The invention relates to the field of drying ovens for crosslinking a continuous mat of mineral or plant fibers, particularly mineral wool, of the glass wool or rockwool type. These mats are intended to be cut to later form, for example, panels or rolls of thermal and/or acoustic insulation.
The manufacture of such mats of insulating fibers primarily involves fiberizing and depositing fibers on a perforated mobile conveyor or transporter. The newly-formed mass of fibers is pressed against the conveyer using suction boxes arranged under the transporter on which they are placed. During the fiberizing, a binder is sprayed in solution or suspension in a volatile liquid such as water onto the stretched-out fibers, this binder having adhesive properties and usually containing a heat-curable material such as a thermosetting resin.
The primary layer of relatively loose fibers on the collecting conveyor is then transferred to a heating device commonly known in the relevant field as a crosslinking drying oven. The continuous mat of fibers passes through the drying oven over the entire length thereof, thanks to conveyors facing one another above and below, pressing the mat between them and the separation of which is adjustable. Such a mat therefore exhibits a density that varies according to the amount of compression applied by the two conveyors in the drying oven.
As it passes through the drying oven, the mat is simultaneously dried and subjected to a specific heat treatment that causes the thermosetting resin in the binder present at the surface of the fibers to polymerize (“cure”, “set” or “harden”).
The procedure used to cause the binder to cure is to pass heated air through the entire thickness of the mat such that the binder present throughout the thickness of the mat is itself progressively raised to a temperature above its curing temperature. For this purpose, the crosslinking drying oven is made up of an enclosed space constituting a closed chamber in which there are a series of boxes supplied by burners with hot air circulated by blowers. Each box thus defines an independent heating zone in which specific heating conditions are set. The boxes are separated by walls having openings for the mat and the upper and lower conveyors. The use of a plurality of boxes advantageously allows a graduated and better controlled increase in the temperature of the mat as it passes through the drying oven and prevents the appearance of hot spots caused by locally excessive heating, or alternatively the presence within the mat of zones in which the binder has not been fully polymerized. A drying oven used in the method of manufacturing mineral wool thus very often comprises a multitude of boxes (for example between 2 and 10) and known means for establishing variable and independent thermal conditions within each box.
At the present time, the drying ovens used do, however, consume a great deal of energy. It is an object of the present invention to reduce the energy consumption of such drying ovens.
To this end, one subject of the invention is a drying oven for crosslinking a continuous mat of mineral or plant fibers, comprising:
Such a drying oven makes it possible to have a compact device that combines heating, blowing and supply ducts which are reduced to the strict minimum, thus minimizing pressure drops and improving the efficiency of the blowing. Such a configuration in particular makes it possible to achieve an appreciable saving on the energy needed to manufacture the mineral wool.
What is more, thanks to its compactness, the device can be included inside the jacket of insulating material provided around the box, so as to minimize heat losses in the ducts and so as to heat the ducts by radiation from the box.
According to particular embodiments, the drying oven includes one or more of the following features considered in isolation or in any technically feasible combinations;
Another subject of the invention is a box as described hereinabove and in particular comprising:
A final subject of the invention is a production line comprising a drying oven as described hereinabove. This is in particular a production line for the manufacture of a continuous mat of mineral and/or plant fibers, comprising at least one fiberizing unit for producing a continuous mat of mineral and/or plant fibers, a conveyor for conveying the mat and a drying oven as described hereinabove.
Such a production line may further comprise means for shaping the mat into panels and/or into rolls.
The invention will be better understood from reading the description which will follow, given solely by way of example made with reference to the attached drawings in which:
bis schematically illustrate the operation of the box according to
bis illustrate a second example of another box according to the invention, this time comprising two radial turbines within a drying oven according to the invention.
Throughout these figures, the same numbering denotes elements that are identical or that perform the same function within the drying oven.
By way of example in the case of glass wool, the line comprises a fiberizing unit 1, for example using the method of fiberizing by internal spinning. The fiberizing unit comprises a hood (not depicted in
Heating means 7, for example of the induction type, are used to keep the glass and spinner at the correct temperature. The veil 6 is enclosed by a gaseous stream of air introduced under pressure, indicated schematically by the arrows 8. The torus 6 thus created is surrounded by a device that sprays the binding containing a thermosetting binder in aqueous solution, only two elements 9 of which have been depicted in
This may for example be a phenolic binder or an alternative binder with a low formaldehyde content, preferably even containing no formaldehyde, which binders are sometimes termed “green binders” in particular since they are at least partially derived from a renewable, particularly plant-based, raw material base, in particular based on hydrogenated or non-hydrogenated sugars.
