WO2019063085A1

WO2019063085A1 - Method and device for producing inorganic fibres from waste materials, mineral wool products formed therefrom, and use thereof

Info

Publication number: WO2019063085A1
Application number: PCT/EP2017/074676
Authority: WO
Inventors: Jürgen Riegel
Original assignee: Vivera Corporation
Priority date: 2017-09-28
Filing date: 2017-09-28
Publication date: 2019-04-04

Abstract

The present invention relates to a method for producing inorganic, in particular mineral, fibres and mineral wool products which are obtained from the homogenised, inorganic, hot melt of a thermoselect process. The present invention provides economic and ecological advantages compared to the conventional production of mineral wool products from cold natural stone. In the present invention, waste materials containing organic and inorganic components are compressed, dried in a degassing channel, and then treated in a high-temperature reactor at temperatures ≥ 1000°C, wherein the inorganic melt obtained as a result is thermally refined and homogenised in a homogenisation reactor at temperatures ≥ 1600°C. The thermally refined and homogenised inorganic melt is conducted via a melt discharge pipe and through a siphon, which remains filled with inorganic melt, so that gases are prevented from passing through. The inorganic melt conducted through the siphon, after having been stored temporarily in a mixing and buffer tank, is lastly spun into inorganic fibres.

Description

Method and device for producing inorganic fibers from waste, mineral wool products formed therefrom and their use

The present invention relates to a process for producing inorganic, in particular mineral, fibers and mineral wool products, which are obtained from the homogenized, inorganic, hot melt of the Thermoselect process. The present invention brings economic and environmental advantages over the conventional production of mineral wool products from cold natural rock. In the present invention, waste containing organic and inorganic components are compressed, dried in a degassing and then treated in a high temperature reactor at temperatures> 1000 ° C, wherein the inorganic melt obtained in a homogenization at temperatures> 1600 ° C is thermally refined and homogenized , The thermally refined and homogenized inorganic melt is passed through a melt discharge pipe and through a siphon, which remains filled with inorganic melt, so that a passage of gases ausge- will conclude. The inorganic melt passed through the siphon is, after intermediate storage in a mixing and buffer tank, finally spun into inorganic fibers. Furthermore, the present invention is directed to a corresponding

Apparatus for producing inorganic fibers from waste, mineral wool products formed from the fibers and their possible uses.

With the "Thermoselect method", waste of different composition is environmentally friendly transformed into usable products by means of a high-temperature gasification process. DE 41 30 416 C1 describes the "Thermoselect method" in detail.

In the "Thermoselect" process, the compressed waste packages are dried in an indirectly heated degassing channel and the organic components are at least partially degassed.These pretreated waste packages pass without interruption into a high-temperature reactor.The organic waste components are gasified with oxygen at about 2,000 ° C, and The inorganic melt is completely melted, and the inorganic melt flows into a homogenizing reactor connected in a gas-tight manner to the high-temperature reactor, where the inorganic melt is thermally refined.The residence time of the inorganic melt in the homogenization reactor and the different volumetric weight result in the much heavier metallic melt settles and the mineral melt floats on the metallic melt.

The efficient use of the inorganic components of the waste has not received attention so far. Most of the inorganic parts, which make up about 25% of the waste land after thermal treatment in road construction or even landfills. The patented Thermoselect process offered at least the opportunity to commercialize mineral and metallic granules as products with low sales (for example for sandblasting).

Mineral wool is the most commonly used insulating material of high ecological value. The conventional production of mineral wool What is common is that the raw materials are cold. They are weighed in a batch insert and fed to a blast furnace. In all processes, the raw materials must be melted energy-intensive between 1200 - 1600 ° C. The melt is then used for fiber production. This is done by drawing, blowing or spinning, which are often combined. The resulting fibers can be further processed into a variety of mineral wool products.

Normally, the following raw materials are used for producing mineral wool from natural rock (rock wool fibers):

• Spat, dolomite, basalt, diabase, anorthosite and recycled material

• Coke, as an energy supplier

• 0.5-7% binder (phenolic resins)

· 0.5% mineral oil for dust binding and air purification.

• additives

• Magnesium

• cement (binder)

Most of the rocks are mined in opencast mines.

