Oven for manufacturing a mineral wool product
09664443 ยท 2017-05-30
Assignee
Inventors
Cpc classification
B29C35/06
PERFORMING OPERATIONS; TRANSPORTING
F27B2009/3016
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F27B9/243
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F26B3/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C35/0277
PERFORMING OPERATIONS; TRANSPORTING
F26B13/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F26B13/108
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C67/249
PERFORMING OPERATIONS; TRANSPORTING
B29C67/248
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C35/06
PERFORMING OPERATIONS; TRANSPORTING
B29C35/02
PERFORMING OPERATIONS; TRANSPORTING
B29C67/24
PERFORMING OPERATIONS; TRANSPORTING
F27B9/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F27B9/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F26B13/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F26B3/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F26B13/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An oven for baking a thermally curable binder in a mat of mineral fibers, including plural compartments through which the mat of fibers passes successively, the mat being compressed and transported through the compartments by gas-permeable upper conveyors and lower conveyors, each compartment having a length along a direction of movement of the mat and including a mechanism introducing a hot air flow, located either below or above the fiber mat, and a mechanism extracting the air after having passed through the mat, respectively arranged either above or below the opposite face of the mat, so that the binder is progressively brought to a temperature higher than its curing temperature. In one compartment the mechanism introducing hot air includes air inlets that open partly on openings formed on a first lateral side of the compartment and partly on openings formed on the opposite lateral side of the compartment.
Claims
1. An oven for baking a thermally curing binder present in a mat of mineral fibers, comprising: a plurality of compartments through which the mat of fibers passes successively, the mat being compressed and configured to be transported through the compartments by gas-permeable upper conveyors and gas-permeable lower conveyors, each compartment including a top wall, a bottom wall, a first lateral side wall and a second lateral side wall that is opposite the first lateral side wall, each compartment having a length L along a direction of movement of the mat; means for introducing a hot air flow, which means is located either below or above the fiber mat; and means for extracting the air after the air has passed through the mat, the means for extracting arranged either above or below the fiber mat and opposite the means for introducing so that the fiber mat is positioned between the means for extracting and the means for introducing, and so that the binder is progressively brought to a temperature higher than its curing temperature; wherein at least one of the compartments includes the means for introducing a hot air flow, the means for introducing a hot air flow including an air inlet opening formed on the first lateral side wall of the at least one compartment and an air inlet opening formed on the second lateral side wall of the at least one compartment.
2. The oven as claimed in claim 1, wherein the at least one compartment includes the means for extracting the air after the air has passed through the mat, the means for extracting comprising an air outlet opening formed on the first lateral side wall and an air outlet opening formed on the second lateral side wall of the at least one compartment.
3. The oven as claimed in claim 2, wherein the air inlet opening and the air outlet opening on the first lateral side wall and the air inlet opening and the air outlet opening on the second lateral side wall are positioned such that none of the openings face each other across a width of the at least one compartment along the direction given by the length L of the at least one compartment.
4. The oven as claimed in claim 1, wherein: the means for introducing a hot air flow includes a plurality of air inlet openings formed on the first lateral side wall of the at least one compartment and a plurality of air inlet openings formed on the second lateral side wall of the at least one compartment, and along the direction given by the length L of the at least one compartment, the openings formed for the air inlets on the first lateral side wall are arranged substantially facing the openings formed for the air inlets on the second lateral side wall.
5. The oven as claimed in claim 1, wherein the air inlet opening formed on the first lateral side wall and the air inlet opening formed on the second lateral side wall are offset so as to not face each other across a width of the at least one compartment along the direction given by the length L of the at least one compartment.
6. The oven as claimed in claim 5, wherein: the means for introducing a hot air flow includes a plurality of air inlet openings formed on the first lateral side wall of the at least one compartment and a plurality of air inlet openings formed on the second lateral side wall of the at least one compartment, and along the direction given by the length L of the at least one compartment, the openings on the first lateral side wall and the openings on the second lateral side wall have an overlap region of between 5 and 30% of the length L.
7. The oven as claimed in claim 1, wherein: the means for introducing a hot air flow includes a plurality of air inlet openings formed on the first lateral side wall of the at least one compartment and a plurality of air inlet openings formed on the second lateral side wall of the at least one compartment, and along the direction given by the length L of the at least one compartment, the openings formed for the air inlets on the first lateral side wall and second lateral side wall are offset and are arranged: on the first lateral side wall: from a first end of the length of the at least one compartment toward the opposite end of the compartment, over a portion having a length of less than 80% of the length of the at least one compartment, on the second lateral side wall: from the opposite end of the length of the at least one compartment toward the first end, over a portion having a length of less than 80% of the length of the at least one compartment.
