Stone Wool Production Using Steel Slag and Cascade Spinner
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Solution Overview
Problem
Current stone wool production methods fail to meet stringent health safety requirements due to potential carcinogenic effects of certain fiber compositions, necessitating the development of a safer, biologically durable product.
Innovation Solution
Incorporating raw steel slag into the raw materials for stone wool production, melting the mixture in a furnace, and processing it through a cascade spinner with specific rotor diameters, speeds, and air flow control to produce stone wool with a defined chemical composition that minimizes carcinogenic effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional stone wool production methods are used, then production efficiency is maintained, but the wool may have carcinogenic effects due to inappropriate fiber composition and size
Solution Approach 1:
The patent changes the chemical composition parameters of the raw materials, specifically using steel slag containing Fe2O3 in the range of 2-12% by weight, along with controlled amounts of SiO2, Al2O3, CaO, and other oxides. This parameter modification ensures the resulting fibers have appropriate composition and dimensions that prevent carcinogenic effects while maintaining biological durability.
Solution Approach 2:
The patent creates a composite raw material mixture by combining steel slag with traditional stone wool ingredients in specific proportions. This composite approach allows the final product to inherit beneficial properties from both materials, achieving both safety requirements and production efficiency.
2Reliability
If steel slag is added to raw materials to achieve safe composition, then biological durability is improved, but the production process complexity increases
Solution Approach 1:
The patent utilizes steel slag, which is an industrial waste material, as a component of the raw materials. This self-service approach converts a waste product into a valuable ingredient, achieving the desired chemical composition for safe stone wool while simplifying the overall production system by incorporating readily available materials.
3Manufacturing precision
If specific rotor speeds and diameters are used to control fiber formation, then fiber composition precision is improved, but energy consumption increases
Solution Approach 1:
The patent employs dynamic control of the cascade spinner rotors, with each of the four rotors rotating at specifically controlled speeds (first rotor: 3000-4500 rpm, second rotor: 5000-7500 rpm, third rotor: 5500-8000 rpm, fourth rotor: 5500-8000 rpm). This dynamic parameter control enables precise fiber formation and composition control while optimizing energy utilization through the cascading configuration where each rotor processes material from the previous stage.
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 method produces biologically durable stone wool that meets stringent safety requirements by controlling the chemical composition and fiber formation, reducing the risk of carcinogenic effects.
Implementation Method 1
The entire mixture is melted in a furnace, after which lava at a temperature of 1,350-1,550°C is gravitationally fed
Implementation Method 2
uses the centrifugal force of the rotors and the air blowing from the rotor crowns
Implementation Method 3
air blowing from the rotor crowns
Implementation Method 4
lava at a temperature of 1,350-1,550°C is gravitationally fed by a chute to a cascade spinner
Data Source
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AI summary
A method of producing stole wool of a specific composition using steel slag as a component of raw materials used for lava production, which is fed to a cascade spinner comprising rotors, which uses the centrifugal force of the rotors and the air blowing from the rotor crowns, characterised in that, to obtain wool with a composition of: SiO2 in the range of: 31.16% ÷ 44.86%, Al2O3 in the range of: 18.12% ÷ 29.97%, CaO in the range of: 14.13% ÷ 24.81%, MgO in the range of: 5.67% ÷ 15.44%, CaO+MgO in the range of: 24.03% ÷ 37.68%, Na2O in the range of: 0% ÷ 4.87%, K2O in the range of: 0% ÷ 4.63%, Na2O+K2O in the range of: 0% ÷ 6.95%, Fe2O3 in the range of: 0% ÷ 11.56%, TiO2 in the range of: 0% ÷ 4.32%, P2O5 in the range of: 0% ÷ 4.15%, SO3 in the range of: 0% ÷ 4.78%, MnO in the range of: 0% ÷ 4.15%, BaO in the range of: 0% ÷ 4.89%, Cr2O3 in the range of: 0% ÷ 4.25%, SrO in the range