The production of mineral wool requires a lot of energy to melt the raw materials. The Gütegemeinschaft Mineralstoffe eV calls for the production of rock wool 150 to 400 kWh / m ³ of required primary energy. The Thermoselect melt has a structure similar to that of natural rock, more specifically basalt, making it an ideal replacement for natural rock:

THERMOSELECT basalt lava basalt standard sample 15.5.91 Fore Eifel l) 23955/03 2) mass% mass% mass%

SiO 2 47.1 45 49.5

AI203 8.3 18 16.2

Fe as Fe203 10.1 11 9.7

CaO 12.9 9.6 6.5

K20 1.4 5.2 0.2

Na20 2.6 3.2 4.6

MgO 3.2 6.7 7.5

MnO 0.7 0.1 0.1

TiO 2 0.8 0 1.14

1) Central Institute of Solid State Physics and Materials Research, Dresden 11.7.1991

2) TGL 23955/03 Geological Industry, Rock Standard Samples Basalt BM

Central Geological Institute, Berlin 21.10.75

When using the mineral Thermoselect melt as a raw material, the energy consumption for mineral fiber production is drastically reduced. Natural rock resources are spared. Waste is used to produce high-quality products. In addition, it is an object of the present invention to optimize the process safety of the Thermoselect method and to increase the energy yield of the Thermoselect method.

Based on this, it was therefore an object of the present invention to provide a method and apparatus for producing inorganic fibers (mineral wool / rock wool), which is energy and cost-saving and in which the process safety can be ensured.

These objects are related to a method having the features of claim 1 and to a device having the features of Patent claim 15 solved. Claim 25 specifies a correspondingly produced fiber, while claim 27 describes a mineral wool product. Claim 28 mentions uses of the mineral wool products. Claim 29 relates to the use of an inorganic see hot melt, which is obtained in the process according to the invention, as a replacement for cold natural rock in the production of mineral fibers and / or mineral wool products. The respective dependent claims represent advantageous developments.

The invention thus provides a process for producing inorganic, in particular mineral, fibers from waste, which comprises the following steps: a) compressing wastes containing organic and inorganic constituents, b) drying the waste compressed in step a) in a degassing duct, the organic constituents of the waste are at least partially degassed, c) treatment of the wastes dried in step b) in a high-temperature reactor at temperatures> 1000 ° C., preferably temperatures> 1200 ° C., the organic constituents of the waste being gasified with oxygen and the inorganic constituents of the waste are melted to obtain an inorganic melt, d) passing the inorganic melt obtained in step c) into a gas-tight manner connected to the high-temperature reactor

Homogenization reactor in which the inorganic melt is thermally refined and homogenized at temperatures> 1600 ° C. e) removal of the in step d) thermally refined and homogenized inorganic melt from the homogenization reactor via a melt-discharge tube gas-tightly connected to the homogenization reactor, f) passing the melt, derived in step e) from the homogenization reactor via the melt discharge pipe, through a siphon which is gas-tightly connected to the melt discharge pipe and has a bent pipe section which remains filled with inorganic melt so as to prevent the passage of gases; Preparation of the inorganic melt in a heated buffer and mixing tank,

h) spinning at least part of the inorganic melt into inorganic fibers processed in step b) in the buffer and mixing tank (8).

Waste of various types and compositions may be used in the process of the invention as long as they contain at least organic and inorganic constituents. The waste used in step a) of the process according to the invention is preferably selected from the group consisting of residual waste, household waste, dry stabilizer (RDF), shredder light fractions, industrial waste, industrial waste and mixtures thereof.

Preferably, the waste has a calorific value of 10 to 15 MJ / kg.

The present invention utilizes the already molten, rock-like material obtained at about 1600 ° C in the Thermoselect process as a starting point and thus makes mineral wool production more economical and environmentally friendly. Fluctuations in the composition of the mineral melt are possible and likely due to the starting material waste. They are compensated for by the chosen procedure and thus do not affect the production of marketable mineral wool products.

In step a) of the method according to the invention, the waste is first compressed or compacted.

In step b) of the process according to the invention, the amounts obtained in step a) are dried compressed waste in a degassing and thereby at least partially degassed. Broken solid conglomerate is introduced directly into the high temperature reactor used in step c). In step c) of the process according to the invention, the dried wastes obtained in step b) are treated in a high temperature reactor. In this high-temperature treatment, the organic constituents of the waste are gasified with oxygen and the inorganic constituents are melted to obtain an inorganic melt.

The gasification of the organic components of the waste with oxygen in the high-temperature reactor produces synthesis gas. It can be used for the synthesis of organic molecules or for the production of electricity. With the method according to the invention, not only the organic but also the inorganic components of the refuse are reused in a valuable way.

