Projects / Programmes
Improvement of the mineral wool fiberization process
| Code |
Science |
Field |
Subfield |
| 2.05.05 |
Engineering sciences and technologies |
Mechanics |
Fluid mechanics |
| Code |
Science |
Field |
| T150 |
Technological sciences |
Material technology |
| Code |
Science |
Field |
| 2.03 |
Engineering and Technology |
Mechanical engineering |
mineral wool, product quality improvement, flow visualization, computer-intensive methods
Researchers (1)
| no. |
Code |
Name and surname |
Research area |
Role |
Period |
No. of publicationsNo. of publications |
| 1. |
35646 |
PhD Benjamin Bizjan |
Mechanics |
Head |
2017 - 2019 |
132 |
Organisations (1)
Abstract
Mineral wool is a fibrous material commonly used for thermal and sound insulation of buildings and appliances, thus contributing to a reduction of energy consumption for heating and cooling as well as noise pollution, which is one of the basics of sustainable construction. Main mineral wool subtypes are glass and rock wool, and the manufacturing process of both is highly complex and energy intense. Despite the maturity of this technology, some technological challenges (presence of unfiberized material in mineral wool, wheel abrasion, non-uniform liquid binder distribution and lack of real-time process monitoring) remain inadequately resolved, limiting quality improvements and production costs reduction. Key for solving these issues is a good knowledge of the melt fiberization process on spinners and of pneumatic transport of fibers to the collecting chamber grid, where primary layer is formed.
A review of relevant scientific publications shows these production segments to be inadequately researched because their existing models are mostly empirical or integral-scale, and as such not accurate enough for description of relevant phenomena. Another issue is the inaccessibility of industrial research results. In proposed project we aim to improve the understanding of fiberization-related phenomena, with the aim to reduce the end product manufacturing costs by 5-10% as well as thermal conductivity and density by at least 5% (consequent quality improvement). For this purpose we will utilize the cutting edge technology for flow visualization: high-speed cameras and computer-intensive analysis methods. At the Faculty of mechanical engineering in Ljubljana, we have already contributed to a significant increase of the mineral wool-oriented research as our recent journal and conference papers represent more than half of the world's publications in this field of research. The emphasis of our project will be on addressing key open issues of mineral fiber production, and then implementation of results into the industrial environment. The topic will be approached in 5 work packages (WP):
WP1: Design and construction of an experimental station for fiber production. A scaled-down reproduction of industrial production lines will reduce costs and technical difficulties in performing of experiments.
WP2: Mineral melt fiberization modeling. The phenomenon will be visualized by high-speed imaging, supported by our own computer-intensive algorithms for analysis of flow velocity (ADMflow) and temperature (patented method) conditions.
WP3: Modeling of fiber pneumatic transport by the blow-away flow, and binder wetting. Through high-speed and IR imaging and flow velocity-temperature field analysis, we will address the problem of non-uniform spatial distribution of fibrous structures and binder droplets, and develop more advanced fiber transport models.
WP4: Modeling of the mineral wool primary layer formation on the accumulation grid of the collecting chamber. The effect of blow-away and suction flows on accumulation grid velocity conditions and consequently the primary fiber layer structure will be determined. To characterize the layer properties we will develop a method for analysis of anisotropic fibrous structures.
WP5: Pilot testing of project results in the industry. The effects of the findings from WP2-WP4 on manufacturing chain improvements (reduction in production price, increase in quality) will be verified with end users. China is one of the most promising markets for the transfer of knowledge into practice, as we have already established contact with one of the large rock wool manufacturers.
By determining the accurate mechanisms of phenomena investigated in this project it will be possible, through more efficient process monitoring and control, to improve the competitiveness of mineral wool manufacturers. At the same time, our research will lead to further development of robust and low-cost computer-aided methods for flow visu
Significance for science
The mineral wool technology is known to be controlled by a few multinational companies (in Europe: Rockwool, Paroc and URSA) that sell complete production lines to other rock wool and stone wool manufacturers, but keep their knowledge largely confidential from their clients. Consequently, the clients (other mineral wool manufacturers) are unable to optimally adjust the mineral wool production technology for their specific needs, and are strongly interested in obtaining the knowledge required for process optimization. For this reason, open research is crucial for further development of this field of science and technology, as it will improve the competitiveness between mineral wool producers and motivate them for technological innovations.
As a response to these issues, there has been a significant increase in the amount of mineral wool-oriented research in Slovenia. At the Faculty of mechanical engineering in Ljubljana, we have published more than half of the world's journal and conference manuscripts in this field of knowledge. Therefore, our work greatly contributes to this science field. Besides, our research topic can be categorized as the development of improved materials as the end products, which is one of the important points of Slovenia's development policy.
Besides the mineral wool production technology, our project will, due to its interdisciplinarity, also contribute to development of computer intensive methods for flow analysis. The possibility of velocity and temperature measurement by using standard (visible-light) digital cameras instead of more expensive PIV and infrared cameras will make process measurements in scientific and industrial environment significantly less complex and more affordable.
Significance for the country
Our research work will have a direct effect on the company Abelium and its clients, as the results of my work will be used to solve real world problems in industry. Our potential customers are the large multinational mineral wool producers (Knauf Insulation, Rockwool, Paroc Group, Saint-Gobain, URSA…), which have 75 production plants in the EU27 zone alone, controlling about 90% of its market. This figure includes 2 large plants in Slovenia (Knauf Insulation – Škofja Loka, URSA – Novo mesto). Among potential clients outside of the EU zone, mineral wool manufacturers in China (largest production volume globally) are especially important as there are around 100 large mineral wool factories, and most of these have not yet achieved the European level of quality. Through the Guandong University of Petroleum Technology, we have already established contact with a large Chinese rock wool manufacturer Bosheng Rockwool Company, and plan to extend our cooperation to other manufacturers in the region. A positive effect of postdoc project results can also be expected on small and medium Slovenian enterprises, which develop and sell industrial equipment in this branch (Izoteh, BKL).
Due to the lack of scientific research, this branch of industry is known to still face unsolved technological problems in the phase of melt fiberization and primary layer formation. This presents a major obstacle in further development of the industry. Besides the base field of application as heat and sound insulation, innovative uses of mineral wool are growing (e.g. substrates for plant growing by the hydroponic technology), resulting in a higher added value of products. However, production of such products brings along even stricter requirements for high quality and well monitored manufacturing process, which is difficult to maintain by the state-of-the-art technology. Industrial partners, who will decide to cooperate with us, can expect to become more competitive in the market, as the realization of this project will ultimately reduce the production price and improve the quality of mineral wool insulation products.
Most important scientific results
Interim report,
final report
Most important socioeconomically and culturally relevant results
Interim report,
final report
