Canadian Patents Database / Patent 2435261 Summary
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|(12) Patent:||(11) CA 2435261|
|(54) English Title:||METHOD FOR PRODUCING INSULATING MATERIALS FROM MINERAL FIBERS|
|(54) French Title:||PROCEDE DE PRODUCTION DE MATERIAUX ISOLANTS EN FIBRES MINERALES|
- Bibliographic Data
- Representative Drawing
- Admin Status
- Owners on Record
|(51) International Patent Classification (IPC):||
|(72) Inventors :||
|(73) Owners :||
|(71) Applicants :||
|(74) Agent:||NORTON ROSE FULBRIGHT CANADA LLP/S.E.N.C.R.L., S.R.L.|
|(74) Associate agent:|
|(86) PCT Filing Date:||2001-04-21|
|(87) Open to Public Inspection:||2002-07-25|
|(30) Availability of licence:||N/A|
|(30) Language of filing:||English|
|Patent Cooperation Treaty (PCT):||Yes|
|(86) PCT Filing Number:||PCT/EP2001/004535|
|(87) International Publication Number:||WO2002/057194|
|(85) National Entry:||2003-07-18|
|(30) Application Priority Data:|
The invention relates to a method for producing insulating materials from
mineral fibers, especially from glass and/or rock wool. A silicate melt is
produced in a melting unit, especially a cupola melting furnace, and is
disintegrated in a disintegration device to preferably microfine fibers.
Preferably, a binder and/or proofing agent is added to the fibers and they are
placed on a conveyor means in the form of an unwoven material. The aim of the
invention is to improve said method and said melt in such a manner that the
method can be carried out at lower costs or that an inexpensive melt is
provided by using inexpensive starting materials. To this end, the silicate
melt is at least partially produced from catalysts derived from oil refining
that are especially no longer useful.
L'invention concerne un procédé de production de matériaux isolants en fibres minérales, notamment en laine de verre et/ou en laine minérale. Ce procédé consiste à produire une masse fondue silicatée dans un ensemble de fusion, notamment un cubilot et à défibrer, de préférence, des microfibres dans un dispositif de défibrage ; à ajouter aux fibres, de préférence, un agent liant et/ou d'imprégnation et à déposer les fibres en nappe sur un dispositif de transport. Pour améliorer un procédé et une masse fondue selon l'invention de telle manière que l'utilisation de produits de départ économiques permette d'exécuter un procédé bon marché ou de disposer d'une matière fondue économique, la matière fondue silicatée est produite au moins partiellement à partir de catalyseurs du traitement du pétrole, qui ne sont notamment plus utilisables.
1. An improved method for producing insulating materials from mineral fibers,
silicate melt is prepared in a melting unit, and disintegrated in a
disintegration unit, and
the fibers are placed on a conveyor means in the form of an unwoven material,
improvement comprising preparing the silicious melt at least partly from oil
2. A method as claimed in claim 1, wherein the mineral fibers are selected
from glass, rock
wool and mixtures of both.
3. A method as claimed in claim 1, wherein the melting unit is a cupola
4. A method as claimed in claim 1, wherein the disintegration unit produces
which are mixed with binders, proofing agents or mixtures thereof.
5. A method as claimed in claim 4, wherein the oil refining catalysts are no
6. A method as claimed in claim 1, wherein catalysts from cracking and/or
processes are used.
7. A method as claimed in claim 1, wherein the catalyst is a zeolite with a
8. A method as claimed in claim 1, wherein metals precipitated during a
melting of the
catalysts are collected and periodically drained.
9. A method as claimed in claim 8, wherein the metals are collected and
drained together with metallic iron reduced from raw materials.
10. A method as claimed in claim 1, wherein the melt is prepared from the
usual raw materials for the production of insulating materials from mineral
11. A method as claimed in claim 10, wherein the mineral fibers are selected
basalt, limestone, dolomite and raw materials obtained during production or
12. A method as claimed in claim 1, wherein oxidic constituents contained in
the melt are
13. A method as claimed in claim 12, wherein the oxidic constituents are at
least one of the
rare earths La2O9, CeO2 and Pr6O11.
14. A method as claimed in claim 1, wherein fine-grained catalyst masses are
lumpy bodies before they are melted open.
15. A method as claimed in claim 14, wherein residual materials taken from a
cycle and/or silicious stones are used as supporting grain and/or binders and
to the fine-grained catalyst masses.
16. A method as claimed in claim 15, wherein the constituents of the melt are
they are fed to the melting unit.
17. A method as claimed in claim 1, wherein the catalysts are blown through
into the melting unit.