In step d) of the process according to the invention, the inorganic melt obtained in step c) is passed into a homogenization reactor connected in a gastight manner to the high-temperature reactor. In this, the inorganic melt is thermally refined at temperatures> 1600 ° C and homogenized. In this case, temperatures of more than 2000 ° C. are preferably achieved in at least one region of the homogenization reactor. Due to these high temperatures, e.g. the depletion evaporates

Components and the stable incorporation of metals in the mineral system and in the iron-rich metal alloy can be ensured.

The steps a) to d) of the process according to the invention are in a particularly preferred embodiment at least partially according to the

"Thermoselect method" are carried out, as described in the patent DE 41 30 416 Cl, in the book "Thermoselect" by Günther Häßler (2nd edition 1995, Verlag Karl Goerner, Karlsruhe) or in the book "Thermoselect- method for Ent- and gasification of waste "by Franz J. Schweitzer (1994, EF-Verlag for energy and environmental technology GmbH, Berlin) and in European Patent 26 20 426, process for the production of urea from Wastes, is described. The content of these documents is included in the present teaching.

In step e) of the process according to the invention, the thermally refined and homogenized inorganic melt obtained in step d) is removed from the

Homogenization reactor derived. This discharge takes place via a Schmelzaustragsrohr, which is gas-tightly connected to the homogenization reactor.

In step f) of the process according to the invention, the melt derived from the homogenization reactor via the melt discharge pipe in step e) is passed through a siphon. According to the invention, the siphon is gas-tightly connected to the melt discharge pipe. According to the general definition, a siphon is a gas-tight but liquid-permeable closure of pipe systems and vessels. The principle of operation of a siphon is based on a curved (for example S-shaped) pipe whose lower bend always remains filled with liquid and thus prevents the passage of gases. In the present invention, the bent pipe section of the siphon corresponds to this lower bend. According to the invention, the siphon has at least one curved pipe section (or a lower bend) which remains filled with inorganic melt, so that a passage of gases is prevented.

Under the characteristic that the bent pipe section of the siphon remains filled with inorganic melt, it should be understood that under normal operating conditions it always remains filled with inorganic melt. For abnormal operating conditions, e.g. Maintenance purposes, however, the curved pipe section of the siphon can also be emptied. For this purpose, a closable opening can be provided at the lowest point of the siphon. Through this opening, the melt can be discharged discontinuously, e.g. To carry out maintenance work. The discharge takes place via a sufficiently long dip tube into the granulation tank.

In one possible variant, the bent pipe section of the heated siphon can always remain filled with inorganic melt. Finally, in step g) of the process according to the invention, at least part of the inorganic melt conducted through the siphon in step f) is spun into inorganic fibers, optionally after the melt has been stored and processed in a buffer and mixing tank. Preferably, the spinning of the inorganic melt takes place according to the state of the art

Technique, preferably using a rotating disk. Preferably, the entire in step f) passed through the siphon inorganic melt is spun into inorganic fibers. In the present application, a melt is always understood as meaning a liquid melt, unless stated otherwise.

The inorganic fibers produced according to the invention can be used for example for insulation. They are not flammable and are also referred to as mineral wool or rock wool.

The method according to the invention is distinguished by the fact that it saves energy and costs compared to conventional mineral wool production, ensures the process reliability of the Thermoselect technology and improves its energy balance.

With the method according to the invention, simple waste such as e.g. Household or industrial waste, inorganic fibers are produced. Since the use of cold raw materials can be largely dispensed with, which must be heated to a temperature of about 1400 ° C to liquefy the fiber production, energy costs and natural resources can be saved with the inventive method. At the same time, not only are the organic components of the waste recycled in a sensible way, but also the inorganic components of the waste are immediately recovered, i. without previous cooling, transferred to high quality products (mineral wool). All these effects make a valuable contribution to environmental protection.

It is particularly advantageous in the process according to the invention that the inorganic melt obtained in the process can be used directly for fiber production without the energy bound in the melt being used. lorengeht, while the process safety of thermal waste treatment is guaranteed. In order to ensure process safety, the prior art, the inorganic melt was passed through a dip tube in a granulation. As a result, it was prevented that hot gas escape or air can enter the reactor, and thus forms an explosive gas mixture. In the method according to the invention a passage of gases is prevented due to the use of the siphon.

