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Introduction to Fly Ash Rock Wool Electric Furnace
Fly Ash Rock Wool Electric Furnace is a specialized submerged‑arc electric melting furnace designed for high‑temperature vitrification of municipal solid waste incineration fly ash and production of high‑quality rock wool insulation materials. It converts hazardous fly ash into value‑added rock wool via electric heating, achieving harmless disposal and resource recycling simultaneously.
Core Working Principle
Raw Material Preparation: Fly ash is mixed with modifiers (e.g., lime, feldspar) to adjust acidity coefficient (1.5–2.0) and melt viscosity.
Electric Melting: Three‑phase AC or DC power generates submerged arcs, heating the furnace to 1,350–1,550°C to fully melt the mixture into homogeneous molten slag.
Vitrification & Purification: High temperature decomposes dioxins (destruction rate >99.99%) and stabilizes heavy metals in the glassy phase.
Fiber Formation: Molten slag flows continuously to a centrifuge at 3.3–4.0 t/h to form rock wool fibers.
Main Structure
Furnace Body: Steel shell with high‑purity MgO‑C refractory lining, resistant to high temperature and corrosive slag.
Electrode System: 3 graphite electrodes (φ400–600 mm) with automatic lifting; powered by a dedicated transformer.
Power Supply: Transformer capacity 3,000–10,000 kVA (common: 5,000–7,500 kVA).
Tilting & Tapping: Hydraulic tilting (max 45°) and bottom tapping for continuous slag discharge.
Control System: PLC/DCS for automatic temperature, power, and flow regulation.
Auxiliary Systems: Dust collection, waste heat recovery, and flue gas treatment.
Typical Technical Parameters
Parameter
Common Range
Typical 7,500 kVA Furnace
Transformer Capacity
3,000–10,000 kVA
7,500 kVA
Furnace Shell ID
φ5,200–6,500 mm
φ6,200 mm
Melting Temperature
1,350–1,550°C
1,450°C
Molten Slag Flow Rate
3.3–4.0 t/h
3.8 t/h
Slag Acidity Coefficient
1.5–2.0
1.8±0.3
Smelting Cycle
Continuous operation
>8,000 hours/year
Hourly Output (Rock Wool)
4–6 t/h
5.5 t/h
Annual Capacity
30,000–50,000 t
45,000 t
Unit Power Consumption
300–400 kWh/t
350 kWh/t
Electrode Consumption
1.5–2.5 kg/t
2.0 kg/t
Dioxin Destruction Rate
>99.99%
>99.99%
Carbon Reduction
~245 kg CO₂/t
~245 kg CO₂/t
Product Specifications (Rock Wool)
Item
Standard
Density
60–150 kg/m³
Thermal Conductivity
≤0.044 W/(m·K)
Acidity Coefficient
≥1.8
Fiber Diameter
≤7.0 μm
Fire Resistance
Non‑combustible (Class A)
Heavy Metal Leaching
Meets GB/T 41015–2021
Key Advantages
Harmless Disposal: Destroys dioxins and stabilizes heavy metals, fully complying with fly ash treatment standards.
Resource Recycling: Converts hazardous waste into high‑value insulation material.
Energy Efficient: Electric heating reduces energy consumption by >40% vs. coke‑fired cupolas.
Stable Quality: Precise temperature control ensures uniform fiber properties.
Low Emission: Near‑zero dust and flue gas pollution.
Long Service Life: Continuous operation >8,000 hours annually.
Typical Application Process
Batching: Fly ash + modifiers → proportioning and mixing.
Charging: Continuous feeding into the electric furnace.
Melting: Submerged‑arc heating to form molten slag.
Refining: Slag homogenization and impurity removal.
Fiberization: Slag → centrifuge → rock wool fibers.
Post‑Treatment: Cooling, curing, and cutting into finished products.
Applications
Waste Treatment: Harmless disposal of municipal solid waste incineration fly ash.
Building Insulation: High‑performance rock wool for walls, roofs, and pipelines.
Industrial Insulation: High‑temperature insulation for furnaces and equipment.
Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. is a high-tech enterprise specialized in the research, design, and manufacturing of various industrial furnaces, including AC and DC steelmaking electric arc furnaces, ladle refining furnaces, ferroalloy ore thermal furnaces, ferroall... Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. is a high-tech enterprise specialized in the research, design, and manufacturing of various industrial furnaces, including AC and DC steelmaking electric arc furnaces, ladle refining furnaces, ferroalloy ore thermal furnaces, ferroall...
