A method for producing mineral wool composites, including: (a) producing a first mineral wool composite by extracting a portion of circulating water to prepare a first binder composition and spraying it onto mineral fibers, while providing clean water to the circulating water; (b) performing (b1) and (b2) in any order or at the same time (b1) pausing extraction of the circulating water for preparation of the first binder composition and (b2) extracting a portion of the circulating water and storing the extracted circulating water in a first tank; (c) producing a second, different mineral wool composite by extracting a portion of the circulating water to prepare a second binder composition, and spraying it onto mineral fibers, while providing clean water to the circulating water, wherein the circulating water is used to clean a production apparatus for producing mineral wool composites and is filtered and reused in the production apparatus.

A method for producing mineral wool composites, including: (a) producing a first mineral wool composite by extracting a portion of circulating water to prepare a first binder composition and spraying it onto mineral fibers, while providing clean water to the circulating water; (b) performing (b1) and (b2) in any order or at the same time (b1) pausing extraction of the circulating water for preparation of the first binder composition and (b2) extracting a portion of the circulating water and storing the extracted circulating water in a first tank; (c) producing a second, different mineral wool composite by extracting a portion of the circulating water to prepare a second binder composition, and spraying it onto mineral fibers, while providing clean water to the circulating water, wherein the circulating water is used to clean a production apparatus for producing mineral wool composites and is filtered and reused in the production apparatus.

A method for the manufacture of mineral wool, is disclosed. In one example, the method comprises reacting an aqueous phenol-formaldehyde resole with free formaldehyde with a first amount of urea, thereby preparing a prereact; contacting the prereact with a second amount of urea; applying the resulting mixture of prereact and second amount of urea, as part of a binder, optionally with additives, to the surface of mineral fibers; and curing the binder on the surface of the mineral fibers. The total amount of urea used ranges 10-40 wt. % relative to the sum of the dry weight of the phenol-formaldehyde resole and the total amount of urea, and the second amount of urea used is at least 40 wt.-% of the total amount of urea. The invention also relates to a mineral wool product with reduced emissions of formaldehyde obtained by the method.

A method for the manufacture of mineral wool, is disclosed. In one example, the method comprises reacting an aqueous phenol-formaldehyde resole with free formaldehyde with a first amount of urea, thereby preparing a prereact; contacting the prereact with a second amount of urea; applying the resulting mixture of prereact and second amount of urea, as part of a binder, optionally with additives, to the surface of mineral fibers; and curing the binder on the surface of the mineral fibers. The total amount of urea used ranges 10-40 wt. % relative to the sum of the dry weight of the phenol-formaldehyde resole and the total amount of urea, and the second amount of urea used is at least 40 wt.-% of the total amount of urea. The invention also relates to a mineral wool product with reduced emissions of formaldehyde obtained by the method.

An aqueous binder for mineral fibers, in particular glass fibers, includes at least one ammonium lignosulfonate or one alkali metal or alkaline earth metal salt of lignosulfonic acid, and at least one carbonyl compound of formula: R—[C(O)R.sub.1].sub.x (I) in which: R represents a saturated or unsaturated and linear, branched or cyclic hydrocarbon radical, a radical including one or more aromatic nuclei which consist of 5 or 6 carbon atoms, a radical including one or more aromatic heterocycles containing 4 or 5 carbon atoms and an oxygen, nitrogen or sulfur atom, it being possible for the R radical to contain other functional groups, in particular hydroxyl or alkoxy groups, especially methoxy groups, R.sub.1 represents a hydrogen atom or a C.sub.1-C.sub.10 alkyl radical, and x varies 1 to 10, the binder being devoid of hydrogenated sugar and of melamine.

An aqueous binder for mineral fibers, in particular glass fibers, includes at least one ammonium lignosulfonate or one alkali metal or alkaline earth metal salt of lignosulfonic acid, and at least one carbonyl compound of formula: R—[C(O)R.sub.1].sub.x (I) in which: R represents a saturated or unsaturated and linear, branched or cyclic hydrocarbon radical, a radical including one or more aromatic nuclei which consist of 5 or 6 carbon atoms, a radical including one or more aromatic heterocycles containing 4 or 5 carbon atoms and an oxygen, nitrogen or sulfur atom, it being possible for the R radical to contain other functional groups, in particular hydroxyl or alkoxy groups, especially methoxy groups, R.sub.1 represents a hydrogen atom or a C.sub.1-C.sub.10 alkyl radical, and x varies 1 to 10, the binder being devoid of hydrogenated sugar and of melamine.

A sizing composition for insulating products based on mineral wool, in particular glass or rock wool, which includes at least one ammonium lignosulfonate or alkali metal or alkaline earth metal salt of lignosulfonic acid, and at least one carbonyl compound of formula: R—[C(O)R.sub.1].sub.x (I) in which: R represents a saturated or unsaturated and linear, branched or cyclic hydrocarbon radical, a radical including one or more aromatic nuclei which consist of 5 or 6 carbon atoms, a radical including one or more aromatic heterocycles containing 4 or 5 carbon atoms and an oxygen, nitrogen or sulfur atom, it being possible for the R radical to contain other functional groups, in particular hydroxyl or alkoxy groups, especially methoxy groups, R.sub.1 represents a hydrogen atom or a C.sub.1-C.sub.10 alkyl radical, and x varies from 1 to 10.

A sizing composition for insulating products based on mineral wool, in particular glass or rock wool, which includes at least one ammonium lignosulfonate or alkali metal or alkaline earth metal salt of lignosulfonic acid, and at least one carbonyl compound of formula: R—[C(O)R.sub.1].sub.x (I) in which: R represents a saturated or unsaturated and linear, branched or cyclic hydrocarbon radical, a radical including one or more aromatic nuclei which consist of 5 or 6 carbon atoms, a radical including one or more aromatic heterocycles containing 4 or 5 carbon atoms and an oxygen, nitrogen or sulfur atom, it being possible for the R radical to contain other functional groups, in particular hydroxyl or alkoxy groups, especially methoxy groups, R.sub.1 represents a hydrogen atom or a C.sub.1-C.sub.10 alkyl radical, and x varies from 1 to 10.

The invention relates to a method for manufacturing water treated man-made vitreous fibres (MMVF) comprising:

a. providing a mineral melt,

b. providing a fiberizing apparatus,

c. fiberizing the mineral melt to form man-made vitreous fibres (MMVF),

d. collecting the MMVF, and thereafter

e. applying about 0.1 wt % to about 1 wt % water, based on the weight of the MMVF, to the MMVF to form water treated MMVF.

The invention relates to a method for manufacturing water treated man-made vitreous fibres (MMVF) comprising:

a. providing a mineral melt,

b. providing a fiberizing apparatus,

c. fiberizing the mineral melt to form man-made vitreous fibres (MMVF),

d. collecting the MMVF, and thereafter

e. applying about 0.1 wt % to about 1 wt % water, based on the weight of the MMVF, to the MMVF to form water treated MMVF.