Through the use of the siphon can thus be dispensed (in the usual course of the process) to a directing the melt from the homogenization reactor in a granulation and the associated cooling of the melt. Rather, the inorganic melt from the homogenization reactor is passed hot over the siphon and later spun into inorganic fibers. The elimination of cooling the melt leads to a significant energy savings both in the cooling of the

Granulation tank water as well as in fiber production, without affecting the process safety.

A preferred embodiment of the method according to the invention provides that before step e) the inorganic melt into a mineral rich

Melting fraction and a metal-rich melt fraction is separated and a separated discharge of mineral-rich and metal-rich melt fraction from the homogenization reactor takes place, the mineral-rich melt fraction, which makes up the main part, is discharged through the siphon.

In this case, the term "mineral rich" is to be understood as meaning that the fraction of mineral constituents of this melt fraction is higher than the fraction of mineral constituents in the metal-rich molten fraction This fraction is higher than the proportion of metallic constituents in the mineral-rich melt fraction.

In a particularly preferred embodiment, a density separation of the melt contained in the homogenization reactor takes place, for example by sedimentation. In this case, the inorganic melt is preferably separated into a mineral-rich melt fraction having a density of <5 t / m ³ , preferably <4 t / m ³ , more preferably <3 t / m ³ and a metal-rich melt fraction having a density of> 5 t / m ³ , preferably> 6 t / m ³ , particularly preferably 7.5 t / m ³ . The separation takes place in particular due to prevailing temperature and choice of residence time of the inorganic melt in the homogenization reactor.

The residence time of the inorganic melt in the homogenization reactor and the different volume weight usually result in the much heavier metallic melt settling in the homogenization reactor and the mineral melt floats on the metallic melt. In this way, a kind of separation of metallic and mineral melt takes place.

The mineral-rich melt fraction may preferably be subjected to steps d) to g) for the production of mineral fibers.

The gas-tight deduction of the metal-rich melt fraction occurs discontinuously after reaching a selected level in the homogenization reactor via a bottom outlet arranged in a granulation.

The obtained metallic granules (iron alloy) can be used for example in the metal industry.

The method according to the invention makes it possible to produce standard-compliant mineral wool with sufficiently high biosolubility which fulfills, for example, the EU Guidelines 97/69 CE, Q. and R, and D.M 01-09 1998 and later updates. The basic raw material used is the thermally refined mineral melt resulting from the Thermoselect process.

The mineral-rich melt fraction contains in particular the following constituents in the stated amounts.

From 30 to 70% by weight, preferably from 40 to 50% by weight, Al ₂ O ₃ : 2 to 15 wt.%, Preferably 5 to 10 wt.

Fe ₂ O ₃ : 4 to 15% by weight, preferably 7.5 to 12.5% by weight,

CaO: 6 to 20% by weight, preferably 10 to 15% by weight,

MgO: 0.5 to 7% by weight, preferably 2 to 4% by weight.

Thus, the obtained mineral-rich melt fraction is very similar to the natural basalt and can therefore be referred to as basalt-like.

The mineral-rich melt fraction may possibly also contain the following components:

K ₂ 0: 0.1 to 4 wt .-%, preferably 0.5 to 3 wt .-%,

Na ₂ O: 0.1 to 5 wt.%, Preferably 1.5 to 4 wt.

MnO: 0.1 to 2% by weight, preferably 0.3 to 1% by weight,

Ti0 ₂ : 0.1 to 2 wt .-%, preferably 0.5 to 1.5 wt .-%.

The proportion of the mineral-rich melt fraction in the entirety of the inorganic melt is in particular 50 to 99 wt .-%, for example 90 to 95 wt .-%.

A preferred variant of the method according to the invention is characterized in that the melt discharge pipe and / or the siphon (as well as all other constituents of the components of the device which come into contact with the melt in the process according to the invention, such as, for example, the discharge possibility described below). genisierungsraktor, the melt deflector and / or the buffer and mixing tank) consist of a material which at a temperature of 1800 ° C, preferably 1900 ° C, more preferably 2000 ° C, most preferably 2100 ° C, in particular 2200 ° C, is heat resistant for a period of at least 8000 hours. Such a heat resistance of the material is understood here to mean that the said aggregates remain operational at the temperature mentioned over a period of at least 8,000 h (in the process according to the invention) and not for safety reasons must be replaced because of material fatigue or wear. The said heat resistance is given, for example, when the material at the said temperature over a period of at least 8000 h no (significant) wear and tear, such as thermal or mechanical abrasion, embrittlement or decomposition, has. As essential, the signs of wear are considered when the material is no longer operational for safety reasons, since due to the wear melt could escape uncontrollably. The material is preferably selected from the group consisting of refractory metal, ceramic, bricklayer, and mixtures thereof.

