Mineral Wool Insulation Binder for Corrosion Under Insulation

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Solution Overview

Problem

Corrosion under insulation (CUI) in steel structures is a significant economic issue due to the inability of existing insulation materials to effectively prevent water contact and subsequent corrosion, especially in temperature ranges where water absorption increases, leading to inefficient thermal insulation and high maintenance costs.

Innovation Solution

A mineral wool product with mineral fibers bound by a binder composition comprising a phenol-formaldehyde-based resin, a hydrophobic agent such as silicone compounds, and a hardener like silane, which inhibits corrosion by reducing water absorption and enhancing dry-out times, thereby preventing moisture retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional insulation materials are used, then thermal insulation is provided, but water absorption increases at elevated temperatures leading to CUI

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidwater absorption resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The invention modifies the binder's chemical structure through silane incorporation and curing reactions. The silane groups condense to form cross-linked networks and silica gel structures that maintain dimensional stability and hydrophobicity at elevated temperatures, preventing the water absorption increase that occurs with conventional binders.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the typically harmful effect of moisture in the binder system into a beneficial curing mechanism. The silane components undergo hydrolysis and condensation reactions with trace moisture to form water-repellent silica gel structures, transforming potential water sensitivity into a mechanism for enhanced water repellency and thermal stability.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides effective thermal insulation while minimizing corrosion under insulation, maintaining durability and reducing maintenance costs, even at elevated temperatures.

Implementation Method 1

a hydrophobic agent or composition comprising (i) at least one silicone compound, such as silicone resin

Methodology Applied

Scientific EffectHydrophobic effect: Hydrophobe

Implementation Method 2

mineral fibers bound by a binder resulting from the curing of a binder composition

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS10920920B2Use of a mineral wool product

Publication Date: 2021.02.16 ROCKWOOL AS

AI summary

A mineral wool product comprises mineral fibers bound by a binder resulting from the curing of a binder composition comprising a phenol-formaldehyde-based resin, and/or a carbohydrate containing component; a hydrophobic agent comprising (i) at least one silicone compound, such as silicone resin; (ii) at least one hardener, such as silane; (iii) optionally, at least one emulsifier; as insulation of a metallic structure, said structure having an operating temperature between 0-650° C.