstract

A method for manufacturing a mineral wool composite material using recycled water is provided. [Solution] The present invention relates to a method for producing a mineral wool composite material, in which circulating water used to clean a manufacturing apparatus for producing the mineral wool composite material is filtered and the circulating water is reused in the manufacturing apparatus, the method comprising the following steps (a) to (c): (a) extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a first binder composition containing the extracted circulating water, and then spraying the first binder composition onto mineral fibers to produce a first mineral wool composite material; (b) carrying out the following substeps (b1) and (b2) in any order or simultaneously: b2): (b1) pausing the extraction of circulating water for preparing a first binder composition; (b2) extracting at least a portion of the circulating water and storing the extracted circulating water in a first tank; (c) extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a second binder composition containing the extracted circulating water, and then spraying the second binder composition onto mineral fibers to produce a second mineral wool composite material, in this order, wherein the first binder composition and the second binder composition are different from each other.

Description

[Technical Field]

[0001] Technical Field The present invention relates to a method for producing a mineral wool composite material, and more particularly to a method for producing a mineral wool composite material in which circulating water used in a manufacturing apparatus for producing the mineral wool composite material is reused in the manufacturing apparatus. More specifically, the present invention relates to a method for producing a mineral wool composite material in which a portion of the circulating water is extracted and used as a raw material for a binder composition, which allows the target quality of the mineral wool composite to be obtained without disposing of a large amount of circulating water, even when the type of binder composition is changed. [Background technology]

[0002] Background technology As disclosed in JP2009-155172A, methods for producing mineral wool composite materials are known, for example, the method described in Japanese Patent Application Laid-Open No. 2009-155172 includes blowing out molten inorganic material at high temperature from a spinner by centrifugal force to obtain mineral fibers, and spraying a binder composition onto the mineral fibers to agglomerate the mineral fibers to obtain a mineral wool composite material. The binder composition includes an aqueous dispersion of a binder resin such as a phenolic resin and an acrylic resin.

[0003] When producing mineral wool composite materials, water is used in large quantities to clean the production equipment. WO2009 / 007648A and US8821625B disclose methods for circulating and reusing the circulating water used in the process of producing mineral wool composite materials. Summary of the Invention

[0004] Summary of the Invention technical challenges The circulating water reused in the process of manufacturing the mineral wool composite contains the binder resin derived from the binder composition, while a portion of the circulating water can be extracted and reused as a raw material for the binder composition.

[0005] However, in the method in which a portion of the circulating water is extracted and used as a raw material for the binder composition, if the type of binder composition is changed during the continuous production of the mineral wool composite material, it is necessary to dispose of a large amount of circulating water, because if the circulating water containing the original binder resin is used as a raw material for preparing the changed binder composition, the quality of the mineral wool composite material produced using the changed binder composition may be adversely affected.

[0006] The present invention provides a method for producing a mineral wool composite material, in which a portion of the circulating water is extracted and used as a raw material for the binder composition, and when the type of binder composition is changed, it is possible to obtain the target quality of the mineral wool composite material without disposing of a large amount of circulating water.

[0007] Solutions to the problems The present inventors have found that the above problems can be solved by the invention having the following aspects. [1] A method for producing a mineral wool composite material, in which circulating water used to clean a manufacturing apparatus for producing the mineral wool composite material is filtered and reused in the manufacturing apparatus, comprising the following steps (a) to (c): (a) producing a first mineral wool composite material by extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a first binder composition containing the extracted circulating water, and then spraying the first binder composition onto mineral fibers; (b) in any order or simultaneously, the following substeps (b1) and (b2): (b1) pausing the extraction of circulating water for preparing the first binder composition; (b2) extracting at least a portion of the circulating water and storing the extracted circulating water in a first tank. To carry out; (c) extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a second binder composition containing the extracted circulating water, and then spraying the second binder composition onto mineral fibers to produce a second mineral wool composite material. A method comprising, in this order: [2] The method according to [1], wherein step (b) is carried out while producing the first mineral wool composite material and / or the second mineral wool composite material. [3] Step (b) may be performed in any order or simultaneously. The following sub-step (b3): (b3) providing purified water to prepare a first or second binder composition containing the purified water; and performing sub-steps (b1) and (b2). [4] Step (b) may be performed in any order or simultaneously. The following sub-step (b4): (b4) Suspending the supply of purified water to the circulating water supply and performing sub-steps (b1) and (b2). [5] The step (c) comprises the following substep (c1): (c1) Providing water stored in the first tank for circulating water. The method according to any one of [1] to [4], further comprising: [6] The step (c) further comprises the following substep (c2): (c2) providing water stored in a first tank and circulating water to prepare a second binder composition; The method according to any one of [1] to [5], further comprising: [7] after step (c), an additional step (d), In this additional step (d), the following sub-steps (d1) and (d2) are carried out: (d1) pausing the extraction of circulating water for the preparation of the second binder composition; (d2) extracting at least a portion of the circulating water and storing the extracted circulating water in a second tank. The method according to any one of [1] to [6], wherein the steps are carried out in any order or simultaneously. [8] The method of [7], wherein the first and second tanks are the same tank. [9] The method of [7], wherein the first and second tanks are separate tanks.