In a further preferred variant of the method according to the invention, the melt discharge pipe and / or the siphon are continuously heated, preferably to a temperature between 1600 and 2200 ° C., more preferably to a temperature between 1800 and 2100 ° C., most preferably to a temperature between 1900 and 2000 ° C. In this way it can be ensured that the inorganic melt, in particular the mineral-rich melt fraction, which is located in the siphon, does not cool and solidifies. In particular, when there is no melt flow through the siphon (for example, during a production stoppage), it is possible for the melt therein to cool and solidify, thereby affecting the flow in the siphon. By continuously heating the melt discharge pipe or siphon this can be prevented. A further preferred variant of the method is characterized in that the bent pipe section of the siphon has a closable opening, wherein the opening is preferably located on the underside of the bent pipe section. Particularly preferably, the closable opening is located at the lowest point of the bent pipe section. By such a closable opening located in the siphon

Melt be discharged from the siphon discontinuously, e.g. for maintenance or in case of emergency for safety reasons.

Preferably, a bursting disc is integrated in the closable opening, which is designed such that it breaks down at a predetermined overpressure, preferably at 1 bar overpressure, particularly preferably at 0.8 bar overpressure. bursts, so that after a rupture of the rupture disk, the inorganic melt, in particular the mineral-rich melt fraction, is discharged through the opening from the siphon. As a result, in an emergency or in the event of a safety-relevant overpressure (for example in the case of an explosion), the melt in the siphon is diverted without the need for additional intervention. In this preferred variant of the method, the bent pipe section of the siphon thus only remains filled with inorganic melt as long as the overpressure predetermined within the siphon, or preferably 1 bar overpressure, or particularly preferably 0.8 bar overpressure, is reached , In the event that the high-temperature reactor has a gas outlet tube, which is secured with a water lock, the entry of a safety-relevant overpressure in the siphon of a theoretical nature, since in this case an overpressure in the system can be derived via the water lock behind the gas outlet pipe. The resistance of gas mixtures is less than the resistance of the inorganic melt.

Preferably, after a rupture of the rupture disk, the inorganic melt, in particular the mineral-rich melt fraction, is passed through the opening from the siphon into a granulation basin filled with water, in which it is shock-cooled. In this way, the (in an emergency) derived from the siphon hot melt cooled as quickly as possible and safety risks are avoided.

In a further preferred variant of the method, the spinning of the inorganic melt into inorganic fibers takes place in step g) with a

Spinning process, which is selected from the group consisting of

Spin-coating method, in particular disk spinning method, ring-spinning method, nozzle-spinning method,

Drawing process, in particular nozzle drawing process,

Blow molding, in particular nozzle blow molding,

as well as combination thereof.

According to a further preferred variant of the method according to the invention, the inorganic melt passed through the siphon in step f), in particular the mineral-rich melt fraction, is temporarily removed with the aid of a Melt deflector passed into a granulation tank. In normal operation, the inorganic melt is passed to a device for subsequent spinning to inorganic fibers, and passed in non-normal operation by means of the Schmelzabweisers in the granulation. Between the melt deflector and the device for spinning a buffer and mixing tank can be arranged, in which the inorganic melt is stored and supplemented.

Preferably, the melt deflector can be heated, in particular to prevent solidification of the melt on the Schmelzabweiser.

It is particularly preferred that the Schmelzabweiser can be arranged in two different positions and is moved in the course of the process between these two positions back and forth, wherein in the first of these positions, the Schmelzabweiser is arranged so that in step f) by the Siphon-guided inorganic melt, without being derived from the melt deflector, passed in the direction of fiber production and arranged in the second of these positions so that the inorganic melt flows into a granulation.

In the process according to the invention, it is desirable for the inorganic melt, in particular the mineral-rich melt fraction, to be as constant and homogeneous in composition as possible and in the amount to be processed. Since these conditions are not given, for example, when starting and stopping the thermal line, it may be advantageous not to use this part of the melt for fiber production. This part of the melt can then be discharged with the help of the melt deflector into a granulation tank, and is thus initially not spun. However, the granules can be recycled to the process as input, eg together with the waste in step a), and later used for fiber production. Once a steady state of operation is achieved, the inorganic melt, especially the mineral-rich melt fraction, can then be used to make mineral wool without being derived from the melt deflector. In the case of a malfunction of the fiber production, the melt can also be passed directly into the granulation. This ensures the uninterrupted operation of garbage gasification. Thus result from the use of the melt deflector procedural advantages. However, the use of the Schmelzabweisers also brings safety advantages with it. Thus, in an emergency, for startup and shutdown or maintenance of the device for fiber production, the melt can be quickly discharged into the granulation, where it is cooled quickly and thus harmless.