8. The oven as claimed in claim 7, wherein: along the direction given by the length L of the at least one compartment, the openings formed on the first lateral side wall extend from a first end to the center of the at least one compartment, and wherein the openings formed on the second lateral side wall extend from the opposite end to the center of the at least one compartment.
9. The oven as claimed in claim 1, wherein: the means for introducing a hot air flow includes a plurality of air inlet openings formed on the first lateral side wall of the at least one compartment and a plurality of air inlet openings formed on the second lateral side wall of the at least one compartment, and along the direction given by the length L of the at least one compartment, the means for extracting air after the air has passed through the mat of fibers is arranged above all of the air inlet openings.
10. The oven as claimed in claim 1, wherein: the means for introducing a hot air flow includes a plurality of air inlet openings formed on the first lateral side wall of the at least one compartment and a plurality of air inlet openings formed on the second lateral side wall of the at least one compartment, the means for extracting the air after the air has passed through the mat includes a plurality of air outlet openings formed on the first lateral side wall of the at least one compartment and a plurality of air outlet openings formed on the second lateral side wall of the at least one compartment, and along the direction given by the length L of the at least one compartment, the air outlet openings formed on the first lateral side wall are offset from the air inlet openings on both the first and second lateral side walls and the air outlet openings on the second lateral side wall are offset from the air inlet openings on both the first and second lateral side walls.
Description
(1) The characteristics of the various embodiments will now be described with reference to the appended
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10) As represented in
(11) Heating means 5, for example of the inductor type, are used to keep the glass and the centrifuger at the correct temperature. The veil 107 is enclosed by a gas flow of air introduced under pressure, schematized by the arrows 6. The torus 107 is surrounded by a device for spraying a bonding agent containing a thermally curable binder in aqueous solution, only two elements 7 of which are represented in
(12) The bottom of the fibering hood consists of a device for receiving fibers, comprising a conveyor incorporating an endless belt 9 which is permeable to gases and water, under which compartments 10 are arranged for receiving gases, such as air, the fumes and the excess aqueous compositions coming from the fibering process described above. A mat 11 of glass wool fibers mixed intimately with the bonding composition is thus formed on the belt 9 of the conveyor. The mat 11 is transported by the conveyor to an oven 12 for crosslinking the thermally curable binder.
(13) As represented in
(14) While ensuring passage of the hot gases so as to promote rapid setting of the binder, the conveyors 13, 14 compress the mat 11 in order to give it the desired thickness. By way of example, for a rolled panel, this typically lies between 10 and 450 mm, the density of the glass wool layer lying for example between 5 and 150 kg/m.sup.3. Distinction is thus made, for example, between so-called low-density products, for which the density varies between 5 and 20 kg/m.sup.3, and so-called high-density products, in which the density varies between 20 and 150 kg/m.sup.3.
(15)
(16) The entry and exit ports open onto fume extraction hoods 19 (the extraction direction of which is represented in
(17) In the first port 17, the entry port, the hot air introduced into the mat makes it possible to vaporize the water which is present. After it has passed through the mat, the air laden with moisture is extracted through the fume extraction hood 19.
(18) In the figures, the circulation of the air in the oven is represented by dotted arrows 40. The direction of movement of the mat is indicated by the arrows 50.
(19) In the first compartments, for example compartments 21-24, the hot air is introduced through the bottom of the oven and extracted through the top, after it has passed through the mat. The use of a plurality of compartments permits a progressive temperature rise of the fiber mat to a temperature higher than the curing temperature of the binder present on the fibers of the mat.
(20) In the subsequent compartments, for example compartments 25-27, the hot air is this time introduced through the top of the oven and extracted from the bottom.
(21) The additional fumes generated in the compartments are finally extracted in the exit port 19, via the hood 19.
(22) The mechanical properties of the final product depend on the control of the temperature in the various compartments, particularly if a green binder is used, as indicated above.
(23)
(24) On the compartment 30 represented in
(25) In the sense of the present description, an opening means a single opening over the entire length in question, or a series of openings for slots which are close together and respectively separated by reinforcing segments (not represented in the figures).