[10] After step (d), the following step: (a)' extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a third binder composition containing the extracted circulating water, and then spraying the third binder composition onto mineral fibers, thereby producing a third mineral wool composite material. The method according to any one of [7] to [9], further comprising:

[11] The method according to

[10] , wherein the third binder composition and the third mineral wool composite are the same as the first binder composition and the first mineral wool composite, respectively.

[12] One of the binder compositions is Compositions comprising phenol / formaldehyde condensates or phenol / formaldehyde and urea / formaldehyde condensates; a composition comprising a Maillard reactant comprising an amine and a carbohydrate (especially a reduced one); a composition comprising an acrylic polymer and a crosslinker such as a polyhydroxyl or polyamino compound; A composition comprising a non-reducing sugar and / or hydrogenated sugar, and a polycarboxylic acid reactant, such as citric acid; and Compositions containing amino-amide compounds, especially those obtained by reacting anhydrides with alkanolamines The method according to any one of [1] to

[11] , wherein the aqueous composition is selected from the aqueous compositions selected from the group consisting of:

[13] The method according to any one of [1] to

[12] , wherein one of the binder compositions results in a light-colored or white binder. [Brief explanation of the drawings]

[0008] BRIEF DESCRIPTION OF THE DRAWINGS [Figure 1]FIG. 1 is a diagram showing the flow of liquid in the steps included in the basic configuration of the method of the present invention. [Figure 2] FIG. 2 is a diagram showing the flow of liquid in sub-step (b3) preferably included in step (b) included in the method of the present invention. [Figure 3] FIG. 3 is a diagram showing the flow of liquid in sub-step (b4) preferably included in step (b) included in the method of the present invention. [Figure 4] FIG. 4 is a diagram showing the flow of liquid in sub-step (c1) preferably included in step (c) included in the method of the present invention. [Figure 5] FIG. 5 is a diagram showing the flow of liquid in sub-step (c2) preferably included in step (c) included in the method of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0009] Embodiment The present invention relates to a method for producing a mineral wool composite material, in which circulating water used for cleaning a mineral wool composite material production apparatus is filtered and reused in the production apparatus, the method comprising the following steps (a) to (c): (a) extracting at least a portion of the circulating water to prepare a first binder composition containing the extracted circulating water while providing purified water to the circulating water, and spraying the first binder composition onto mineral fibers to produce a first mineral wool composite material; (b) in any order or simultaneously, the following substeps (b1) and (b2): (b1) ceasing the extraction of circulating water for the preparation of the first binder composition; and (b2) extracting at least a portion of the circulating water and storing it in a first tank; To carry out; (c) extracting at least a portion of the circulating water to prepare a second binder composition containing the extracted circulating water while providing purified water to the circulating water, and spraying the second binder composition onto the mineral fibers to produce a second mineral wool composite material. in that order, wherein the first binder composition and the second binder composition are different from each other.

[0010] Since each operation needs to be performed at least once at a suitable timing during the process, it is not necessary to perform each operation of each step of the present invention all the time during the process.

[0011] The arrows in the drawing indicate the flow of liquids such as circulating water, purified water, water stored in a tank, and the first and second binder compositions, but there may be additional liquid flows in each step that are not shown in the drawing. Also, as long as the advantageous effects of the present invention are obtained, the liquid flows in each step shown in the drawing do not necessarily have to be present during that step.