Furthermore, it is preferred that the melt deflector is moved hydraulically or pneumatically via a cylinder.

In a further preferred variant of the method according to the invention, the melt deflector is heated continuously (from the outside), preferably to a temperature between 1600 and 2200 ° C., more preferably to a temperature between 1800 and 2100 ° C., very particularly preferably to a temperature between 1900 and 2000 ° C. In the granulation, in which the inorganic melt with time

Help can be derived from the Schmelzabweisers, it may be the same granulation, in which the inorganic melt is derived after the bursting of the rupture disk from the siphon. The metal-rich melt fraction taken separately from the homogenization reactor can also be passed into the same granulation basin. It is also possible that the metal-rich melt fraction is fed into a separate granulation. A separate granulation tank has the advantage that mineral and metallic granules do not have to be separated magnetically before further use.

Preferably, the guided through the heated siphon mineral-rich melt fraction is stored in a heated buffer or mixing tank.

On the one hand, the buffer and mixing tank serves to compensate for quantitative and qualitative fluctuations of the inorganic melt, in particular that of the mineral-rich melt fraction that goes along with the raw material waste. On the other hand, the heated tank allows the production of a suitable raw material mixture for a standard-compliant mineral fiber production. For example, the current EU standard for mineral wool products (EN 13162 Directive 89/106 / CEE) requires fibers with high biosolubility. These require, for example, a mixture of raw materials with a limited iron oxide content, so that the waste resulting from inorganic melt is optionally to be processed. Since the waste composition and thus also its metal oxide content fluctuates, it is ensured in the process according to the invention that the raw material mixture required for a mineral wool production - regardless of the quality of the waste - by adding natural stones and / or recycled material and / or chemical additives can be reached. The inorganic melt produced in the buffer and mixing tank preferably corresponds in its chemical composition to the starting material which is used in conventional mineral wool production from cold rock which must be melted.

The raw material mixture for mineral fiber production varies i.a. depending on the availability of natural rock and recycled material. Usually used:

40 - 70% basalt or similar rocks

30 - 60% waste material, secondary recycling material trapped in cement blocks

0.5 - 7% phenolic resin

0.2 - 0.5% fatty mineral oil

0.1 - 0.5% binder (such as siloxanol)

In addition, the mixture can be adjusted depending on the desired end product. In the process according to the invention, its main constituent is the homogenized inorganic or mineral melt from the Thermose- lect process using its inherent energy. It at least partially replaces the two main raw materials basalt / rock and waste material bound in cement. For example, natural rock (eg dolomite, spade, diabase, anorthosite) can be abandoned or mineral, cement-bound recycled material can be added. The additional cold rock or recycled material can be added in solid form and melted in the heated mixing tank, or it is already added in the molten state. In any case, a homogenization of the added material with the in-tank melt of the Thermoselect process takes place.

After addition of binders (such as phenolic resin and mineral oil, which influence the material behavior of the fiber), the raw material mixture flows from the buffer and mixing tank into spinning units for the production of mineral fibers, which can then be further processed into mineral wool products. Spinning into fibers and further processing take place according to the state of the art.

The present invention also relates to an apparatus for producing inorganic fibers from waste containing

a device for compressing waste,

a heated degassing duct for drying compressed waste,

a high-temperature reactor which can be heated to temperatures> 1000 ° C., preferably temperatures> 1200 ° C.,

a homogenization reactor, which is gas-tightly connected to the high-temperature reactor and which can be heated to temperatures> 1600 ° C,

a Schmelzaustragsrohr which is gas-tightly connected to the homogenization reactor,

a siphon, which is gas-tightly connected to the Schmelzaustragsrohr and having a bent pipe section, a buffer and mixing tank for adjusting the suitable raw material mixture for mineral wool production and a device for spinning inorganic melt to inorganic fibers.

The device for compressing waste is preferably a press, in particular a trash compactor.

The degassing channel for drying compressed waste may preferably be heated above 100 ° C. The degassing duct may be connected to the apparatus for compressing waste. Preferably, the degassing is heated from the outside, i. from outside the degassing channel.