18. A method as claimed in claim 17, wherein the blast forming is performed in
19. A method as claimed in claim 1, wherein the catalysts are preheated before
they are fed
to the melting unit.
20. A method as claimed in claim 19, wherein the preheating temperature is
600° C at
21. A melt for producing mineral fibers for a mineral fiber web, which can be
insulating materials, wherein oil refining catalysts that are no longer usable
are used to
prepare a silicious melt.
22. A melt as claimed in claim 21, wherein the catalysts originate from
23. A melt as claimed in claim 21, wherein the catalysts are mixed with
from a primary waste cycle and/or recycling materials from the mineral fiber
24. A melt as claimed in claim 21, wherein
20 - 60% by weight of SiO2
and 10 - 60% by weight of Al2O3 are
25. A melt as claimed in claim 24, wherein 10 - 30% by weight of Al2O3 are
26. A melt as claimed in claim 21, wherein the catalysts have a grain size of
between 2 and
27. A melt as claimed in claim 21, wherein the catalysts have a mean diameter
30 and 100 µm.
28. A melt as claimed in claim 21, wherein the catalysts are formed as
29. A melt as claimed in claim 21, wherein the catalysts comprise 10 - 30% by
metals Ni or W.
30. A melt as claimed in claim 26, wherein the grain size is between 3 and 4
31. A melt as claimed in claim 27, wherein the mean diameter is between 50 and
32. A melt as claimed in claim 28, wherein the length of the extrudate is
between 1 and 5
33. A melt as claimed in claim 28, wherein the length of the extrudate is
between 2.5 and 3
34. A melt as claimed in claim 29, wherein the catalysts comprise 15 - 25% by
weight of the
metals Ni or W.
35. A melt as claimed in claim 21, wherein the catalysts comprise 15 - 35% by
CoO and MoO3.
CA 02435261 2005-12-21
Method for ProducingInsulating Materials from Mineral Fibers
This invention relates to a method for producing insulating materials from
bers, especially from glass and/or rockwool, wherein a silicate melt is
prepared in a
melting unit, especially a cupola furnace, and is disintegrated in a
disintegration unit to
preferably microfine fibers, and wherein a binder and/or proofing agent is
added to the
fibers and the fibers are placed on a conveyor means in the form of a fibrous
The invention further relates to a melt for producing mineral fibers for a
Insulating materials made from mineral fibers are produced from silicious
melts. To this
end a silicious starting material, e.g. glasses, natural or artificial stone,
are fed for ex-
ample to a cupola furnace or shaft furnace. The silicious melt thus obtained
is then fed
to a disintegration unit where the silicious melt is disintegrated to
fibers. The mineral fibers which are thereafter supplied to a collecting
chamber are as a
rule wetted with binders and/or proofing agents and are placed on a conveyor
usually a coveyor belt, arranged under the collecting chamber. The mineral
ted with binder and/or proofing agents form on said conveyor means a mineral
web which is treated in a manner known per se in downstream thermal and/or
cal devices, in order to produce insulating materials in the form of webs,
moulded bodies or the like.
With insulating materials made from mineral fibers a difference is made
from glass wool and those from rockwool. Rockwool insulating materials usually
been melted open from stones like diabase, basalt and limestone, dolomite. In
meantime, these natural stones are increasingly replaced by artificial stones
or are sub-
ject to the melting process together with artificial stones. In this melting
mostly takes place in cupola furnaces, there exists a strong dependence
viscosity and temperature. Moreover, the nucleation number and hence the
crystallization are very high. At the formation of the mineral fibers on so-
CA 02435261 2005-12-21
spinning machines these properties lead to relatively short mineral fibers
swirled in themselves. The individual mineral fibers per se have a glassy
pearance. Due to their composition the temperature resistance of mineral
duced from a melt of rock is higher than that of insulating materials from
Glass wool insulating materials contain as a network transformer
dium oxide and boroxide. The melt for glass wool insultating materials
weakly developed dependence of the viscosity from temperature. The
this glass melt does not take place on cascade spinning machines, but is
the aid of rotating bowl-shaped bodies, of which the walls include bores. Due
centrifugal force which is produced in this case the glass melt is forced
bores, so that mineral fibers are extruded from glass wool which have a longer
compared to those from rock wool.
An important factor at the production and evaluation of mineral fibers is the
ity, i.e. the dwell time of the mineral fibers in the human organism. The
insulating materials from rockwool is decisively influenced by the A1203
increasing A1203 moieties the temperature resistence of the fibers increases
on the one
hand and, surprisingly, on the other hand also the biosolubility.
