Coke-Fired Rock Wool Production Line
Product Introduction
The coke-fired rock wool production line uses a vertical coke furnace as the core melting unit. High temperatures generated by coke combustion (above 1500°C) melt mixed mineral raw materials into molten lava, which is then fiberized by a high-speed centrifuge. Binders and dust-suppressing oil are applied, and the material is processed through fiber collection, forming, curing, and cutting to produce various rock wool products.
Main components of the production line include:
Raw material processing system: crushing, screening, weighing, mixing, and feeding equipment
Coke furnace system: furnace body, hot air circulation, tapping outlet, and melt conveying system
Fiberizing and collection system: four-roller/multi-roller centrifuge, collection chamber, binder spraying unit
Forming and curing system: pleating machine, compression conveyor, hot air curing oven
Post-processing system: cross-cutting, longitudinal cutting, edge trimming, stacking, and packaging equipment
Environmental protection system: flue gas purification, waste heat recovery, and exhaust treatment units
The entire production line adopts PLC/DCS automatic control, enabling real-time monitoring of key parameters such as furnace temperature, melt viscosity, and fiber diameter to ensure consistent product quality.
Product Features
|
Feature |
Description |
|
Strong fuel adaptability |
Uses coke as the main fuel with high calorific value and stable combustion; compatible with metallurgical coke and foundry coke |
|
High melting efficiency & low energy consumption |
Compact vertical furnace structure with higher thermal efficiency than traditional cupola furnaces; coke consumption per ton is well controlled |
|
Strong continuous operation capability |
Furnace lining made of high-quality refractory materials supports long-term continuous operation with reduced downtime |
|
Excellent fiber quality |
With efficient centrifuge, fiber diameter can be controlled at 3–7 μm, low shot content, fiberizing rate ≥90% |
|
Flexible product specifications |
Can produce rock wool boards, blankets, pipe sections, and strips with densities from 30–200 kg/m³ |
|
Comprehensive environmental system |
Equipped with bag filters, desulfurization, and flue gas treatment systems to meet emission standards |
|
High automation level |
Centralized control reduces manual errors and improves production stability |
Main Applications
Rock wool products produced by this line are widely used in:
Building insulation: external wall insulation systems, roofing insulation, partition filling, fire barriers
Industrial insulation: petrochemical pipelines, storage tanks, heating networks, boilers, furnace linings
Marine and offshore engineering: fireproof partitions, deck insulation, pipe wrapping
Agriculture: greenhouse insulation blankets, seedling substrates
Transportation: high-speed train carriages, automotive engine compartment insulation
Fire doors: A-class fire-resistant core materials
Production Process Flow
Raw material preparation
↓
Weighing and mixing (basalt, dolomite, slag, etc.)
↓
Coke furnace melting (1500–1600°C)
↓
Molten flow discharge (through furnace outlet into channel)
↓
Centrifugal fiberizing (four-roller centrifuge + binder & oil spraying)
↓
Fiber collection and forming (negative pressure collection to form primary mat)
↓
Pleating and pressing (multi-layer structure, thickness & density adjustment)
↓
Hot air curing (binder crosslinking through curing oven)
↓
Cooling and shaping (natural or forced cooling)
↓
Cutting and trimming (cross-cutting + longitudinal cutting)
↓
Quality inspection and packaging
Note: Waste heat recovery systems can be added to utilize flue gas heat for drying or combustion air preheating.
FAQ
Q1: What are the advantages of a coke furnace compared to an electric furnace production line?
A: Coke furnaces have lower investment costs and flexible fuel sourcing, making them suitable for large-scale continuous production. Electric furnaces are more environmentally friendly but have higher operating electricity costs. Coke furnaces are more economical in regions with high electricity prices.
Q2: What are the quality requirements for coke?
A: Recommended specifications: fixed carbon ≥82%, ash ≤15%, volatile matter ≤3%, particle size 40–80 mm, using metallurgical or foundry coke to ensure stable operation and melt quality.
Q3: What is the annual capacity of a standard production line?
A: Common configurations include a 1.2 m line with an annual output of 30,000 tons, or a customized 2.4 m line with up to 40,000 tons per year.
Q4: Can the rock wool products meet A-class fire rating?
A: Yes. Rock wool is an inorganic material and meets GB 8624 A-class non-combustibility standards, with a melting point above 1000°C.
Q5: Does the production process generate pollution? How is it handled?
A: Main pollutants include flue gas containing dust, SO₂, and NOx. Our system includes complete flue gas treatment solutions such as waste heat boilers, cyclone separators, bag filters, and desulfurization towers to meet emission standards.
If you require a customized solution based on specific capacity, raw materials, or environmental requirements, feel free to contact us for technical proposals and process flow diagrams.
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