Mineral Wool, Rock Wool Electric Furnace - AC Rock Wool Furnace(New)

Product Specification

Mineral wool, rock wool electric furnace - AC rock wool furnace

Application of equipment:

  This equipment is used to melt the production of rock wool basalt, slag, dolomite and auxiliary materials, after heating homogeneous insulation, control the temperature and flow of the slurry transported to the centrifuge, continuous production of rock wool products.

Process overview:

  Basalt ore and auxiliary materials are the main raw materials of rock wool electric furnace. After drying by drying system, the prepared raw materials are loaded into the high bin of electric furnace through feeding system for storage. After measuring and weighing the raw materials through the distributing system, the raw materials are lowered into the furnace by the feeding pipe in the furnace, and the thin materials are continuously heated by electric power for submerged arc smelting. After melting to meet the temperature requirements, the thin materials are released through the slag outlet and enter the centrifuge to make rock wool products.

Structural features:

(1) The operation flexibility of the equipment is strong, the slag flow is controllable, the operation is simple;
(2) Adopt advanced impedance control method and introduce temperature feedback;
(3) high degree of automation, centralized control of the whole smelting process;
(4) Fast melting speed, continuous feeding, continuous discharge;
(5) smelting melting process without coke;
(6) The equipment performance is stable and can work continuously for 24 hours;
(7) Production waste can be recycled, resulting in less waste;
(8) The flue gas is easy to recover, and the emission is small (mainly for soot 350mg/m²);

Schematic diagram of process flow:

Main parameters and indicators:

1 Furnace capacity ~ 55t
2 Shell diameter Φ6000
3 Shell height 4000 mm
4 Electrode diameter Φ450mm
5 Electrode center circle Φ1450mm
6. Transformer rated capacity 7000 KVA

Performance index:
1 Output per hour (finished product) 5 ~ 6 tons
2 Power consumption per ton of product (finished product) ≤1100KWh/T
3 Electric furnace long-term insulation power consumption 700-800KWh/h

1. Core Definition & Key Functions

1.1 Definition

1.2 Key Functions

• Efficient High-Temperature Melting: Upgraded arc-stabilizing technology ensures rapid temperature rise (melting temperature up to 1700℃), shortening the melting cycle by 10-15% compared with traditional models; complete melting of raw materials eliminates crystalline impurities, improving molten slag purity (impurity content ≤0.8%).
• Molten Slag Homogenization: Optimized electrode arrangement and furnace body structure enhance the natural convection and stirring effect of molten slag, ensuring uniform temperature (temperature difference ≤±15℃) and chemical composition, and stable viscosity (1.2-2.8 Pa·s) to meet the requirements of continuous fiber formation.
• Energy Conservation & Emission Reduction: Adopts high-efficiency iron core transformer and low-resistance short network, increasing thermal efficiency to ≥78% (8-10% higher than traditional AC furnaces); power consumption per ton of molten slag is reduced by 15-20%; equipped with efficient flue gas purification and waste heat recovery systems, achieving energy recycling and low pollutant emissions.
• Intelligent Stable Operation: Integrates advanced PLC intelligent control system, realizing real-time monitoring and automatic adjustment of key parameters (furnace temperature, current/voltage, molten slag level); supports remote operation and fault early warning, ensuring 24/7 continuous and stable production.
• Waste Resource Utilization: Compatible with a variety of raw materials, including industrial solid wastes such as metallurgical slag and tailings, realizing "waste-to-treasure" and reducing raw material costs while responding to environmental protection policies.

2. Core Structure & Technical Principles

2.1 Core Components

2.2 Technical Principles

1. Feeding Stage: Raw materials (basalt, metallurgical slag, etc.) are crushed and screened to 5-30mm, then transported to the furnace body through the sealed intelligent feeding system at a constant speed.
2. Arc Ignition & Heating Stage: The AC power supply system outputs low-voltage, high-current electricity to the three graphite electrodes; arcs are generated between the electrode tips and raw materials, releasing a large amount of heat to rapidly melt the raw materials.
3. Molten Slag Homogenization Stage: Under the action of arc heat and natural convection, molten slag is fully stirred, ensuring uniform temperature and chemical composition; the intelligent temperature control system maintains the molten slag at 1550-1650℃ (adjustable according to raw material characteristics).
4. Discharging & Fiber Formation Stage: The molten slag flows out stably through the overflow port or tapping port, then is sent to centrifugal spinners for high-speed fiberization, forming rock wool fibers with uniform thickness.
5. Waste Heat Recovery & Flue Gas Treatment Stage: High-temperature flue gas generated during melting is cooled by the heat exchanger (recovering waste heat), then purified by the dust collector and desulfurization device to meet emission standards before being discharged.

3. Key Technical Parameters

4. Product Features (New Upgrades)

• Higher Energy Efficiency: Upgraded energy-saving transformer and low-resistance short network reduce energy loss; thermal efficiency increased by 8-10% compared with traditional AC furnaces, significantly lowering production costs.
• Stable & Reliable Performance: Optimized electrode arrangement and arc-stabilizing technology ensure stable arc discharge; reduced electrode consumption (2-3kg/t molten slag) and extended refractory lining service life, improving equipment operation rate.
• Intelligent Operation: Full-process intelligent control realizes automatic parameter adjustment and remote monitoring; fault early warning function reduces maintenance time, ensuring continuous production.
• Strong Raw Material Adaptability: Compatible with basalt, diabase, metallurgical slag, tailings, and other raw materials; flexible adjustment of melting parameters to meet different raw material melting requirements.
• Environmentally Friendly & Low Carbon: Efficient flue gas purification system achieves near-zero pollutant emissions; waste heat recovery realizes energy recycling, meeting global strict environmental protection policies.
• Cost-Effective & Easy Maintenance: Mature AC technology, simple structure, and standardized components reduce maintenance difficulty and spare parts costs; short commissioning cycle and quick return on investment.

5. Application Scenarios

• Rock Wool/Mineral Wool Production: Core melting equipment for insulation material manufacturers, producing rock wool boards, blankets, pipes, and other products widely used in construction, petrochemical, power, and transportation industries.
• Industrial Solid Waste Utilization: Treatment of metallurgical slag (steelmaking slag, non-ferrous metal smelting slag), tailings, and other industrial solid wastes, converting them into high-value rock wool raw materials, in line with circular economy development trends.
• Low-Carbon Building Materials Industry: Providing high-quality raw material melting support for green buildings, producing fire-resistant, thermal insulation, and sound-absorbing rock wool products to meet low-carbon building standards.
• Large-Scale Insulation Projects: Supporting equipment for large-scale projects such as high-speed railways, highways, and industrial workshops, providing stable and high-quality rock wool materials for thermal insulation and fire protection projects.

6. Competitive Advantages

• Upgraded Core Technology: Optimized AC arc-stabilizing technology and energy-saving design, balancing efficiency and cost-effectiveness, suitable for medium and large-scale rock wool production enterprises.
• Proven Reliability: Mature and stable AC technology, with thousands of successful application cases in domestic and foreign markets; equipment operation rate ≥95%.
• International Certification & Compliance: Products have passed CE, ISO 9001, ISO 14001, and other international certifications, complying with technical and environmental standards in Europe, Southeast Asia, Africa, and other regions.
• Customized Solutions: Provides personalized equipment design and process optimization according to user's raw material characteristics, production capacity, and product requirements, including furnace capacity, power configuration, and waste heat recovery systems.
• Comprehensive After-Sales Service: Offers one-stop services including equipment installation, commissioning, operation training, and overseas technical support; 24-hour online service and timely spare parts supply ensure uninterrupted production.