Particularly preferably, at least one region, preferably a lower region, of the high-temperature reactor can be heated to temperatures of more than 2000 ° C. The high temperature reactor may be connected to the degassing channel.

Preferably, the waste compacting device, the degassing channel and the high temperature reactor are interconnected so that compressed waste can be passed from the waste compacting device into the degas channel and from there into the high temperature reactor.

In a preferred embodiment, the high-temperature reactor has a gas outlet. For example, synthesis gas can be removed from the high-temperature reactor via this gas outlet. Particularly preferred is the gas outlet, a gas outlet tube which is secured by a water lock. Furthermore, it is preferred that at least a portion of the homogenization reactor can be heated to temperatures above 2000 ° C.

In a particularly preferred embodiment of the device according to the invention is as a device for compressing waste, as a degassing channel for drying compressed waste, as a high-temperature reactor and / or as Homogenisierungsreaktor, such a corresponding Device used as used in the "Thermoselect method", as described in the patent DE 41 30 416 Cl, in the book "Thermoselect" by Günther Häßler (2nd edition 1995, Verlag Karl Goerner, Karlsruhe), or in the book "Thermoselect method for the degassing and gasification of waste" by Franz J. Schweitzer (1994, EF-Verlag for energy and environmental technology GmbH,

Berlin) is described.

A further preferred embodiment of the device according to the invention is characterized in that the Schmelzaustragsrohr and / or the siphon and / or the Schmelzabweiser and / or the buffer and mixing tank made of a material which at a temperature of 1800 ° C., preferably 1900 ° C. , more preferably 2000 ° C, most preferably 2100 ° C, in particular 2200 ° C, is heat resistant over a period of at least 8000 h. Under such a heat resistance of the material is understood here that these devices at the temperature above a period of at least 8,000 h remains operational and must not be replaced for safety reasons due to material fatigue or wear. The said heat resistance is given, for example, when the material at the said temperature over a period of at least 8000 h no (significant) signs of wear, such. thermal or mechanical abrasion, embrittlement or decomposition. As essential, the signs of wear are considered when the material is no longer operational for safety reasons, since due to the wear melt could escape uncontrollably. The material is preferably selected from the group consisting of refractory metal, ceramic, bricklayer, and mixtures thereof.

A further preferred embodiment of the device according to the invention is characterized in that the curved pipe section of the siphon has a closable opening, wherein the opening is preferably located on the underside of the bent pipe section, particularly preferably at the lowest point of the bent pipe section. By such a closable opening, melt in the siphon can be drained from the siphon, e.g. for maintenance or in case of emergency

Security reasons. In the embodiment just mentioned, it is possible for a rupture disk to be integrated into the opening, which is designed so that it ruptures at a predetermined overpressure, preferably at 1 bar overpressure, particularly preferably at 0.8 bar overpressure. In this case, the device preferably contains a granulation basin filled with water, wherein the granulation basin is arranged so that after bursting of the rupture disk, the inorganic melt, in particular the mineral-rich melt fraction, can be passed through the opening from the siphon into the granulation basin. As a result, the melt located in the siphon can be derived from this in an emergency at a safety-relevant excess pressure, wherein the derived hot melt is cooled as soon as possible, whereby safety risks can be avoided. The homogenization reactor preferably has a bottom-side outlet, which opens into a granulation bath. By way of example, a denser melt fraction which separates out in the homogenization reactor at the bottom can be removed separately from the homogenization reactor.

The granulation bath is filled with water. This may be the same granulation bath into which the siphon flows, or alternatively a separate granulation tank. More preferably, the homogenization reactor has a weir, the one

Accumulation of inorganic melt, in particular metallic melt allowed up to a maximum height and on reaching this level has a fractional withdrawal of the metallic melt via a bottom side arranged drain, which opens into a granulation. The weir may for example be formed as a wall and assume an overflow function, so that the homogenization reactor can be filled with melt up to a certain desired state, without melt running into the discharge pipe. In this case, it can be ensured that the inorganic melt remains in the homogenization reactor for a certain residence time. This allows in particular that a separation of a metal-rich melt fraction (of high density) and a mineral-rich Melting fraction (of low density) can be done. The mineral-rich melt fraction can flow off after reaching the desired state by overflowing the weir into the discharge pipe. As soon as the homogenization reactor has reached a certain level of metal-rich melt, it can be discharged discontinuously from the homogenization reactor via the outlet.

The process is thus designed in particular closable. More preferably, before the device for spinning a buffer and

Mixing tank arranged in the aggregates and / or additives can be added, so that the composition of the melt can be influenced.

