Mineral Wool, Rock Wool Electric Furnace - DC Hot Melt Slag Electric Furnace

Product Specification

 Mineral wool, rock wool Electric Furnace - DC Hot Melt Slag Electric 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.

Product process description:

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:

Compared with AC furnaces, DC furnaces have the following advantages:

1. Save electrode; (Energy-saving electrode consumption is 40% to 60% of the AC furnace)

2. Save energy; (10%-15% lower power consumption per ton of cotton than AC furnace)

3. The temperature of the reaction zone of the molten pool is high, the furnace eye is easy to open, and the iron is smooth.

4. It has low flicker effect and noise, which is very beneficial to the power grid and the operator, and its flicker effect is only 50% to 70% of the AC electric furnace, and the noise during submerged arc operation is more than 20dB lower than that of the AC electric furnace.

1. Core Definition & Key Functions

1.1 Definition

1.2 Key Functions

• Ultra-High Temperature Melting: DC arc heating achieves rapid temperature rise (up to 1750℃), ensuring complete melting of mineral raw materials and industrial solid wastes, decomposing impurities, and improving molten slag purity (impurity content ≤0.5%).
• Molten Slag Homogenization: Strong electromagnetic stirring effect of DC current makes molten slag temperature and chemical composition more uniform (temperature difference ≤±10℃), optimizing viscosity (1.0-2.5 Pa·s) for stable fiber formation and reducing fiber breakage rate.
• Energy Conservation & Emission Reduction: DC heating technology has thermal efficiency ≥82% (10-15% higher than AC furnaces), reducing power consumption by 20-30% per ton of molten slag; equipped with waste heat recovery and flue gas purification systems, achieving near-zero pollutant emissions.
• Hot Melt Slag Resource Utilization: Directly uses hot melt slag from metallurgical processes (e.g., steelmaking, non-ferrous smelting) as raw material, saving preheating energy and realizing "waste-to-treasure" in circular economy.
• Continuous & Stable Operation: Large-capacity furnace body (5-40t) and automatic feeding/discharging system support 24/7 continuous production, matching mineral wool/rock wool production lines with annual capacity of 10,000-100,000 tons.

2. Core Structure & Technical Principles

2.1 Core Components

2.2 Technical Principles

1. Feeding Stage: Raw materials (basalt, hot melt slag, tailings) are crushed and screened to 5-30mm, then transported to the furnace through the sealed feeding system.
2. Arc Ignition & Heating Stage: DC power supply outputs low-voltage, high-current electricity; arcs are generated between the graphite electrode (cathode) and furnace bottom anode, releasing massive heat to melt raw materials.
3. Molten Slag Homogenization Stage: DC current generates strong electromagnetic force, stirring molten slag violently to ensure uniform temperature and composition; temperature control system maintains molten slag at 1600-1700℃.
4. Discharging & Fiber Formation Stage: Molten slag flows out stably through the overflow port/tapping port, then is sent to centrifugal spinners for fiberization, forming mineral wool/rock wool fibers.
5. Waste Heat Recovery & Flue Gas Treatment Stage: High-temperature flue gas is cooled by heat exchanger (recovering waste heat), then purified by dust collector and desulfurization device before emission.

3. Key Technical Parameters

4. Product Features

• Higher Energy Efficiency: DC arc heating has no phase shift loss, thermal efficiency 10-15% higher than AC furnaces; power consumption per ton of molten slag is reduced by 20-30%, significantly lowering production costs.
• Superior Molten Slag Quality: Electromagnetic stirring ensures uniform temperature and composition, low impurity content, and stable viscosity, improving mineral wool/rock wool fiber quality (tensile strength ≥0.03MPa, thermal conductivity ≤0.038W/(m·K)).
• Strong Raw Material Adaptability: Suitable for basalt, diabase, metallurgical hot melt slag, tailings, and other raw materials; can adjust melting parameters according to raw material composition to ensure product stability.
• Environmental Protection & Low Carbon: Waste heat recovery rate ≥60%, flue gas dust concentration ≤10mg/m³, SO₂ concentration ≤35mg/m³; no noise pollution (≤85dB), meeting global strict environmental standards.
• Stable & Reliable Operation: DC arc is more stable than AC arc, with fewer electrode consumption (1-2kg/t molten slag); refractory lining has long service life, and the furnace can operate continuously for 8000 hours/year.
• Modular Design: Supports parallel operation of multiple furnaces, easy to expand production capacity; standardized components reduce maintenance difficulty and spare parts inventory.

5. Application Scenarios

• Mineral Wool/Rock Wool Production: Core melting equipment for high-end thermal insulation material manufacturers, producing insulation boards, blankets, pipes, and other products for construction, petrochemical, and power industries.
• Industrial Solid Waste Utilization: Treatment of metallurgical slag (steelmaking slag, non-ferrous smelting slag), tailings, and other industrial solid wastes, converting them into high-value mineral wool/rock wool raw materials.
• Hot Melt Slag Resource Utilization: Supporting equipment for steel plants, non-ferrous smelters, and circular economy industrial parks, realizing in-situ utilization of hot melt slag.
• High-End Thermal Insulation Engineering: Providing high-performance mineral wool/rock wool materials for green buildings, high-speed railways, ships, and other fields requiring strict fire resistance and thermal insulation.

6. Competitive Advantages

• Advanced DC Technology: Leading DC arc melting and electromagnetic stirring technology, with independent intellectual property rights, ensuring technical leadership in the industry.
• Cost-Effective Operation: Lower energy consumption and electrode consumption reduce production costs by 15-25% compared with traditional furnaces, enhancing enterprise competitiveness.
• International Certification & Compliance: Products have passed CE, ISO 9001, ISO 14001, and other international certifications, complying with technical and environmental standards in Europe, North America, Southeast Asia, and other markets.
• Customized Solutions: Provides personalized design according to user's raw material characteristics, production capacity, and product requirements, including furnace structure, 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 ensures timely problem-solving.

Main parameters and performance:

1 Furnace capacity ~ 50t
2 Shell diameter Φ5200 ~Φ5600
3 The height of the shell is 3500 mm
4 Cathode electrode diameter Φ500mm
5 Bottom electrode diameter Φ700
6 Maximum electrode stroke 1800 mm
7. Dc transformer rated capacity 4000 KVA

Performance index:
1 Output per hour (finished product) 5 ~ 6 tons
Power consumption of 2 tons of cotton 300-350KWh/T;

3. Ton of cotton electrode consumption: 1.5-2.5Kg/t

Process diagram below: