Magma Industry has been working on the basis of new equipment since the beginning of 2009, and is the largest manufacturer of super-thin basalt fiber (STBF) in Ukraine.
Mineral wool production line
1.Purpose of the line
VM-100 line is designed for the production of mineral wool of rocks. Wool production is based on the method of vertical air blowing of molten basalt.
The smelt is prepared in a continuous high-frequency induction furnace. The blowing is performed using a pneumatic ejection cap. Staple fibers separation occurs in the air stream that is perpendicular to the blow.
Deposition of the fibers and the formation of the mineral wool mat is made by melt blowing. The mat that we have as a result is pressed and rolled for transportation and storage.
Wool is intended for manufacturing of thermal insulating, sound insulating and sound absorbing products, as well as of insulating material in the construction and in the industry for surface insulation at less than 700°C.
Wool belongs to the group of non-toxic and non-combustible materials.
2.Requirements for raw materials
Raw materials are used in the form of chips sized from 1 to 5 mm. The presence of dust fractions may be 5% or less. The raw material must not contain metal or foreign objects like sand or debris. The charge should be dry and free-flowing.
3.Technological characteristics of the line
The VM-100 line produces raw materials melting in an induction furnace with a continuous discharge of the smelt and its subsequent processing by ejection cap blowing.
The work of high-frequency induction furnace is based on the energy absorption of the electromagnetic field by the mineral smelt material. Effective energy absorption occurs in a certain volume of the boundary layer of the smelt. The superheated boundary layer is the thermal energy supplier for the entire volume of the smelt, which is intensively mixed due to convective forces.
A water-cooled crucible is the part of the induction furnace of the present line and it helps to keep the smelt. The walls of the crucible are made in the form of plates with copper tubes cooled by flowing water. When melting the charge material, the walls of the crucible are covered with the crust of solidified mineral, which forms a layer of skull. Skull protects the walls from the interaction with a high-temperature smelt. Skull has a low thermal conductivity and high density, so there are the conditions for effective charge melting with little heat loss and without any contamination of the smelt. The crucible is mounted within the melt-inductor coil connected to the load circuit of the generator. With such a position of the crucible, the inductor electromagnetic field is concentrated in the area of the smelt.
The diagram of the basalt fiber production line BM-100 shows the principle of the line operation: rock (charge), located in the hopper loading mechanism is continuously poured into the water-cooled crucible of the induction furnace of the melting complex "Basalt". The design of the induction furnace allows making it work with the temperature more than 2000°C for 40 minutes, and if necessary, to perform multiple cycles "heating-cooling" without any damage to the furnace. The high temperature of basalt smelt heating and small size of the induction furnace gives a chance to produce a continuous stream of homogenized smelt.
Advantages of induction heating:
- lack of refractory;
- practical heat free-wheeling condition at the beginning and at the end;
- small volume of liquid smelt in an induction furnace, which excludes emergency when abnormal power failure.
The water-cooled crucibles' service life is about a year before the repair is needed. The charge is melting in the induction furnace, and the smelt is fed as a continuous stream into the blow head, where it becomes fiber with the help of high-speed turbulent air flow. The exhaust air, the fiber and non-fibrous inclusions fall within the forming chamber. The fiber is separated and falls on the conveyor belt in the form of a carpet, and non-fibrous inclusions are collected in a special bin. When you exit the camera, the carpet is pressed to a predetermined thickness and is transmitted to the mat wiring machine.
All the equipment of the mini-plant runs on electricity. Precious metals are not used in the design of the lines.
In addition to the technological line, the mini-plants of BM series include the following systems:
- water recycling;
- technological ventilation;
- compressed air supply.
4. Basalt mat wiring line
The line is designed for wiring of micro-, ultra-, super thin and micro glass ceramic glass and basalt staple fiber by fiber glass filament or glass roving, basalt roving, polyamide fiber (breaking force of 300 to 600 N). For smaller wiring thicknesses, less breaking force is enough. It consists of three independent drives with smooth digital speed control and is used for the manufacturing of basalt wired mats according to TU U 88 023.012-93 (technical standards of Ukraine), as well as of long strips of thermal insulation according to TU U 88 023.015-94 (technical standards of Ukraine). The line consists of the mat wiring and the mat consolidation systems.