[0012] In the method of the present invention, it is not necessary to dispose of large amounts of circulating water when switching from the production of a first mineral wool composite to the production of a second mineral wool composite. In methods for producing mineral wool composites in which circulating water used to clean the production equipment is reused for preparing a binder composition, it is often necessary to dispose of circulating water when switching to the production of a mineral wool composite using a different binder composition because resins such as binders washed away by the cleaning contaminate the circulating water. For example, because reactions may occur between the binder compositions before and after the switch, and because the color of the mineral wool composite may be unacceptable if the binder compositions before and after the switch have different colors, the circulating water containing the binder resin needs to be disposed of before the switch so that the quality of the mineral wool composite after the switch is within an acceptable range.

[0013] In the method of the present invention, the circulating water containing the binder resin before switching is stored in a tank and reused, thereby minimizing the waste of circulating water. For example, the circulating water containing the binder resin before switching that has been stored in a tank can be gradually mixed with the circulating water used in the production of the mineral wool composite material after switching, to the extent that the quality of the mineral wool composite material after switching is acceptable, or it can be stored for use in the subsequent production of the mineral wool composite material containing the binder composition before switching.

[0014] In the method of the present invention, circulating water is used to clean a manufacturing equipment for a mineral wool composite material and to prepare a binder composition. The manufacturing equipment to be cleaned can be a conveyor or the like on which mineral fibers sprayed with a binder composition are accumulated. Since such manufacturing equipment can potentially contain adhered material from the binder composition, the wash water after cleaning the adhered material contains components from the binder composition. When circulating water is to be used to prepare a binder composition, it can be used as a dispersion medium or solvent for the binder composition.

[0015] In the method of the present invention, the circulating water is filtered before reuse. Filtration can be performed by known methods such as screen filtration or ultrafiltration. Filtration does not need to be performed continuously during the method of the present invention, but rather needs to be performed at least once at a desired time during the method of the present invention.

[0016] A biocide such as monochloramine can be added to the circulating water, preferably after filtration. The amount of biocide added to the circulating water depends on the configuration of the circulation circuit and the binder composition. The biocide should be added in an amount of 50-500 g / m 2 of circulating water. 3 is added to the circulating water in amounts typically multiple times per day.

[0017] In the method of the present invention, the purified water is water in which the concentration of components derived from the binder composition is lower than that of the circulating water. The purified water can be water that is essentially free of components derived from the binder composition, for example, it can be purified water, deionized water, distilled water, tap water, ground water, or industrial water.

[0018] As shown in FIG. 1(a), in step (a), purified water is supplied to circulating water, while at least a portion of the circulating water is extracted, a first binder composition containing the extracted circulating water is prepared, and the first binder composition is sprayed onto mineral fibers to produce a first mineral wool composite material.

[0019] In step (a), purified water is provided to the circulating water. For example, as shown in FIG. 1(a), the purified water can be supplied to the circulating water by being used to clean a mineral wool composite manufacturing apparatus, then recovered and mixed with other circulating water. Alternatively, although not shown, the purified water can be supplied directly to the circulating water. In addition, although also not shown, the purified water can be supplied to the circulating water by preparing a binder composition, then recovering the purified water after the binder composition has been used to manufacture a mineral wool composite, and then mixing it with other circulating water.

[0020] In step (a), at least a portion of the circulating water is extracted to prepare a first binder composition containing the extracted circulating water. The extracted circulating water can be supplied to a binder composition preparation tank for preparing the first binder composition, or it can be mixed with another binder resin in a pipeline, for example, using a static mixer, for preparing the first binder composition. Additional purified water can also be used to prepare the first binder composition.

[0021] For the method of producing the first mineral wool composite material by spraying the first binder composition onto the mineral fibers carried out in step (a), reference can be made to methods known in the prior art.

[0022] In step (a), if there is a tank for storing previously collected water, the stored water can be used to prepare the first binder composition or to provide circulating water. In such cases, the stored water can be reused as long as the quality of the first mineral wool composite material is within an acceptable range.

[0023] As shown in FIG. 1(b), the following sub-steps (b1) and (b2) are carried out in any order or simultaneously in step (b). (b1) pausing the extraction of circulating water for preparing the first binder composition; and (b2) extracting at least a portion of the circulating water and storing it in a first tank;

[0024] In step (b), preparations are made to switch from the production of the first mineral wool composite to the second mineral wool composite. The production of the first mineral wool composite can continue in step (b), or the production of the second mineral wool composite can be started, or the production of the mineral wool composite can be stopped.

