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Knauf Insulation Sprl

Gerard Demott

David Ducarme

Bostjan Marolt

Randy Etzkorn

Mitja Oresnik

The present disclosure relates to mineral wool compositions and articles, as well as methods for manufacturing mineral wool compositions and articles.

Mineral wool

The invention relates to a material feeding system () for a melter comprising: (i) a substantially horizontal feeding barrel () designed to feed solid material through the melter wall () into the melt () contained in the said melter, and arranged below the level () of the melt () contained in the melter (), (ii) said feeding barrel () comprising a material input opening () and material output opening (), the material output opening () leading into the melt () contained in the melter (), said feeding barrel () comprising an internal feeder () designed to push solid material () loaded through the material input opening (), in the direction of the longitudinal barrel axis () toward the material output opening (), the end of the internal feeder () on the material output side extending at a minimum at a distance from the internal melter surface () of two (2) to ten (10) times the diameter of the feeding barrel (), preferably three (3) to eight (8) times the diameter of the feeding barrel, more preferably three (3) to six (6) times the diameter of the feeding barrel or three (3) to five (5) times the diameter of the feeding barrel (). The invention further covers a submerged combustion melter equipped with above material feeding system and a process for feeding material into a melter.

Melter feeding system

Mineral wool fibers having a mineral wool fiber composition are manufactured by introducing batch materials into a melter, melting the mineral batch materials in the melter to provide a melt and fiberizing the melt to form the mineral wool fibers. The batch materials comprise i) fibers having a first batch material composition which is different from the mineral wool fiber composition and consisting of scrap fibers which have broken at a bushing producing continuous fibers; and ii) one of more additional mineral batch materials.

A submerged combustion melter is arranged with a melting chamber, which may be cylindrical, and at least five submerged combustion burners.

Submerged combustion melters and methods

High alumina cement is produced in a submerged combustion melter, cooled and ground.

Process for the preparation of high alumina cement

The invention relates to a submerged combustion burner () and to a melter comprising submerged combustion burners (). The burner comprises at least one oxidant feeding tube, at least one fuel feeding tube, a burner head having a peripheral envelope, the fuel and oxidant feeding tubes abutting against the burner head, at least two, preferably at least three, peripheral outward directed nozzles, each of the nozzles having a nozzle outlet, the nozzle outlets being arranged on a peripheral line on the peripheral envelope of the burner head, the nozzle outlet axis being inclined by an angle of 5 to 30&#xb0; to the horizontal, and the nozzles practiced in the burner head being connected to the oxidant feeding tube and to the fuel feeding tube.

Submerged combustion melter

The invention relates to a submerged combustion burner () and to a melter comprising submerged combustion burners (). The burner comprises a substantially parallelepipedic body, the melt oriented face of which shows a longitudinal slot, two opposite walls of the slot comprising a series of nozzles each supplied separately with fuel and oxygen containing gas. The slot advantageously shows a narrow opening comprised between 10 and 30 mm, preferably between 15 and 25 mm, most preferably about 20 mm. The burner is advantageously made of steel plates, preferably high temperature resistant steel. The walls of the slot as well as the melt oriented face of the burner are advantageously cooled. According to the invention, the parallelepipedic burner body comprises a first external longitudinal volume showing a generally U-shaped cross-section and a second internal longitudinal volume fitted within the said first external longitudinal volume, showing also a generally U-shaped cross-section, one of the longitudinal volumes comprising a connection to a supply of oxygen and the other comprising a connection to a supply of fuel gas. The ends of the branches of the longitudinal volumes are connected to the burner nozzles. A flange is arranged around the parallelepipedic burner body at a distance from the melt oriented face of said body.

Burner for submerged combustion melter

The present invention relates to a melter assembly () for melting solid raw batch material, which comprises a submerged combustion melter section () and an afterburner section (), wherein the submerged combustion melter section is designed to contain the melt bath () at a maximum melt level (') and comprises at least one submerged combustion burner () and a melt outlet (), and wherein the afterburner section () is designed as a space contiguous with, and in continuity of, the internal space defined by the submerged combustion melter section (), and arranged over the maximum melt level (&#x2032;) of the submerged combustion melter section (). The afterburner section () is dimensioned such that the gases escaping from the melt bath () remain for at least 2 seconds at a temperature of at least 850&#xb0; C. in said afterburner section (), prior to being evacuated to the environment. The invention also relates to a process making use of such melter assembly ().

Submerged combustion melter and method

The invention relates to a submerged combustion burner () and to a inciter comprising submerged combustion burners (). The burner comprises at least one oxidant feeding tube, at least one fuel feeding tube, a burner head having a peripheral envelope, the fuel and oxidant feeding tubes abutting against the burner head, at least two, preferably at least three, peripheral outward directed nozzles, each of the nozzles having a nozzle outlet, the nozzle outlets being arranged on a peripheral line on the peripheral envelope of the burner head, the nozzle outlet axis being inclined by an angle of 5 to 30&#xb0; to the horizontal, and the nozzles practiced in the burner head being connected to the oxidant feeding tube and to the fuel feeding tube.

Vitrified products are manufactured using a melt produced from batch materials comprising 35 to 100 w % man-made mineral fibers produced in a submerged combustion melter.

Process for manufacturing vitrified material by melting

The present invention relates to a process for melting solid batch material, comprising the steps of introducing solid batch material into a melter, and melting the solid batch material in the melter by submerged combustion and subjecting the melt to a flow pattern which when simulated on a computer by making use of common fluid dynamic equations shows a substantially toroidal melt flow pattern in the melt, comprising a major centrally inwardly convergent flow at the melt surface, the central axis of revolution of the toroid being substantially vertical. The invention further relates to a melter assembly for carrying out the process. The toroidal melt flow pattern is achieved by suitable arrangement, angle and spacing of multiple submerged combustion burners in the floor of the melter.

Method and apparatus for melting solid raw batch material using submerged combustion burners

The claims define a submerged combustion melter comprising a submerged combustion burner () comprising three concentric tubes, all being closed at one end and open at the same opposite end, the internal tube () being connected to a source of oxygen containing gas (), the middle tube () surrounding the internal tube () being connected to a source of fuel gas (), and the outer tube () being connected to a source () of oxygen containing gas. The claims are also directed to a method of introducing a flame and/or combustion products into a melt from a submerged combustion burner and also directed to the use of the burner as a submerged combustion burner in a melter.

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Majcichov, Slovakia

Gerard Demott