The end of the fiberizing hood is made up of a fiber receiving device comprising a conveyor incorporating an endless belt 10 which is permeable to gases and to water, under which are positioned suction boxes 11 for gases such as air, fumes and excess aqueous compositions derived from the fiberizing process described hereinabove. A mat 12 of glass wool fibers intimately mixed with the binding compound is thus formed on the belt 10 of the conveyor. The mat 12 is conveyed by the conveyor 10 into a drying oven 14 where the thermosetting binder is crosslinked.
As depicted in
The enclosed space normally has two conveyors 18A, 18B passing through it to transport and size the mat 12. These conveyors are, for example, set in rotation by motors placed on the floor (and not depicted in
While allowing the passage of the hot gases that encourage the binder to set quickly, the conveyors 18 usually compress the mat 12 in order to give it the desired thickness. By way of example, for a rolled up panel, this thickness is typically between 10 and 450 mm, the density of the layer of glass wool being, for example, between 5 and 150 kg/m3. A distinction can thus be made for example between products referred to as low-density products, for which the mass per unit volume varies between 5 and 20 kg/m3 and products referred to as high-density products, in which the density varies between 20 and 150 kg/m3.
The mineral wool mat sprayed with binder first of all enters an inlet lock 17A, provided with a fume extraction hood 19A, these hoods being connected to a dedicated circuit for the treatment of said fumes (which is not depicted in the figures). In this first inlet lock 17A, the hot air introduced into the mat first of all allows the residual water present in the mat of fibers to vaporize.
In the first boxes, for example boxes 21-24, the hot air is introduced from the bottom of the drying oven and removed from the top, after having passed through the mat. In the following boxes, for example boxes 25-27, the hot air is introduced this time from the top of the drying oven and removed from the bottom.
In all the figures, the circulation of air through the drying oven is indicated by arrows 30. The direction in which the mat circulates is indicated by the arrows 31. Of course, each box has an inlet and outlet opening or lock which is dimensioned to allow the passage of the mat of fibers.
The use of a plurality of boxes allows the temperature of the mat of fibers to be increased progressively up to a temperature higher than the curing temperature of the binder present on the fibers of the mat. The mechanical properties of the end-product are dependent on perfect control of the temperature in the various boxes, in particular if a green binder is used, as indicated above.
The additional fumes generated in the boxes are generally removed in an outlet lock 17B, via a hood 19B.
Each box 21-27 comprises a central compartment 40 surrounded by an insulating material, generally made of glass wool, the central compartment being surrounded by an external metal enclosed space. This then delimits an external insulating jacket for the drying oven surrounding the plurality of boxes (which is not depicted in
Although not depicted in
As indicated previously, the object of the present invention is to reduce the energy consumption of present-day drying ovens.
To this end, one subject of the invention is a drying oven as will now be described in relation to
In a drying oven according to the invention, use is made of a compact device combining heating, blowing and supply ducts reduced to the strict minimum, thus minimizing pressure drops while at the same time improving the efficiency of the blowing.
In particular, in order to achieve such a result and according to one essential feature of the present invention, the present drying oven comprises at least one box which incorporates a specific device for generating and circulating the stream of hot gas that allows the progressive curing of the binder. For preference, all of the boxes of a drying oven according to the invention are constructed in this way.
The principles of operation and certain structural features of a drying oven/of a box according to the invention are described in greater detail and nonlimitingly hereinafter, with the aid of
Orifices or openings 47 and 48 are made on each side of the central compartment 40 of the box, as visible in
A radial turbine 50 is situated on the upper wall 45 of the central compartment 40, facing the hot-gas outlet orifice 48, such that its axis of rotation is situated substantially vertically. The housing of the turbine 50 may be either fixed directly to the wall 45 or alternatively connected to the outlet orifice 48 via an extraction duct (which is not depicted in
This turbine is thus positioned on the compartment 40 in such a way that it draws gas through the gas outlet orifice 48 after it has passed through the mat 12. The gas (in theory air initially) is discharged from the turbine in a radial direction as indicated schematically by the arrows 30, toward recirculation loop means comprising, for example, a divergent 51 hermetically connected to the outlet of the turbine and a lateral blowing duct 52 which then distributes the discharged gas over the entire length L of the box. The divergent 51 is hermetically extended by a lateral blowing duct 52 situated along and advantageously over the entire surface of a lateral wall 43 of the central compartment 40. Such a configuration makes it possible considerably to reduce the bulk of the lateral blowing duct 52, which may therefore be small in thickness. For preference also, the cross section of the duct 52 is rectangular. Optionally, the duct 52 is provided with internal guide walls, for better distribution of the stream across the duct, and when reintroducing it into the compartment 40 via the orifice 47.