[0025] In sub-step (b1), if the production of the first mineral wool composite material is still continuing and a preparation tank for preparing the first binder composition exists, the first binder composition in the preparation tank can be provided for the production of the first mineral wool composite material. Further, the first binder composition can be prepared by the following sub-step (b3), and the production of the first mineral wool composite material continues.

[0026] In sub-step (b2), the circulating water containing the components from the first binder composition is stored in a first tank, thereby reducing the absolute amount of the components from the first binder composition in the circulating water, which allows the components from the first binder composition present in the circulating water to be reduced during the production of the second mineral wool composite material, so that the quality of the second mineral wool composite material can be within an acceptable range.

[0027] The circulating water stored in the first tank as a result of sub-step (b2) may be only a portion of the circulating water, and components derived from the first binder composition may be allowed to be present in the circulating water if the quality of the second mineral wool composite material is within an acceptable range during its production.

[0028] A portion of the circulating water can be disposed of to reduce the absolute amount of components from the first binder composition in the circulating water.

[0029] Step (b) may further comprise the substep (b3) of providing purified water and preparing the first or second binder composition using the purified water instead of the circulating water.

[0030] Figure 2 shows an example of the liquid flow in sub-step (b3). Although Figure 2 does not show the flow of the first or second binder composition for the production of the first or second mineral wool composite material, the production of the first mineral wool composite material can continue or the production of the second mineral wool composite material can begin in sub-step (b3).

[0031] Specifically, when the production of the first mineral wool composite material is continued in sub-step (b3), purified water can be provided for the preparation of the first binder composition, and when the production of the second mineral wool composite material is started, purified water can be provided for the preparation of the second binder composition.

[0032] While the extraction of circulating water for preparing the first binder composition is stopped by sub-step (b1), purified water can be provided by sub-step (b3), and the preparation of the first binder composition continues, thereby continuing the production of the first mineral wool composite material. Also, when the production of the second mineral wool composite material is started, purified water can be provided by sub-step (b3), and the second binder composition is prepared, and the production of the second mineral wool composite material is started.

[0033] Before the start of sub-step (b1), sub-step (b3) can be carried out, for example, while extracting circulating water, to provide purified water for the preparation of the first binder composition.

[0034] In sub-step (b3), the purified water is provided to a tank and mixed with other raw materials for the binder composition, or the purified water can be mixed with other raw materials for the binder composition in a piping system using a static mixer or the like, thereby preparing the first or second binder composition.

[0035] Step (b) may further include a sub-step (b4) of stopping the supply of purified water to the circulating water.

[0036] 3 shows an example of the liquid flow in substep (b4). Because the circulating water containing the components from the first binder composition is stored in the first tank in substep (b2), the absolute amount of the components from the first binder composition in the circulating water is continuously reduced. Therefore, if the supply of purified water to the circulating water is continued, the concentration of the components from the first binder composition continues to decrease, but the amount of circulating water stored in the first tank increases correspondingly.

[0037] Therefore, in substep (b4), the supply of purified water to the circulating water can be suspended to maintain a constant concentration of the components from the first binder composition in the circulating water stored in the first tank, which allows the amount of water stored in the first tank to be relatively reduced.

[0038] As shown in FIG. 1(c), in step (c), while providing purified water to the circulating water, at least a portion of the circulating water is extracted, a second binder composition containing the extracted circulating water is prepared, and the second binder composition is sprayed onto mineral fibers to produce a second mineral wool composite material.

[0039] The purified water is similarly supplied to the circulating water in step (c), similar to step (a). The purified water can be supplied directly to the circulating water by mixing with the circulating water, or it can be supplied indirectly to the circulating water.

[0040] In step (c), the circulating water can be fed to a tank for the preparation of a binder, for the preparation of a second binder composition, or the circulating water can be mixed in the pipeline with another binder resin, for example using a static mixer, for the preparation of a second binder composition.

[0041] For the method of producing the second mineral wool composite material by spraying the second binder composition onto the mineral fibers carried out in step (c), reference can be made to methods known in the prior art.

[0042] As shown in FIG. 4, step (c) may further include a substep (c1) in which the water stored in the first tank by substep (b2) of step (b) is provided to circulating water and used to clean the manufacturing equipment.

[0043] When sub-step (c1) is performed, the water stored in the first tank can be provided as circulating water so that the quality of the second mineral wool composite material is within an acceptable range. The water stored in the first tank can be gradually consumed by sub-step (c1).

[0044] Furthermore, as shown in FIG. 5, step (c) can further include substep (c2) in which the water stored in the first tank in substep (b2) of step (b) is used to prepare a second binder composition.

[0045] When substep (c2) is performed, the water stored in the first tank can be provided as circulating water so that the quality of the second mineral wool composite material is within an acceptable range. The water stored in the first tank can be gradually consumed by substep (c2).

[0046] When sub-step (c2) is carried out, the water stored in the first tank can be reused so that the quality of the second mineral wool composite material is acceptable.

[0047] In step (c), substeps (c1) and (c2) can be carried out in any order or simultaneously with other operations.

[0048] The method of the present invention may further comprise, after step (c), an additional step (d) in which the following substeps (d1) and (d2) are carried out in any order or simultaneously: (d1) pausing the extraction of circulating water for the preparation of the second binder composition; and (d2) Extracting at least a portion of the circulating water and storing it in a second tank.

[0049] Step (d) is essentially a repeat of step (b) above, and therefore substeps corresponding to substeps (b3) and (b4) of step (b) may also be included in step (d).

[0050] When the water stored in the first tank by substep (b2) is completely consumed in substeps (c1) and (c2) of step (c), substep (d2) can be carried out in the same tank for the first tank and the second tank.

[0051] However, the second tank can alternatively be a different tank than the first tank.

[0052] In the method of the present invention, the aforementioned steps (a) to (c) can be repeated after step (d). The repetition of step (a) can be step (a)' in which a third mineral wool composite is produced using a third binder composition different from the first and second binder compositions, rather than the first binder composition.

[0053] A person skilled in the art will be able to repeat steps (a)'-(c)' as described above to produce any desired type of mineral wool composite material using any desired type of binder composition.

[0054] The first binder, second binder and optionally third binder compositions can be aqueous compositions selected from the following: (i) compositions comprising phenol / formaldehyde condensates, such as compositions comprising phenol / formaldehyde and urea / formaldehyde condensates, compositions comprising phenol / formaldehyde and phenol / formaldehyde / glycine condensates, or compositions comprising phenol / formaldehyde condensates but not urea / formaldehyde condensates, as disclosed, for example, in WO2008 / 043960, WO2008 / 043961 or WO2012 / 025699; (ii) compositions comprising Maillard reactants comprising an amine and a carbohydrate (especially a reducing sugar), for example as disclosed in WO2007014236; (iii) a composition comprising an acrylic polymer and a crosslinker such as a polyhydroxyl or polyamino compound, as disclosed in EP 583086, EP 990727, EP 1741726, US 5318990 and US 2007 / 173588; (iv) a composition comprising a non-reducing sugar and / or a hydrogenated sugar, and a polycarboxylic acid reactant such as citric acid, as disclosed in WO2009 / 080938, WO2013 / 021112 and WO2015 / 159012; and (v) Compositions comprising amino-amide compounds obtained in particular from the reaction of anhydrides with alkanolamines, as disclosed in WO99 / 36368, WO01 / 05725, WO01 / 96460, WO02 / 06178, WO2004 / 007615 and WO2006 / 061249.

