Fiber diameter and slag inclusion content are key indicators that determine the thermal insulation performance and mechanical strength of mineral wool products. The electric melting process, with its precise temperature control and clean melting environment, provides an ideal technical platform for the fine regulation of these two critical parameters.
I. Raw Material Pretreatment: The Foundation of Precise Control
Raw material stability is a prerequisite for achieving accurate control:
Formulation Optimization: Precise control of the acidity coefficient (Mk) ensures that the melt maintains an appropriate viscosity range, which is the fundamental condition for fiber formation.
Particle Size Control: Uniform particle size prevents uneven melting and residual crystalline nuclei, which are major sources of coarse fibers and slag inclusions.
II. Melting Process Control: Creating Optimal Fiber-Forming Conditions
The electric furnace creates ideal conditions for fiberization through precise thermal control:
Zoned Temperature Control: Modern electric furnaces adopt multi-zone independent temperature regulation, keeping melt temperature fluctuations within ±5°C to ensure melt homogeneity.
Atmosphere Regulation: Maintaining a slightly reducing atmosphere stabilizes the chemical state of the melt and reduces impurity formation.
III. Fiber-Forming Process: The Key Stage of Fine Regulation
Centrifugal fiberization is the core step determining fiber morphology:
Precise Centrifuge Control: Rotational speed directly affects fiber diameter. Frequency conversion technology enables millisecond-level adjustment. Roller diameter and temperature must be precisely matched with process parameters.
Optimized Air Ring Design: CFD simulation is used to optimize airflow distribution. By adjusting air pressure, air temperature, and airflow velocity, secondary fiber attenuation and rapid solidification can be achieved.
IV. Intelligent Monitoring System: Enabling Closed-Loop Control
Online Monitoring: Laser particle size analyzers are used to monitor fiber diameter distribution in real time.
Intelligent Feedback: An APC system automatically adjusts process parameters to form a closed-loop control system.
Quality Traceability: Image recognition technology enables online monitoring of slag inclusion content and root cause analysis of deviations.
Key Technological Breakthroughs
Multi-Parameter Coordinated Control: Establishing an integrated model linking temperature, rotational speed, air pressure, and other critical parameters.
Predictive Regulation: Achieving predictive adjustment of process parameters based on big data analytics.
Practical Application Results
Production lines equipped with this control system can achieve:
Fiber diameter standard deviation controlled within 0.5 μm;
Slag inclusion content (particle size >0.25 mm) stably below 5%;
Thermal conductivity fluctuation controlled within 3%.
Through the systematic integration of raw material pretreatment, melting control, fiberization optimization, and intelligent monitoring, the electric melting process enables precise control of fiber diameter and slag inclusion content. This integrated "Raw Material–Process–Equipment–System" control framework represents the technological direction toward high-end and precision-oriented mineral wool production, providing reliable technical support for improving product quality and market competitiveness.