(26)
(27)
(28)
(29) On each side, the openings 32 are formed directly above the openings 31, that is to say the opening (or the series of openings) 31a is arranged above the opening (or the series of openings) 32a on the lateral side 33, and the opening 31b is arranged above the opening 32b on the lateral side 34). On a given side, the openings 31 and 32 therefore do not have an offset along the length L and cover substantially the same surface area (L.sub.1L.sub.2). During operation, the hot air 40 is introduced under the fiber mat 11 through the two sides of the compartment via the openings 31a and 31b, passes through it (cf. arrows 41) then is extracted (cf. arrows 42) in the upper part of the compartment, through the openings 32a and 32b.
(30) Just like the configuration described above with reference to
(31)
(32) According to this embodiment, according to the same principle, the openings for the air outlets 32a and 32b on each of the respective faces 33 and 34 do not face one another but are offset with respect to one another in the same way as explained above. Thus, the air outlets 32 (32a and 32b) are not, on a given side, arranged directly above the air inlet openings 31 (respectively 31a and 31b) but are also offset with respect to the latter. In this way, a compartment is ultimately obtained in which both respectively the openings 31a and 31b for the air inlets and the openings 32a and 32b for the air outlets do not face one another but are offset with respect to one another along the direction of movement of the mat.
(33) Examples are given by way of illustration and in order to assess the performance of the various embodiments explained above and compare them with current oven systems.
(34) More precisely, in the examples which follow, modeling of these various embodiments was carried out on a single compartment having one of the configurations above. The conditions of the simulation and the results obtained are given below:
(35) In order to carry out this comparative study, an aeraulic model for studying the hot air flows inside a compartment as described above was used on the basis of the following assumptions and approximations: The heat exchanges inside the mat are taken into account through a source term which models the heat loss overall. The temperature difference between the upper and lower parts of the mat is adjusted by means of this source term. An absence of inertia of the components is assumed (no heating of the belts, conveyors, metal sheets, etc.). The hot gases of the oven are likened to hot air, the air being considered as an ideal gas. The permeability of the product is assumed to be isotropic, and the leakage regions between the pallets are modeled with the aid of a porous medium, the permeability of which is varied in order to obtain the level of leaks. The heat losses at the walls are not taken into account.
(36) Although this model may be considered as approximate in relation to the heat exchanges between the mat and the hot gases which flow in the model compartment, it has sufficient accuracy for analyzing the distribution of the pressure over the upper and lower faces of the mat in relative terms. In particular, it makes it possible to analyze the relative differences in the distribution of speed when passing through the mat for the various configurations described above with reference to appended
(37) Furthermore, the simulations are carried out with a constant set flow rate and with constant permeability of the mat, which allows the pressure drop generated in the oven to be visualized directly and compared between the various configurations. The pressure drop is directly related to the energy consumption of the installation.
(38) The following parameters are used for the simulations:
(39) The simulations employ the Fluent software, used in steady state. The solver used is based on the pressure, according to a decoupled algorithm of the SIMPLE type.
(40) A single-species air flow likened to an ideal gas with variable thermodynamics is assumed, with (thermal conductivity), c.sub.p (specific heat) and (viscosity) being functions of temperature.
(41) The turbulence is modeled by the k-w SST model provided by the Fluent software.
(42) The following boundary conditions were set:
(43) For the hot air inlets at the exit of the fan: Total air flow rate set: 5 kg/s Total temperature: 235 C.
(44) The gases of the burner are likened to hot air.
(45) As regards the glass wool mat: Permeability K of the mat for air, the perpendicular index meaning that it is measured through the thickness of the product and the parallel index indicating that it is measured in the plane of the glass wool mat:
a) for a product of higher density (density more than 20 kg/m.sup.3): K.sub.=K.sub.=2.10.sup.9 m.sup.2
b) for a product of lower density (density less than 20 kg/m.sup.3): K.sub.=K.sub.=1.10.sup.8 m.sup.2. Thickness: 100 mm, Heat losses: T=30 C., Speed of movement: 0.18 m/s.
(46) As regards the perforated grilles: High transverse permeability: the pressure drop generated by the flow through the grilles is assumed to be negligible compared with the pressure drop generated in the mat. Low longitudinal permeability: the longitudinal permeability is 10 times less than in the mat.
(47) The heat losses of the walls of the oven are neglected.
(48) The width of the openings is equal to 12% of the total height of the compartment.
(49) The performance evaluation between the various configurations is made possible by comparing the different values finally obtained for: The pressure drop generated in the ventilation ducts, during passage through the compartment and the fiber mat. The homogeneity of the distribution of the average vertical passage speed through the fiber mat. This homogeneity is measured by calculating the variance of said vertical speed over the width of the fiber mat and integrated over its entire length.
