1. ROCK WOOL AS A MATERIAL 

Rock wool is a mineral non-organic fibrous material of excellent and distinguished properties and characteristics. It is efficiently utilized in all fields of thermo-acoustic insulation; furthermore it is used in many industries and agricultural activities.

          Rock wool is basically manufactured by melting mix of basalt, limeStone(G636) & coke  in a special vertical furnace ( Cupola Furnace ) at a considerable high temperature (1500°C approx.), Then spinning the molten rocks into raw long fibers. The Rock wool fibers are then processed through different chemical and mechanical operations to end up with the final desired product of the specified physical and chemical properties and specifications.

          Rock wool products are made in different types with different sizes and forms to suit the different application needs. Rock wool basic types are:

1. Loose wool.
2. Stitched mattresses.
3. Felted blankets.
4. Semi rigid panels.
5. Rigid panels.
6. Pipe sections.

2. ROCK WOOL CHARACTERISTICS AND APPLICATIONS:

          Rock wool product posse's superior characteristics and properties among all other thermo-acoustical insulation Materials(Stonet), they are considered to be:

• Very efficient in thermal insulation applications, Rock wool has a low thermal conductivity factor, which complies with the international standards.
• An inorganic, non-aging and dimensionally stable material.
• A water-repellent material.
• A non-combustible and non-flammable material.
• Chemically and electrically inert.
• A non-hazardous and medically safe material.
• Excellent for high temperature applications, it functions efficiently at elevated temperatures (up to 700° C)
• Rock wool is an easy material to deal with in handling and installation.

Rock wool products have many practical uses; the following topics are the main fields of applications for Rock wool:

1. In the thermo-acoustical field rock wool is used for the insulation of building of all types and uses, such as houses, department stores, offices, athletic buildings, airports, etc.
2. In insulating industrial plants buildings and mechanical systems like:

• Cooled stores.
• Refineries.
• Chemical and petrochemical plants.
• Central air conditioning.
• Hot water and chilled water systems.

·        For industrial purposes, Rock wool is used in many industries as:

• Industrial furnaces and ovens.
• Boilers.
• Hot air generators.
• Chimneys.
• Heated or cooled trucks.
• Refrigeration units.
• Ducts.
• Automotive industry.
• Solar system industry.
• Lightweight partition walls industry.
• False ceiling industry.

·        In agriculture, Rock wool is mixed with the soil to ease soil airing, penetration of irrigation water and to ease the growth of the plant roots. Rock wool is also used in the modern non- soil agriculture replacing the soil as the incubator for the plant roots.

3. GENERAL DESCRIPTION OF MACHINERIES.

3.A.  RAW MATERIAL SUPPLY SYSTEM

1.      Three Silos for raw material (Basalt, Coke & LimeStone(G636))

2.     Feeders and weighing system control for raw material silos

3.     Belt Conveyor

4.     Bucket and bucket conveyor system

3.B.  CUPOLA SYSTEM

1.      Cupola Furnace

2.     Troughs from furnace outlet to spinner

3.     Emergency stack

4.     Rockwool Filter

5.     After burning chamber (incinerator)

6.     Heat exchanger to make hot blast

7.     Exhaust gas fan

8.     Chimney

9.     Water cooling system for the cupola furnace

10. Control system for keeping level in furnace

3.C.  SPINNER SYSTEM

1.      Spinner

2.     Strip off air fan

3.     Binder supply system

4.     Cooling water supply

5.     Oil mist supply

3.D. PRIMARY FELT SYSTEM

1.      Collection chamber

2.     Collection chamber fan

3.     Filter for collection chamber

4.     Belt cleaning system

5.     Lift off fan and ducts

3.E.  MAIN LINE

1.      Formation Table

2.     Weighing conveyor

3.     Pre-press machine

4.     Curing oven

5.     Cooling zone

6.     Facing Machine

7.     Disk Trimming Machine

8.     Trimming Recycling System

9.     Band Saw Machine

10. Transversal Cutting Machine

11.  Guillotine Cutting Machine (For Panels)

12. Conveyor

13. Roller conveyor with change direction mechanism

14. Stitching  machine and accessories

15. Guillotine shear (For Felts & Mattresses)

16. Automatic Coiler

17. Panel Shrink Oven