[0055] The first binder composition and the second binder composition can be any type of composition (i)-(v), provided that the second binder composition is a different type of binder composition from the first binder composition. The method of the present invention is particularly advantageous when one of the binder compositions results in a light-colored, particularly white, binder, such as composition (iii), (iv), or (v) above. In preferred embodiments, the second binder composition results in a light-colored, particularly white, binder, such as composition (iii), (iv), or (v), and the first binder composition results in a colored binder, such as composition (i) or (ii). In some specific embodiments, the first and second binder compositions can be types (i) and (iii), or (i) and (iv), or (i) and (v), or (ii) and (iii), or (ii) and (iv), or (ii) and (v), respectively. The present disclosure also encompasses the following: [Aspect 1] A method for producing a mineral wool composite material, comprising filtering circulating water used to clean a manufacturing apparatus for producing the mineral wool composite material and reusing the circulating water in the manufacturing apparatus, the method comprising the following steps (a) to (c): (a) extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a first binder composition containing the extracted circulating water, and then spraying the first binder composition onto mineral fibers to produce a first mineral wool composite material; (b) in any order or simultaneously, the following substeps (b1) and (b2): (b1) pausing the extraction of the circulating water for preparing the first binder composition; (b2) extracting at least a portion of the circulating water and storing the extracted circulating water in a first tank. To carry out; (c) extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a second binder composition containing the extracted circulating water, and then spraying the second binder composition onto mineral fibers to produce a second mineral wool composite material. in this order, the first binder composition and the second binder composition are different from each other; method. [Aspect 2] 2. The method of claim 1, wherein step (b) is performed while the first mineral wool composite and / or the second mineral wool composite is being produced. [Aspect 3] The step (b) may be performed in any order or simultaneously. The following sub-step (b3): (b3) providing purified water to prepare the first or second binder composition containing the purified water; and the sub-steps (b1) and (b2) 3. The method according to claim 1 or 2, comprising: [Aspect 4] The step (b) may be performed in any order or simultaneously. The following sub-step (b4): (b4) Suspending the supply of purified water to the circulating water. and the sub-steps (b1) and (b2) The method according to any one of the above-mentioned aspects 1 to 3, comprising carrying out the following. [Aspect 5] The step (c) includes the following sub-step (c1): (c1) providing water stored in the first tank to the circulating water. The method according to any one of the above aspects 1 to 4, further comprising: [Aspect 6] The step (c) further comprises the following sub-step (c2): (c2) providing the water stored in the first tank and the circulating water to prepare the second binder composition; The method according to any one of the above aspects 1 to 5, further comprising: [Aspect 7] after step (c), an additional step (d), In this additional step (d), the following sub-steps (d1) and (d2) are carried out: (d1) pausing the extraction of the circulating water for preparing the second binder composition; (d2) extracting at least a portion of the circulating water and storing the extracted circulating water in a second tank. The method according to any one of the above aspects 1 to 6, wherein the steps of: [Aspect 8] 8. The method of claim 7, wherein the first and second tanks are the same tank. [Aspect 9] 8. The method of claim 7, wherein the first and second tanks are separate tanks. [Aspect 10] After step (d), the following step: (a)' extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a third binder composition containing the extracted circulating water, and then spraying the third binder composition onto mineral fibers, thereby producing a third mineral wool composite material. The method according to any one of the above aspects 7 to 9, further comprising: [Aspect 11] 11. The method of claim 10, wherein the third binder composition and the third mineral wool composite are the same as the first binder composition and the first mineral wool composite, respectively. [Aspect 12] One of the binder compositions is (i) compositions containing phenol / formaldehyde condensates, such as compositions containing phenol / formaldehyde and urea / formaldehyde condensates, compositions containing phenol / formaldehyde and phenol / formaldehyde / glycine condensates, or compositions containing phenol / formaldehyde condensates but not urea / formaldehyde condensates; (ii) a composition comprising a Maillard reactant comprising an amine and a carbohydrate (especially a reduced carbohydrate); (iii) a composition comprising an acrylic polymer and a crosslinker such as a polyhydroxyl or polyamino compound; (iv) a composition comprising a non-reducing sugar and / or a hydrogenated sugar, and a polycarboxylic acid reactant, such as citric acid; and (v) compositions containing amino-amide compounds, especially those obtained by reacting anhydrides with alkanolamines 12. The method according to any one of the above aspects 1 to 11, wherein the aqueous composition is selected from the group consisting of: [Aspect 13] 13. The method of claim 12, wherein the first binder composition and the second binder composition are selected from aqueous compositions selected from types (i) to (v) of compositions, with the proviso that the second binder composition is a different type of binder composition than the first binder composition. [Aspect 14] 14. The method of any one of claims 12 to 13, wherein the first binder composition is selected from an aqueous composition selected from the composition of type (i) or (ii), and the second binder composition is selected from an aqueous composition selected from the composition of type (iii), (iv), or (v). [Aspect 15] 15. The method of any one of the above aspects 1-14, wherein one of the binder compositions provides a light-colored or white binder, preferably the first binder composition provides a colored binder and the second binder composition provides a light-colored, particularly white, binder.

