Controlled process for making a chemically homogeneous melt for producing mineral wool insulation

Claim 2

A controlled method for making a chemically homogeneous melt for producing mineral wool which comprises (a) physically homogenizing a mixture of the following formula: ______________________________________ Ingredient % By Weight ______________________________________ Bottom ash 5-30 Cement kiln dust 10-25 Mineral wool production waste 25-35 Slag (from steel making furnace) 7-24 Portland cement binder 3-6 the total weight equalling 100% ______________________________________ (b) compacting said mixture into agglomerate pieces of predetermined size and shape to a density of 125 to 160 lbs./ft 3 ; (c) melting said agglomerate in a cupola furnace; (d) discharging the molten agglomerate into a receiver; (e) passing hot combustion gases into said melt to chemically homogenize the melt and heat the melt to a predetermined temperature; and (f) converting said melt into fibers.

Claim 3

The method of claim 1 in which the binder consists of 5 to 10% of the total of said wool production waste which has been ground to a particle size of less than 50 microns and 3-4% Portland cement.

Claim 4

The method of claim 1 in which said slag is basic oxygen furnace slag.

Claim 5

The method of claim 1 in which said compacted agglomerate includes fine coke in an amount of 10-15% based upon the total weight of the compacted agglomerate.

Claim 6

A controlled method for making a chemically homogeneous melt for producing mineral wool which comprises (a) physically homogenized a mixture of the following formula: ______________________________________ Ingredient % By Weight ______________________________________ Bottom ash 5-30 Cement kiln dust 10-25 Mineral wool production waste 25-35 Slag (from steel-making furnace) 7-24 Binder Hydrated lime 3 Black liquor 5-6 Ground portion of said wool 5 production waste (<50 microns) ______________________________________ (b) briquetting said mixture into agglomerate pieces of predetermined size and shape to a density of 125 to 160 lbs./ft 3 ; (c) melting said agglomerate in a cupola furnace; (d) discharging the molten agglomerate into a receiver; (e) passing hot combustion gases into said melt to chemically homogenize the melt and the heat the melt to a predetermined temperature; and (f) converting said melt into fibers.

Claim 7

A controlled method for making a chemically homogeneous melt for producing mineral wool which comprises (a) physically homogenized a mixture of the following formula: ______________________________________ Ingredient % By Weight ______________________________________ Bottom ash 5-30 Cement kiln dust 10-25 Mineral wool production waste 25-35 Slag (from steel-making furnace) 7-24 Binder Hydrated lime 3 Black liquor 5-6 Ground portion of said wool 5 production waste (<50 microns) ______________________________________ (b) briquetting said mixture into agglomerate pieces of predetermined size and shape to a density of 125 to 160 lbs./ft 3 ; (c) melting said agglomerate in a cupola furnace; (d) discharging the molten agglomerate into a receiver; (e) passing hot combustion gases into said melt to chemically homogenize the melt and the heat the melt to a predetermined temperature; and (f) converting said melt into fibers.