Solutions for stone wool insulation – Rest fraction from production process. Mix of cuts, out of standard products.



Reference flow in the MFA for which is suitable the technology


Incoming input

Mineral wool is a natural insulating material. It means both rock (rock) and glass wool. Its advantages include: very high thermal insulation, non-flammability and fire resistance, mechanical strength combined with resilience, chemical and biological resistance, water resistance and vapor permeability, and the ability to absorb sound. Mineral wool waste is produced at the producers of mineral wool and its users during renovation works of heating devices, as well as demolition and modernization works of construction and industrial buildings. Stone fiber waste can be contaminated or even reinforced with a metal mesh. They can also be mixed with building debris or refractory scrap. In this case, they must first be pre-treated, i.e. cleaning and segregation in the screening process. Then you can develop and dispose of them.

Outgoing output

In the group of wastes containing inorganic man-made fibers the largest amount is waste of mineral wool based on stone and glass fibers. The possible directions of their management are determined both by the degree of contamination of waste, the degree of their devitrification (the amount of crystallized glass components created during the formation of the product), and the economic viability of economic use. The most important directions for the management and disposal of fibrous stone waste include the production of putties, adhesives and insulating masses as well as heat-resistant plates and casings. Mineral fillers (granulated wool) are produced from waste mineral wool. Waste is also used in the production of construction ceramics (used in the ceramization process) and for the production of melted products.

Technology description

d1) In the production of putties, adhesives and insulating masses, the share of fibrous waste is 40-50%. The products obtained are used for joining insulating products, sealing of partitions, joints and expansion joints.

d2) In turn, in the production of heat-resistant panels and casings, the share of waste is 15-20%. Such panels can be used as fire protection of steel constructions.

d3) Granulated wool from stone fibers is used in building industry to insulate partitions, openings, crevices and cavities.

The utilization of fibrous waste through briquetting allows them to be melted in shaft furnaces in order to produce melted products. In turn, the most important direction for the management and disposal of glass fiber waste is the production of acid-resistant putties or acid-resistant, clinker and stoneware products. Fiber glass waste is used as a flux. This type of waste is used in the manufacture of insulation boards as well as in the ceramization process. Fiber glass waste is used as an addition to the production of particular types of melted products. These waste, after crushing to below 2 mm, can be used as a basic component of acid-resistant putties. These kits are produced with the addition of soda or potassium glass. It is also possible to produce insulating boards on an inorganic bond from these wastes. They can also be used as an additive in the production of acid-resistant stoneware and clinker products, as well as in addition to brick masses. In addition, glass products made of container glass, e.g. candles or foam glass, can also be produced from said fibrous waste. An important direction for waste management of mineral wool, both stone and glass, is their disposal in the ceramization process. In order to determine the economic feasibility of using waste rock fibers, longitudinal cutting dust of the products on the mineral wool process line has been subjected to laboratory tests. They consisted in adding waste fibers to construction ceramics. Properties of the obtained materials with the addition of mineral fiber are presented in tab. 3. The analysis of these properties shows that the addition of 5% and 10% of waste stone fibers in relation to the base sample does not change the compressive strength to such an extent that would indicate deterioration of the quality of the products. The waste stone fibers were also subjected to industrial tests, the purpose of which was to check the correctness of technological assumptions, developed on the basis of laboratory tests. These tests consisted in the use of these fibers for the production of bricks. The process of manufacturing ceramic building materials was carried out in accordance with the technological regime applicable in the brickyard. Due to the difficulties associated with the dosing of fiber wastes, their share in the raw material set ranged from 1.5 to 4.5% by weight. A study of physical and mechanical properties was carried out to assess the quality of bricks with the addition of stone fiber. Burnt construction ceramics were subjected to open porosity, apparent density, water absorption and compressive strength tests. Properties of bricks received are shown in tab. 4. The analysis of these properties shows that the addition of 1.5% and 4.5% fiber waste increases the compressive strength. It is worth mentioning, however, that the addition of 6% by weight of these fibers resulted in a significant reduction in strength.

Organizative processes to support closing the loops

For technical and logistical reasons, the organization of the recycling process should take place at the place of production of mineral wool.
This will ensure minimizing the costs of preparation for transport and the transport itself.

Practitioners opinion

After prior fragmentation of such waste, a special granulate is created, which is then used as an addition to materials such as cement or bricks. However, mineral insulation is not only natural ingredients, but also a type of binder, which is a chemical compound and must be processed into specially prepared treatment centers. Stone wool producers are generally open to further develop their facility and to take up new tasks associated with this innovation process.

Possible limiting factors

It should be noted that the basic feature of mineral wool products is their low volumetric weight. The soft mineral wool board has a density of 60 kg / m3, the semi-hard plate has a density of 80 kg / m3 to 120 kg / m3. In turn, the density of the hardboard varies in the range from 150 kg / m3 to 180 kg / m3.

PP’s opinion of the technology

The project partner has looked into this technology in detail and compared it with other possible technical solutions. This technology was found to be best regarding costs and its performance.

Concept and conclusions how the technology can affect the CE effect

On the basis of the conducted tests, it can be concluded that mineral wool waste can be used economically in production processes, for example in the production of ceramic building materials (bricks). In the ceramization process (under the influence of temperature), permanent phases are formed - as a result of combining the waste of stone fibers with another raw material subjected to sintering. After mechanical processing, i.e. crushing and removal of metallic impurities and plastics, mineral wool waste is added in the amount of 2-3% by weight to brick clays. In the firing process at 950-1100oC, glassy phase formation occurs. The obtained product is qualitatively similar to typical ceramic products.

Is the technology a BAT?

No information

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