(50) Table 1 below summarizes all the results found for the various configurations simulated in connection with
(51) TABLE-US-00001 TABLE 1 Example Example 1 Example 2 Example 3 Example 4 Illustration FIG. 3 FIG. 4 FIG. 5 FIG. 6 (comp.) Length of L.sub.1 = L.sub.2 = L.sub.1 = L.sub.2 = L.sub.1 = L.sub.2 = L.sub.1 = L.sub.2 = opening(s) 0.67 L 0.86 L 0.67 L 0.47 L Configuration 1 inlet 2 inlets 2 inlets 2 inlets of openings (31) (31a-31b) (31a and (31a and 1 outlet 2 outlets 31b) 31b) (32) (32a-32b) 2 outlets 2 outlets (32a and (32a and 32b) 32b) Offset of the Offset No offset Inlets Inlets openings between 31a and 31b 31a and 31b along the inlet 31 offset offset length L and outlet No offset Offset 32 between between inlets 31a inlets 31a (31b) and (31b) and outlets 32a outlets 32a (32b) (32b) Mat of lower density (7 kg/m.sup.3) Pressure drop 212 179 135 110 P (pascals) Average 0.229 0.227 0.218 0.227 vertical speed (m/s) Speed 3.0 1.7 1.0 0.6 standard deviation (10.sup.3 m/s) Mat of higher density (28 kg/m.sup.3) Pressure drop 258 225 186 154 P (pascals) Average 0.096 0.095 0.096 0.096 vertical speed (m/s) Speed 0.4 0.3 0.2 0.1 standard deviation (10.sup.3 m/s)
(52) Appended
(53) The following comments are made:
(54) 1.sup.st) As regards the results obtained with the mat of lower density:
(55) The results reported in Table 1 indicate a substantial decrease in the pressure drop P generated in the ventilation ducts for all the various configurations according to the invention, compared with the reference configuration (Example 1 illustrated by
(56) More particularly, the configuration according to Example 4 (illustrated by
(57) For the configuration according to Example 2, the decrease in the pressure drop is quite significant, but less pronounced than that obtained for the configuration according to Example 4.
(58) An improvement in the pressure drop is also measured for the configurations according to Example 3, albeit more limited.
(59) Furthermore, an improvement of the order of 80% in the standard deviation of the vertical speed is observed to Example 4 when the speed profiles are integrated along the direction of movement of the product, that is to say over the length of the oven.
(60) As represented in
(61) According to the configuration according to the invention, it is seen that this difference can be brought to a value of less than 1% with a very small disparity between the right side and the left side of the mat.
(62) 2.sup.nd) As regards the results obtained with the mat of lower density:
(63) The trends observed are the same as those described above for the product of low-density. A slightly less significant improvement in the pressure drop is observed. The homogeneity of the vertical passage speeds is also improved (cf.
(64) In conclusion, the simulation tests unequivocally indicate that the configurations according to the present invention, in particular the configurations according to Examples 2 and 4, and more particularly the configuration of Example 4, perform better than the comparative configuration considered as representative of the prior art.
(65) For the low-density products, supply of the two sides according to the invention makes it possible to homogenize the left/right speed distribution, which allows better regulation of the temperature seen by the binder at any point in the fiber mat, and consequently makes it possible to improve the baking quality of the product and thus its final properties.
(66) Furthermore, implementation of the invention also leads to a consequent decrease in the pressure drop, which will specifically be manifested by an increase in the capacity of the oven and/or energy efficiency gains.
(67) For the high-density products, the improvement in the homogeneity of the speed is also observed, albeit less significant, the resistance to the passage of air by the mat making it possible to homogenize the speed field if the latter is initially very heterogeneous. A significant gain in the pressure drop, of the order of 40%, is also observed.
(68) In the embodiments and examples above, the openings for the hot air inlets were represented below the fiber mat, so that the air flow passing through the latter is upward, the openings for the air outlets being arranged in the upper part of the compartment. Quite clearly, if the openings for the hot air inlet were arranged above the fiber mat, so that the air flow passing through the latter is downward, the openings for the air outlets then being arranged in the lower part of the compartment, this would not depart from the invention.
(69) Without departing from the scope of the invention, the oven according to the invention may comprise only the improved compartments described above. Alternatively, the oven according to the invention may comprise improved compartments and compartments according to the prior art equipped with openings on only one side. In particular, the improved compartments according to the invention may be positioned in the oven only at the positions where the curing of the binder is carried out, the improved control of the temperature and of the homogeneity of the passage speeds through the mat then being paramount.