A typical composition of biosoluble mineral fibers from rockwool includes a
Si02 between 35 and 43 % by weight, a moiety of A1203 of 17.5 to 23.5 % by
moiety of Ti02 of 0.1 to 3 % by weight, a moitey of FeO of 1.7 to 9.3 % by
moiety of CaO + MgO of 23.5 to 32 % by weight, and a moiety of K20 + Na2 of
7 % by weight.
An important criterion for the economy of insulating materials from rockwool
as a mass
product is the use of raw materials comprising a high moiety of A1203. Even
natural stones frequently include aluminosilicates, they are often not
available in the
required concentrations or only together with undesired minerals. Calcined
the other hand, are comparatively expensive. For this reason, residual
materials are fre-
CA 02435261 2005-12-21
quently utilized which, up to present, were mostly only suitable for dumping
stituted a considerable risk to the environment because of their content of
stances. At the same time these residual materials accrueing on the production
wool, for example in the form of melt residues, separated non-fibrous
dusts, misproductions or the like are almost completely recycled in a primary
system. These residual materials are conditioned prior to their recycling, so
comply with the requirements of the machine equipment, particularly the
For their recycling these residual materials are for example comminuted and
each other or with other splintery raw materials at different grain sizes,
with binders such as cement and pressed to sufficiently large moulded bodies
these moulded bodies are supplied as lumpy raw materials to a shaft furnace or
furnace. From the EP 0 765 295 Cl for example it is known to bind suitable
bodies from fine-grained raw materials also with the aid of lignin. In WO
responding moulded bodies with molasses-containing binders are described.
In view of this prior art the invention is based on the problem of improving
and said melt in such a manner that the method can be carried out at lower
costs or that
an inexpensive melt is provided by using inexpensive starting materials.
The solution of this problem provides that in a method of this kind the
silicious melt is
at least partly prepared from oil refining catalysts, particularly from those
which are no
Accordingly, the invention provides that in a method which is known per se the
melt is at least partly produced from oil refining catalsysts, particularly
which are no longer usable.
Mineral oils consists of mixtures of high-molecular to low-molecular
serve as raw materials for a number of substances like fuels, base products
for the pro-
duction of polymers, or as starting material for bitumen and asphalts. At the
stages of processing a number of processes like the hydrating, dehydrating,
CA 02435261 2005-12-21
reducing of intermediate products run in an economical way only under the use
In this respect the catalysts are classified in two classes. On one side,
like chromic oxide or vanadium pentoxide, metals such as platinum, palladium
are used which catalytically influence the hydrating, dehydrating and
cesses. Here the metals are seated on e.g. aluminium oxide supporting
materials. On the
other side, acid-base-catalysts find use for isomerization, alkylation or
tions that run via ion-like intermediate stages. Typical acid-base-catalysts
acidic aluminium oxides, aluminosilicates or zeolites. Those kinds of
catalysts have a
relatively long useful time, since they can be repeatedly regenerated. These
need to be replaced for example in case of the addition of coke or of so-
poisons or in case of a decreasing specific surface area of noble metals as a
quence of recrystallization. At higher standards the noble metals contained in
lysts can be economically recovered.
However, used catalysts accrueing on catcracking or hydrocracking are normally
of which the recycling is economical only in few other processes, in order to
For example, in order to obtain high-quality fuels from mineral oils,
ucts from mineral oil are subject to a catalytic cracking process. The
takes place in fluid-bed reactors. The catalytic cracking reactions take place
in the pres-
ence of acidic catalysts according to a carbonium ion mechanism. As usual
aluminosilicates doped with protons are mostly used. These catalysts replace
merly used acid-treated clay minerals of the montmorillonite group which have
replaced because of their crystallinity and the present impurities caused for
iron or by amorphous aluminosilicates. Commercially available amorphous
cates contain approx 10 to 15 % by weight of A1203, but there are also known
nosilicates having an A1203 content of between 20 to 30 % by weight.
CA 02435261 2005-12-21
Economically much more important and hence much more popular are catalysts
synthetic zeolites with the crystal structure of the mineral faujasite.
Suitable zeolites are
for example produced by Union Carbide under the name Linde type X or Linde
The total formula of these two zeolite types is:
Linde type X: Na86[A102)86(SiO2)1o6] x H20
Linde type Y: Na56[Al02)56(SiO2)136] x H20
The chemical efficiency extremely increases with the exchange of the NA ions
valent ions like for example lantane, lantanides or other rare earths.
Accordingly, as the
most efficient catalysts so-called H-RE-faujasites are used, wherein "RE" is
viation for "rare earths".
From various technical reasons like increasing the resistance to abrasion,
bility and for a better distribution of the active substances it is useful
that the zeolite
catalysts are distributed in a matrix of silica gel, amorphous
aluminosilicates or clays.