of: 0% ÷ 4.36%, ZrO2 in the range of: 0% ÷ 4.88%, ZnO in the range of: 0% ÷ 4.02%, PbO in the range of: 0% ÷ 3.99% and with biological durability preventing the carcinogenic effect of wool, raw steel slag in the amount of 3÷15 [%] v/v is added to a mixture of raw materials used for stone wool production. The entire mixture is melted in a furnace, after which lava (1) at a temperature of 1,350-1,550°C is gravitationally fed by a chute to a cascade spinner, comprising four rotors (1.0, 2.0, 3.0, 4.0) with diameters of: first rotor (1.0) - from 150 mm to 250 mm, second rotor (2.0) - from 200 mm to 300 mm, third rotor (3.0) - from 350 mm to 450 mm, and fourth rotor (4.0) - from 350 mm to 450 mm, to first rotor (1.0). Rotors (1.0, 2.0, 3.0, 4.0) rotate around their long axes at speeds of: first rotor (1.0) - from 3,000 to 4,500 rpm, rotating anticlockwise (looking from the front of the cascade spinner), second rotor (2.0) - from 5,000 to 7,500 rpm, rotating clockwise (looking from the front of the cascade spinner), third rotor (3.0) - from 5,500 to 8,000 rpm, rotating anticlockwise (looking from the front of the cascade spinner), fourth rotor (4.0) - from 5,500 to 8,000 rpm, rotating clockwise (looking from the front of the cascade spinner). Lava (1) from first rotor (1.0) is fed to second rotor (2.0), then from second rotor (2.0) to third rotor (3.0), and then from third rotor (3.0) to fourth rotor (4.0), with angle (β) at which the stream of lava enters second rotor (2.0) from first rotor (1.0) being 100-150°. On second, third, and fourth rotors (2.0, 3.0, 4.0), on their crowns (2.01, 3.01, 4.01), the following plates are mounted: on second rotor (2.0): first plate (2.1), 7 pieces, inclined to the axis of crown (2.a) at an angle of 0° to 5°, second plate (2.2), 2 pieces, inclined to the axis of crown (2.b) at an angle of 2° to 12°, third plate (2.3), 2 pieces, inclined to the axis of crown (2.c) at an angle of 9° to 19°, fourth plate (2.4), 2 pieces, inclined to the axis of crown (2.d) at an angle of 16° to 26°, fifth plate (2.5), 2 pieces, inclined to the axis of crown (2.e) at an angle of 23° to 33°, sixth plate (2.6), 9 pieces, inclined to the axis of crown (2.f) at an angle of 30° to 40°; on third rotor (3.0): first plate (3.1), 15 pieces, inclined to the axis of crown (3.a) at an angle of 0° to 5°, second plate (3.2), 2 pieces, inclined to the axis of crown (3.b) at an angle of 2° to 12°, third plate (3.3), 2 pieces, inclined to the axis of crown (3.c) at an angle of 9° to 19°, fourth plate (3.4), 2 pieces, inclined to the axis of crown (3.d) at an angle of 16° to 26°, fifth plate (3.5), 2 pieces, inclined to the axis of crown (3.e) at an angle of 23° to 33°, sixth plate (3.6), 21 pieces, inclined to the axis of crown (3.f) at an angle of 30° to 40°; on fourth rotor (4.0): first plate (4.1), 16 pieces, inclined to the axis of crown (4.a) at an angle of 0° to 5°, second plate (4.2), 1 piece, inclined to the axis of crown (4.b) at an angle of 5° to 15°, third plate (4.3), 12 pieces, inclined to the axis of crown (4.c) at an angle of 15° to 25°, fourth plate (4.4), 3 pieces, inclined to the axis of crown (4.d) at an angle of 25° to 35°, fifth plate (4.5), 11 pieces, inclined to the axis of crown (4.e) at an angle of 35° to 45°, sixth plate (4.6), 1 piece, inclined to the axis of crown (4.f) at an angle of 30° to 40°, seventh plate (4.7), 2 pieces, inclined to the axis of crown (4.g) at an angle of 20° to 30°, eighth plate (4.8), 1 piece, inclined to the axis of crown (4.h) at an angle of 8° to 18°, ninth plate (4.9), 1 piece, inclined to the axis of crown (4.i) at an angle of 1° to 11°. To control the angle of the air supplied from the crowns of second rotor (2.0), third rotor (3.0), and fourth rotor (4.0), the flow of which in these crowns (2.01, 3.01, 4.01) is from 10,000 Nm3/h to 20,000 Nm3/h, giving air blow speed directly at the outlets of crowns (2.01, 3.01, 4.01) from 80 m/s to 180 m/s, wherein to control the temperature of four rotors (1.0, 2.0, 3.0, 4.0), a mixture of deionised water and reverse osmosis water is used, with a proportion of deionised water from 50% to 90% and of reverse osmosis water from 50% to 10% and with a mixture temperature of 5-40°C, which is fed to rotors (1.0, 2.0, 3.0, 4.0) in the following quantities: to first rotor (1.0) - from 0.5 l/min to 15.0 l/min, to second rotor (2.0) - from 1.5 l/min to 25.0 l/min, to third rotor (3.0) - from 3.5 l/min to 30.0 l/min, to fourth rotor (4.0) - from 3.5 l/min to 30.0 l/min.