30,000-ton Electric Furnace Rock Wool Production Line—intelligent, Green, Efficient, And Sustainable

1. Project Background

Under the "Dual Carbon" strategy, demand for high-performance thermal insulation materials continues to grow in areas such as building energy conservation, industrial insulation, and transportation. Rock wool, an inorganic material made from natural minerals and offering excellent fireproofing, heat insulation, and sound absorption properties, holds a promising market prospect. To meet the demands of large-scale continuous production, SUNTHERM Group has launched a 30,000-ton electric furnace rock wool production line. This replaces traditional coal/oil furnaces with a highly efficient and energy-efficient electric heating process, providing customers with a green, low-carbon, and intelligent production solution.

2. Equipment Composition

(1) The entire production line consists of the following key modules, each of which can be customized:

(2) Raw material processing system: automatic crushing, screening, batching, and conveying

(3) Electric furnace melting system: electric arc furnace or resistance furnace, precise temperature control, low emissions

(4) Centrifugal fiberization system: multiple high-speed fiberization wheels, fine and uniform fibers

(5) Glue spraying and dust removal system: simultaneous injection of adhesive and dust-proof oil, environmentally friendly and efficient

(6) Cotton laying and pressing system: multi-stage pendulum, automatic control of cotton layer thickness and uniformity

(7) Curing oven system: hot air circulation and intelligent temperature control to ensure stable product strength

(8) Cooling and conveying system: air cooling + conveying shaping to protect the product structure

(9) Cutting system: supports cross-cutting, longitudinal cutting, and edge trimming

(10) Packaging and palletizing system: fully automatic PE film packaging, heat shrinking, and robotic palletizing

(11) Dust removal and emission control system: bag dust removal + flue gas condensation tower to meet emission standards

(12) Central control system: PLC + touch screen control, support SCADA/MES docking

3. Technical Parameters

4. Core Advantages and Highlights

(1) Green Melting, Energy Saving and Emission Reduction

Compared to traditional coal/oil heating methods, electric furnace melting technology can reduce carbon emissions by more than 50%, has no SO₂ and NOₓ pollution, and operates cleaner and more efficiently.

(2) Intelligent Control, Stable and High Yield

Adopting Siemens or Schneider PLC+HMI systems, key equipment is intelligently interconnected, stable operation, and supports rapid switching of multiple categories.

(3) Mature equipment, easy maintenance

The entire line is modularly designed for easy installation and maintenance. Key components use internationally renowned brands, with low failure rates and long service life.

(4) Automatic packaging, improved efficiency

The finished product packaging system supports automatic film changing, counting, stacking, and warehousing, greatly reducing manual intervention and error rates.

5. Applicable Product Types

Rock wool board: Applicable to exterior wall insulation, roofing system, fireproof and heat insulation

Rock wool strip: Applicable to curtain wall fire separation zone

Rock wool roll felt: Applicable to steel structure roof, air duct, industrial equipment insulation

Industrial high-density rock wool board: Applicable to power plant, petrochemical, ship insulation system

Special customized rock wool products: Developed according to customer requirements

6. Production Line Operation Advantages

(1) Continuous production: Automated continuous operation can achieve 24-hour uninterrupted production, greatly improving single-shift production capacity.

(2) Strong flexible manufacturing capabilities: Product size, density, and thickness can be quickly adjusted through the control system to adapt to different markets and application scenarios.

(3) Short equipment depreciation cycle: Core equipment operates stably with low loss, and the investment cost can be recovered within 5 years.

(4) Optimized employment structure: The entire line is automated, and the production line only requires 15 to 20 operators and maintenance personnel, reducing labor costs.

7. Environmental Protection and Compliance

The exhaust system is equipped with a bag filter, exhaust gas purification tower, and VOC treatment device.

It meets multiple environmental standards, including EU CE and US EPA.

It supports the issuance of environmental impact assessment materials, environmental technical specifications, and energy-saving assessment reports.

The electric drive replaces the kerosene system, making it more suitable for green investment requirements in countries along the Belt and Road Initiative.

8. Return on Investment Analysis (Brief Illustration)

9. Application Areas

Exterior Thermal Insulation and Energy Saving System (ETICS);

Insulation of industrial boilers, pipelines, and pressure vessels;

Thermal insulation and fire protection of petrochemical, power, and metallurgical equipment;

Fire barriers and curtain wall fireproofing for high-rise buildings;

Insulation of containers, cold storage, and refrigeration systems;

Rail transit, shipbuilding, and airport terminal projects

10. After-Sales Service and Technical Support

SUNTHERM Group is committed to providing customers with one-stop rock wool production solutions. Our services include but are not limited to:

Pre-project site selection, energy assessment, and capacity analysis

Process planning, plant layout, and construction guidance

Equipment manufacturing, transportation, installation, and commissioning

Full employee training and operation manual provision

Remote diagnostics and spare parts supply during operation

Regular inspections and system upgrades and optimization services

We have representative offices and service teams in Russia, Central Asia, Southeast Asia, and Europe to ensure the smooth implementation and long-term stable operation of your project.

11. FAQ

Q1: What raw materials can this rock wool production line accommodate? Is it limited to basalt?

A1: This production line supports a variety of raw materials, such as basalt, dolomite, and slag. The specific formulation can be optimized based on local resources. We also provide recommended blending ratios to ensure consistent melting performance and finished product quality.

Q2: Does this production line support a variety of product specifications? Is switching between different formats difficult?

A2: It supports flexible switching between rock wool boards, rock wool strips, rock wool rolls, and other formats. Parameters such as thickness, density, and length can be set through the automatic control system, making switching quick and easy without requiring major modifications to the equipment structure.

Q3: Is using an electric furnace significantly more expensive than a coal-fired furnace? Are operating costs high?

A3: While electric furnaces have a slightly higher unit energy cost, they offer higher energy efficiency. Combined with a waste heat recovery system, overall energy consumption can be significantly reduced. Furthermore, they emit no smoke and dust, comply with environmental regulations, and have lower maintenance costs, offering superior long-term cost-effectiveness.

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