The H-RE-faujasite is, for example, embedded at relatively small amounts in
phous aluminosilicates. Zeolite catalysts work more selectively than amorphous
nosilicates, the latter boosting the formation of olefines. Such catalysts
have a high open
porosity and a large specific surface area, which are favourable and necessary
function as a catalyst in the catcracking process. By the separation of coke
centers of the catalysts are deactivated. Cleaning of the expensive catalysts
for example, by a careful burning-off of the coke depositions. However, any
cleaning cannot be guaranteed, so that the service life of such a catalyst is
though it is regularly cleaned.
A permanent deactivation of the catalysts can be caused in addition by metal
pounds in the distillates. Such metals in distillates are in the first line
and/or iron which themselves act as catalysts and cause undesired reactions.
Due to a
decrease in the catalytic activity and in selectivity catalysts become
unusable and need
CA 02435261 2005-12-21
to be exchanged. As a rule, such catalysts are dumped as waste material,
unless they can
be recycled in an economical way in other processes.
Catalysts herein described are used in so-called fixed-bed reactors and are
the form of particles having a good flowability and a grain size of 3 to 4 mm.
bed reactors are used, catalysts will be selected, of which the particles have
diameter of approx 50 to 70 m.
Methods for the refining hydration of mineral oil fractions are part of the so-
drotreatings, of which the various techniques are used for example in order to
harmful or inhibiting tramp materials. To this end catalysts are used which
among others on the use of cobalt and molybdenum oxides with aluminium oxide
supporting medium. Such catalysts are available in the form of extrudates and
initial length of approx 2.5 to 3 mm.
Finally, for the breaking hydration of mineral oil fractions hydrocracking
applied in which typical hydrocrack catalysts are used that contain tor
like nickel or tungsten in amounts of approx 15 to 25% by weight or CoO + MoO3
moieties of approx 22 to 28% by weight as well as support medium. The support
medium either consists of almost pure A1203 or of aluminium silicates.
Surprisingly it has shown now that the above-described catalysts in the used
particularly suited as supplementary raw materials fiir the production of
rials from mineral wool.
According to a further feature of the invention it is advantageous to use as
those from cracking and hydrocracking processes which are very well suited as
tute raw materials, particularly for the production of rockwool insulating
materials. As a
characteristic parameter Si02 in moieties of approx 30 to approx 55 % by
A1203 in moieties of between about 30 to 50 % by weight can be mentioned as
CA 02435261 2005-12-21
However, also catalysts can be used which consist of zeolite, wherein the
scribed zeolites of the type Linde are of interest when the sodium content is
order to avoid an excessive content of alkalies in the insulating material.
All the other
constituents of the catalysts are of minor importance and can thus be added to
without any negative effects.
A further feature of the invention provides that metals which precipitate
melting-open of the catalysts are collected and periodically drained.
metals are collected and periodically drained together with the metallic iron
from the raw materials. Here it is advantageous that the melting units, for
cupola furnaces, have no fire-resistant liniiig in their actual shaft region,
so that the me-
tals present in the catalysts are no danger for the melting unit.
According to an advantageous further improvement of the method according to
vention it is provided that oxidic components contained in the melt, such as
like La203, CeOz, Pr6011, are dissolved in the melt.
A further feature of the invention provides that the melt is prepared from the
and the usual raw materials for the production of insulating materials from
bers, particularly diabase, basalt and limestone as well as dolomite, and/or
from the re-
sidual material obtained during the production or recycling. Accordingly, it
in this embodiment that the catalysts are merely a constituent of the melt of
moiety within the melt is adjusted corresponding to the required quality level
According to a further feature of the invention the fine-grained catalyst
pressed to lumpy bodies before they are melted. Preferably, the fine-grained
masses are mixed together with the residual material from the primary waste
stones used as supporting grain as well as binders like hydraulic cements,
draulic materials, lime and/or lignin, molasses or the like, and pressed to
CA 02435261 2005-12-21
After they have hardened, these lumpy bodies together with lumpy stones and
fed to a melting unit where they are melted open. In this connection it is
that the constituents of the melt are thoroughly mixed before they are
supplied to the
Alternatively, the catalysts can be fully or at least partly blown as a fine-
into the melting unit, particularly a shaft furnace, through blast forming. To
reduce a decrease in temperature within the melting zone of the furnace it has
that preheating the catalyst particles is advantageous, wherein a maximum
temperature of 600 C should be striven for.
