1. Automated Batching and Feeding System
Raw materials (basalt, slag, and dolomite) are electronically metered to exact recipe ratios and transferred via conveyor belts or bucket elevators to the furnace pre-charging hopper. This module integrates dedicated dust extraction and magnetic iron separation systems. The batching accuracy directly determines the chemical melt stability and the targeted acidity coefficient.
2. Melting Furnace (Coke Cupola or All-Electric Melter)
Heats and liquefies raw materials into a homogeneous fluid melt at operating temperatures between 1,400°C and 1,600°C. For capacity expansions, the All-Electric Melter is the preferred technology due to zero combustion emissions, precise thermal profiling, and 100% recycling capability of off-spec fiber. Traditional coke-fired cupolas face severe regulatory and permitting restrictions in major global jurisdictions.
3. Centrifugal Fiberizing Unit (High-Speed Multi-Roll Centrifuge)
The liquid melt is directed via a distribution launder onto high-speed rotating centrifuge rolls (operating at 3,000+ rpm). Intense centrifugal force combined with a high-velocity air-ring blast attenuates the melt stream into micro-fine fibers. Binder and hydrophobic (water-repellent) additives are simultaneously injected through integrated nozzles, making this unit critical to overall fiber geometry and mat quality.
4. Fiber Collector (Drum or Vertical Negative-Pressure Collection Chamber)
Utilizes a high-volume negative-pressure vacuum system to uniformly draw attenuated fibers onto a moving porous mesh conveyor, forming a primary lightweight wool felt. This stage separates non-fibrous particulates (shot/slag balls), which are automatically discharged on a timed cycle and routed back into the melting furnace.
5. Pendulum Layering and Crimping Pre-Press Unit
A heavy-duty pendulum mechanism cross-lays the primary felt in a continuous, multi-layered three-dimensional matrix. This cross-lapping orientation dramatically enhances the transverse tensile strength of the board and prevents delamination. The layered mat then passes through a mechanical crimping and pre-pressing unit to lock in the target density and thickness prior to thermal curing.
6. Curing Oven (Horizontal Flight-Conveyor Curing Oven with Hot Air Recirculation)
Top and bottom heavy-gauge chain flights compress and guide the continuous wool mat through sequential heating zones. Heated air-sourced from natural gas burners or waste heat recovery loops-is forced through the mat to polymerize the binder and stabilize the dimensional matrix. It features integrated explosion-relief venting, precise zoned temperature management, and thermal energy recovery loops, determining the final compressive strength of the insulation product.
7. Cooling and Longitudinal-Transverse Cutting Unit
The cured mat is force-cooled via ambient air blowers, stabilized, and fed into high-precision cutting rigs. Longitudinal circular saws trim the mat to width, followed by a high-speed flying cross-cut saw that sections it to length. An integrated edge-trim granulator犯罪 (pulverizes) waste borders instantly, pneumatically conveying them back to the batching house or furnace to achieve zero-waste manufacturing.
8. Automated Packaging, Palletizing, and DCS Central Control System
Finished insulation products are automatically shrink-wrapped in protective film or cartoned, stacked via robotic articulation or mechanical palletizers, strapped, and dispatched to warehouse storage. The entire production line is managed by a centralized DCS/PLC framework that monitors and synchronizes melt temperatures, roll RPM, chemical injection rates, curing profiles, and plant-wide energy metrics in real time.