The lateral blowing duct 52 opens onto an inlet orifice 47 of the central compartment, which preferably extends over the entire length of the compartment 40. The hot air is thus reintroduced into the compartment 40 underneath the mat of fibers 12 and made to pass through it again under the effect of the suction created on its opposite face by the turbine 50.
For a better understanding of how the invention works, an external insulating jacket 49 has been depicted in
Within the compartment 40, heating means 53 are also provided according to the invention (these being depicted in
bis this time is a schematic view from above of the box 20 already depicted in
For preference, according to such a configuration comprising just one single turbine 50, this turbine is situated in a central position on the box 40. The turbine 50 of course comprises a housing surrounding it in an airtight manner. It has a shape of any suitable type so that the turbine produces a suction effect at the inlet of the housing and a blowing effect at the outlet of the housing.
The in-built heating and extraction device, preferably included within each box of a drying oven according to the invention, comprises, in addition to the radial turbine 50, recirculation means for recirculating the hot gases at the outlet of said turbine so that these can be reinjected onto the opposite face of the mat of mineral wool, with reference to the outlet orifice 48 for said gases. The recirculation means illustrated in
According to this embodiment, the in-built heating and extraction device thus draws the hot gases in from one side of the mat and reinjects them onto the opposite side of the compartment, so as to produce an upward vertical stream of hot gases through the mat.
The figures also depict a configuration whereby the turbine 50 is situated above the compartment 40, which means to say in the upper part of the box. It is obvious that, according to the invention, the turbine may equally be positioned this time underneath the compartment 40, which means to say in the bottom part of the box. In such a case, the outlet orifice 48 for the stream of hot gas 30 is then made in the lower wall 46 of the central compartment 40 and the turbine is mounted on the lower wall 46 of the central compartment, the inlet of the turbine being arranged facing the hot-gas outlet orifice 48. With such a configuration, the recirculation means described above this time allows said gases to be conveyed from the outlet of the turbine 50 to the gas inlet orifice 47 of the compartment 40, said gas inlet orifice 47 then being made in the upper part of the compartment 40 so as to allow said gases to recirculate and to pass through the mat 12 in a downward stream. In this alternative form, the turbine 50 is then arranged underneath the compartment 40 and the extraction of the hot gases is performed on the underside of the box, whereas the hot gases are reintroduced into the compartment on an upper side of the box. The heating and extraction device as a whole is thus identical to the one described earlier but arranged the other way up.
As described earlier, the heating and extraction device according to the invention thus forms an in-built hot-gas recirculation circuit allowing the crosslinking of the binder, thereby limiting heat losses and energy consumption.
As illustrated in
According to the invention, as a general rule, each heating device 53 is independent and comprises means for controlling the temperature and flow rate of the hot gases. The heating device is, for example, configured to produce a stream of hot gas of which the temperature, as it passes through the mat of fibers 12, is between 200° C. and 250° C., the temperature of course being dependent on the type of binder used. Other boxes may be set to different temperatures. As far as the flow rate is concerned, the device is, for example, configured so that the turbine produces a gas flow rate of the order of 1000 to 60 000 m3/h.
bis illustrate another embodiment of the invention in which the box comprises two heating and recirculation devices, including two distinct radial turbines 50A and 50B, the two turbines being arranged relative to one another with central symmetry on the central compartment of the box. The box thus comprises two hot-gas circuits, the first circuit occupying a first half of the length of the main chamber whereas the second circuit occupies the second half.
With such a configuration, each turbine 50A, 50B is connected to separate recirculation means namely respectively:
As depicted in
For preference, the two orifices together cover substantially the entirety of the length of the central compartment 40. According to another advantageous configuration depicted in
Number | Date | Country | Kind |
---|---|---|---|
1555612 | Jun 2015 | FR | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/FR2016/051477 | 6/17/2016 | WO | 00 |