In addition to the above-described method the present invention is also
concerned with a
melt for producing mineral fibers for a mineral fiber web, particularly from
which can be further made into insulating materials. The melt according to the
is characterized by oil refining catalysts that are no longer usable.
Preferably, the catalysts originate from cracking and/or hydrocracking
have shown to be very good substitute raw materials for the production of rock
A further feature of the melt according to the invention provides that the
mixed with residual materials from the primary waste cycle and/or recycling
from mineral fiber production. Such a mixture is particularly suited for the
of rock wool insulating materials of sufficiently high quality.
Preferably, the melt according to the invention includes 20 to 60 % by weight
and 10 to 60 % by weight, particularly 10 to 30 % by weight of A1203.
The catalysts available in the melt preferably have a grain size of between 2
and 6 mm,
particularly of between 3 and 4 mm, so that the same are suitable for being
lumpy bodies to be fed to a melting unit on the one hand, and for being blown
CA 02435261 2005-12-21
shaft furnace on the other hand. To this end catalysts from fixed bed reactors
used, for example, which are available in the form of particles exhibiting
ability. But alternatively also catalyst particles are suited which are used
in fluid bed
reactors and which have an average diameter of 30 to 100 m and preferably of
50 and 70 m.
Another alternative are catalysts that are used in processes for the refining
mineral oil fractions. With such catalysts a configuration as extrudates can
mined, of which the length preferably is between 1 and 5 mm, particularly
and 3 mm.
Finally, a further feature of the invention provides that the catalysts
include 10 to 30 %
by weight, particularly 15 to 25 % by weight of metals like nickel or tungsten
or 15 to
35 % by weight and preferably 22 to 28 % by weight of cobalt oxide and
oxide. As a supporting material in such catalysts aluminium oxide is provided.
Further features of the method according to the invention or of the melt
according to the
invention become apparent from the following description of preferred
For producing a melt a cupola furnace is charged with lumpy material that
15% of a catalyst material and at 85% of artificial stones. As catalyst
phous aluminium silicate catalysts from hydrocracking processes with 12.5% by
of A1203 are used. The artificial stones consist at 60% of recycling material
and at 40%
of re-built mineral fiber insulating materials, wherein the recycling material
from the production process in the form of cuttings or low-quality products.
rial to be fed is pressed from fine-grained catalyst material and the test
for the artificial stones together with stones used as supporting grain with
draulic materials to lumpy bodies.
CA 02435261 2005-12-21
For producing a silicious melt which serves for producing fibrous insulating
cupola furnace is charged with lumpy material that consists at 25% of a
rial, at 20% of natural stone, and at 55% of artificial stones. As a catalyst
lysts from mineral ol refining which are no longer usable are chosen, of which
constituents are Si02 and A1203, wherein the catalyst material includes a
moiety of 45%
by weight of Si02 and 40% by weight of A1203 as well as further oxidic
like rare earths and metal. As natural stone diabase, basalt and limestone as
dolomite are used. The artificial stone is composed of residual materials
the production of fibrous insulating materials or on the re-building of
rnaterial, the proportion of the recycling material as a result of
70%, and the proportion obtained from re-building being 30%.
The catalyst material and the residual material that is to be made into
are prepared into a fine-grained material and are mixed with lime and lignin
to lumpy bodies. Thereafter, the feeding material is fed to the cupola furnace
as a frac-
tion mixed from natural stone and lumpy bodies consisting of catalyst material
ficial stone and melted therein and is subsequently fed to a disintegration
unit in which
the melt is disintegrated to microfine fibers which are then placed on a
conveyor belt in
the form of a mineral fiber web. Therafter, the mineral fiber web is
thermally treated, in order to produce the desired mineral fiber insulating
Also in the third embodiment catalyst material, natural stones and artificial
fed as charging material to a cupola furnace, with a mixture of 45% catalyst
20% natural stone, and 35% artificial stones being provided. The artificial
composed of 80% of recycling material and 20% of re-building material, said
material and re-building material being prepared into a fine-grained structure
with the catalyst material and pressed to lumpy charging material. To this end
CA 02435261 2005-12-21
is used including hydraulic cement. The production of the mineral fiber
rial then takes place in the above-described way.
Sorry, the representative drawing for patent document number 2435261 was not found.
For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee and Payment History should be consulted.
|Forecasted Issue Date||2009-11-10|
|(86) PCT Filing Date||2001-04-21|
|(87) PCT Publication Date||2002-07-25|
|(85) National Entry||2003-07-18|
There is no abandonment history.
|Current Owners on Record|
|ROCKWOOL INTERNATIONAL A/S|
|Past Owners on Record|
|DEUTSCHE ROCKWOOL MINERALWOLL GMBH & CO. OHG|