Fly Ash Large-Scale Rock Wool Melting Electric Furnace
Product Introduction
1. Product Overview
Product Name: Special Melting Electric Furnace for Large-Scale Fly Ash Rock
Wool Production
Manufacturer: Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd.
This furnace is designed for collaborative large-scale disposal of
domestic waste incineration fly ash and hazardous waste fly ash.
Taking water-washed dechlorinated fly ash as core raw material,
mixed with basalt, metallurgical slag and silicon-aluminum
auxiliary materials, it melts raw materials at high temperature to
produce homogeneous molten glass continuously, which is directly
delivered to centrifugal fiber forming line for producing fireproof
thermal insulation rock wool. It realizes thorough harmless
treatment and high-value resource utilization of fly ash, fully
complying with hazardous waste disposal, circular economy and
carbon peaking & carbon neutrality policies.
Adopting three-phase submerged arc melting structure, fully sealed
water-cooled furnace body and complete PLC intelligent control
system, the furnace is specially optimized for fluctuating
composition, high chloride and heavy metal content of fly ash. It
can operate stably and continuously for over 8000 hours, with
dioxin decomposition rate ≥99.99%. Heavy metals are fully
solidified in glass lattice, and leaching indicators are far better
than national hazardous waste control standards. One single set can
support large-scale rock wool production line with annual output of
20,000–50,000 tons.
2. Complete Supporting System Composition
The full set of equipment is delivered as an integrated unit,
consisting of 10 core systems:
- Custom special furnace transformer multi-stage voltage regulation
power supply system
- High-voltage power distribution + PLC full-automatic integrated
electric control & remote monitoring system
- Three-phase self-baking electrodes, hydraulic lifting & clamping
assembly
- Low-impedance energy-saving water-cooled short network
(water-cooled cables, forged copper tiles, conductive cross arms)
- Segmented fully water-cooled sealed furnace shell, high-chromium
corundum anti-corrosion lining system
- Closed soft water circulating cooling system (full cooling coverage
for furnace body, hood and holders)
- Full-automatic sealed weighing batching & top continuous feeding
system
- Constant temperature & pressure molten slag outlet, continuous
self-flow launder device
- Furnace bottom iron tapping hole + automatic opening & plugging
mechanism (separate iron impurities from fly ash)
- Fully enclosed flue gas collection system with reserved interface
for integrated desulfurization, denitrification & dust removal
equipment
3. Standard Technical Parameter Table
| Parameter Item | Technical Index | Remarks |
|---|
| Matched Transformer Capacity | 4000–8000kVA (customizable) | Selected according to annual rock wool output of 20,000–50,000 tons |
| Primary Input Voltage | 10kV / 35kV (optional) | Matches power grid of power plants & hazardous waste disposal parks |
| Secondary Voltage Regulation Stages | 20-stage on-load electric regulation | Adaptable to melting, homogenization & stable slag flow working
conditions |
| Max Melting Working Temperature | 1450–1600℃ | Completely decompose dioxins, stabilize viscosity for fiber forming |
| Hourly Molten Slag Output | 6–15t/h | Corresponding to annual rock wool finished product output of
20,000–50,000 tons |
| Maximum Fly Ash Mixing Ratio | 30%–50% | Water-washed dechlorinated fly ash, adjustable proportion on demand |
| Electrode Specification | Φ500–Φ600mm three-phase self-baking electrodes | Large cross-section conduction, uniform temperature without dead
zone in molten pool |
| Pitch Circle Diameter | Φ2000–2800mm | Optimize molten pool circulation to offset influence of fluctuating
fly ash composition |
| Effective Furnace Volume | 18–40m³ | Large volume buffer tank to guarantee continuous downstream fiber
forming |
| Electrode Lifting Control | PLC closed-loop automatic arc stabilization regulation | Response time ≤0.5s, temperature fluctuation within ±10℃ |
| Total Circulating Cooling Soft Water Flow | 110–220t/h | Inlet water temperature ≤30℃, forced cooling for all water-cooled
components |
| Continuous Stable Operation Cycle | ≥8000h | Long-period uninterrupted production, reduce shutdown loss |
| Flue Gas Collection Mode | Fully closed low hood negative pressure gas collection | No scattered dust or odor, meets EIA acceptance standard |
| Control Mode | Touch screen centralized monitoring + cloud remote operation &
maintenance | Full-process automatic interlock of temperature, current, feeding
and cooling |
| Total Equipment Footprint | 160–260㎡ | Modular layout, suitable for new-built or renovated rock wool
production lines |
4. Core Product Advantages
4.1 Specialized Customization for Fly Ash, Thorough Harmless
Treatment
Optimized molten pool structure targeting high chloride, heavy
metals and fluctuating composition of incineration fly ash. Under
high-temperature oxygen-deficient melting environment above 1450℃,
dioxin destruction rate reaches 99.99%. Heavy metals such as lead,
cadmium and chromium are solidified into stable glass body, with
leaching toxicity far below national standards, completely solving
problems of insufficient landfill capacity and secondary pollution
of fly ash.