Claims

1. 1. A method for producing a mineral wool composite material, comprising filtering circulating water used to clean a manufacturing apparatus for producing the mineral wool composite material and reusing the circulating water in the manufacturing apparatus, the method comprising the following steps (a) to (c): (a) extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a first binder composition containing the extracted circulating water, and then spraying the first binder composition onto mineral fibers to produce a first mineral wool composite material; (b) in any order or simultaneously, the following substeps (b1) and (b2): (b1) pausing the extraction of the circulating water for preparing the first binder composition; (b2) extracting at least a portion of the circulating water and storing the extracted circulating water in a first tank. To carry out the following; (c) extracting at least a portion of the circulating water while providing purified water to the circulating water containing components from the first binder composition to prepare a second binder composition containing the extracted circulating water, and then spraying the second binder composition onto mineral fibers to produce a second mineral wool composite material. in this order, the first binder composition and the second binder composition are different from each other; method.

2. The method of claim 1 , wherein step (b) is carried out while the first mineral wool composite and / or the second mineral wool composite is being produced.

3. The step (b) may be performed in any order or simultaneously. The following sub-step (b3): (b3) providing purified water to prepare the first or second binder composition containing the purified water; and the sub-steps (b1) and (b2) 3. The method of claim 1 or 2, comprising performing:

4. The step (b) may be performed in any order or simultaneously. The following sub-step (b4): (b4) Suspending the supply of purified water to the circulating water. and the sub-steps (b1) and (b2) The method according to any one of claims 1 to 3, comprising carrying out:

5. The step (c) includes the following substep (c1): (c1) providing the water stored in the first tank to the circulating water. The method of any one of claims 1 to 4, further comprising:

6. The step (c) further comprises the following sub-step (c2): (c2) providing the water stored in the first tank and the circulating water to prepare the second binder composition; The method of any one of claims 1 to 5, further comprising:

7. After step (c), an additional step (d) is included, This additional step (d) comprises the following substeps (d1) and (d2): (d1) pausing the extraction of the circulating water for preparing the second binder composition; (d2) extracting at least a portion of the circulating water and storing the extracted circulating water in a second tank. The method according to any one of claims 1 to 6, wherein:

8. 8. The method of claim 7, wherein the first and second tanks are the same tank.

9. The method of claim 7 wherein the first and second tanks are separate tanks.

10. After step (d), the following step: (a)' extracting at least a portion of the circulating water while providing purified water to the circulating water to prepare a third binder composition containing the extracted circulating water, and then spraying the third binder composition onto mineral fibers, thereby producing a third mineral wool composite material. The method of any one of claims 7 to 9, further comprising:

11. The method of claim 10 , wherein the third binder composition and the third mineral wool composite are the same as the first binder composition and the first mineral wool composite, respectively.

12. One of the binder compositions is (i) compositions comprising phenol / formaldehyde condensates, such as compositions comprising phenol / formaldehyde and urea / formaldehyde condensates, compositions comprising phenol / formaldehyde and phenol / formaldehyde / glycine condensates, or compositions comprising phenol / formaldehyde condensates but not urea / formaldehyde condensates; (ii) a composition comprising a Maillard reactant comprising an amine and a carbohydrate; (iii) a composition comprising an acrylic polymer and a crosslinker; (iv) a composition comprising a non-reducing sugar and / or hydrogenated sugar, and a polycarboxylic acid reactant; and (v) Compositions containing amino-amide compounds The method according to any one of claims 1 to 11, wherein the aqueous composition is selected from the group consisting of:

13. 13. The method of claim 12, wherein the first binder composition and the second binder composition are selected from aqueous compositions selected from types (i) to (v) of compositions, with the proviso that the second binder composition is a different type of binder composition than the first binder composition.

14. 14. The method of claim 12 or 13, wherein the first binder composition is selected from an aqueous composition selected from compositions of type (i) or (ii) and the second binder composition is selected from an aqueous composition selected from compositions of type (iii), (iv), or (v).

15. 15. The method according to any one of claims 1 to 14, wherein one of the binder compositions results in a light-colored or white binder, preferably the first binder composition results in a colored binder and the second binder composition results in a light-colored, especially white, binder.

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