4.2 Large-Scale Continuous Production, Stable Rock Wool Quality
Large-volume buffer molten pool offsets fluctuation of fly ash raw
material composition, long-term stable acidity coefficient and
viscosity of molten slag, uniform fiber forming. Tensile, fireproof
and thermal insulation performance of rock wool meets national
standards. One single furnace can support annual output of tens of
thousands tons of rock wool, no need to connect multiple small
furnaces, lowering infrastructure and operation cost.
4.3 Low Carbon & Energy Saving, Greatly Reduced Comprehensive
Disposal Cost
Using electric energy as heat source instead of traditional
coal-fired cupola, no sulfur & nitrogen emission from coal
combustion. Equipped with low-loss special transformer and
optimized water-cooled short network, power consumption per ton
molten slag is reduced by 12%–20% compared with conventional rock
wool electric furnaces. Fly ash replaces natural basalt ore to cut
raw material cost. Each ton of rock wool reduces carbon emission by
about 245kg vs pure ore production line, eligible for carbon
emission reduction policy subsidies.
4.4 Fully Sealed Environmental Structure, Easy to Pass Hazardous
Waste EIA
Negative pressure fully sealed design for furnace body, feeding
port and slag outlet. Smelting flue gas is uniformly collected and
connected to matched dust removal & deacidification system. No
scattered fly ash dust or odor leakage, perfectly matching
environmental approval requirements of hazardous waste
comprehensive disposal centers and waste incineration collaborative
resource projects.
4.5 Intelligent Full-Automatic Control, Low Labor Dependence
The whole system is equipped with multiple preset special process
programs for fly ash rock wool production, one-click switching of
working conditions with different fly ash mixing ratios. Automatic
alarm and interlock shutdown for water shortage, over-temperature,
over-current and excessive flue gas pressure. Support remote cloud
data viewing and fault diagnosis, only 1–2 operators required per
shift.
4.6 One-Stop Turnkey Complete Service
Shaanxi Chengda provides full-chain services including pre-site
survey, fly ash batching process scheme, equipment design &
production, whole-set delivery, on-site installation, furnace
baking & temperature rising, production line linkage commissioning
and operator process training. Complete supporting accessories
including tapping machines, water-cooled cables, hydraulic stations
and electric control systems are self-produced, no third-party
accessories required for customers. The whole machine enjoys
12-month quality warranty with nationwide on-site technical
after-sales service.
5. Applicable Raw Materials & Production Line Scenarios
- Water-washed dechlorinated fly ash from domestic waste incineration
plants (core raw material)
- Collaborative mixing of industrial solid wastes such as
metallurgical slag, fly ash, tailings and waste glass
- Rock wool resource production lines matched with hazardous waste
disposal centers & waste incineration power plants
- Large-scale rock wool manufacturing bases of solid waste circular
industrial parks & environmental new materials
6. Enterprise Supporting Service Introduction
Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. devotes
to R&D and manufacturing of solid waste resource melting
electric furnaces, main products include fly ash rock wool
furnaces, molten slag conditioning furnaces, rare & precious metal
recovery submerged arc furnaces, DC plasma melting furnaces and
other complete sets of equipment. We can customize furnace type and
power according to customer’s fly ash treatment capacity, target
annual rock wool output and plant power supply conditions,
providing integrated turnkey engineering services including
complete process design, on-site installation & commissioning and
lifetime maintenance.
Energy- Rock wool electric furnace with ISO9001 certification