A further preferred embodiment of the device according to the invention is characterized in that it comprises a Schmelzabweiser which can be arranged in two different positions and is movable between these positions back and forth, wherein in the first of these positions, the Schmelzabweiser is arranged so that a through directed to the siphon inorganic melt, in particular the mineral-rich melt fraction, without being derived from the melt deflector is passed to the apparatus for mixing or subsequent spinning inorganic melt to inorganic fibers, and in the second of these positions, the melt deflector is arranged so that the melt in a granulation tank is passed.

Furthermore, it is preferred that the device according to the invention for producing inorganic fibers from waste, or one of the described preferred embodiments thereof, is an apparatus for carrying out the method according to the invention for producing inorganic fibers from waste or one of the described preferred variants thereof.

In addition, the present invention relates to the use of a hot melt, which can be produced according to steps a) to c) of the above-described inventive method, as a substitute for cold natural rock or other cold raw materials (such as recycled material) in the production of mineral fibers and / or mineral wool products , The mineral wool product may optionally contain other conventional additives, such as phenol or mineral oil, among other things for dust binding. The production of the fibers and mineral wool products can be carried out from process steps known in the art. The mineral wool products can be used in particular as a thermal insulation material, acoustic insulation material, building material, flame retardant or as an artificial substrate for the cultivation of plants.

The present invention improves economy and ecology of conventional mineral wool production from cold rock. The use of already liquid, basalt-like melt from the Thermoselect process can greatly reduce energy-intensive smelting and the degradation of natural resources.

Conventional thermal waste treatment focuses on the energetic use of the organic components of the waste. With patent 26 20 426, the Thermoselect method has proven that organics can also be used to higher value, namely for the production of chemicals, in this case of urea.

Inorganic components of the garbage, which until now found only low-value as cold granules their market, can serve a high-quality market segment by the inventive method. Garbage as a secondary raw material attains an important status through the effective use of inorganic, predominantly mineral, components.

The metal-rich melt fraction is typically characterized by a high iron content. In addition, the metal-rich melt fraction may include other metals, such as copper, nickel, chromium, zinc, etc.

According to this embodiment, the method according to the invention thus enables the simultaneous production of mineral fibers (mineral wool) and metallic granules. Thus, in the method according to the invention a complete recycling of the resulting inhomogeneous waste takes place. Organic components are split into synthesis gas, which can be further recycled, the inorganic components are converted into mineral wool and metallic granules. The present invention will be explained in more detail with reference to the following figures, without limiting the invention to the parameters specifically shown.

Fig. 1 shows an exemplary apparatus according to the present invention. This contains a device 1 for compressing waste, a degassing channel 2 for drying compressed waste, a high temperature reactor 3, which can be heated to temperatures> 1000 ° C, a homogenization reactor 5, which is gas-tightly connected to the high temperature reactor 3 and which to temperatures > 1600 ° C can be heated, a Schmelzaustragsrohr 6, which is gas-tightly connected to the homogenization reactor 5, a siphon 7 which is gas-tight connected to the Schmelzaustragsrohr and having a U-shaped bent pipe section, and a mixing and buffer tank. 8 in which the melt obtained can be stored and / or supplemented. On the outlet side, the mixing and buffer tank 8 leads to a device 12, not shown in detail, for spinning inorganic melt into inorganic fibers. The high-temperature reactor 3 also has a gas outlet 4, can be derived by the synthesis gas from the high-temperature reactor 3.

With the device shown in Fig. 1, the inventive method can be carried out as follows. First, wastes containing organic and inorganic components such as household waste are put into the waste compacting apparatus 1. This compresses the waste. Subsequently, the compressed waste is passed into the degassing channel 2 and dried there, wherein the organic components of the waste are at least partially degassed. Subsequently, the waste enters the high-temperature reactor 3, where they are treated at temperatures> 1000 ° C. Here, the organic constituents of the waste are gasified with oxygen to synthesis gas, which is derived by the gas outlet 4 from the high-temperature reactor 3. The inorganic constituents The waste is melted to obtain an inorganic melt. The inorganic melt is passed into the homogenization reactor 5, in which it is thermally refined and homogenized at temperatures> 1600 ° C. Subsequently, the thermally refined and homogenized inorganic melt is discharged from the homogenization reactor via the melt discharge pipe 6 and passed through the siphon 7. Finally, the inorganic melt flows from the outlet of the siphon 7 into a mixing and buffer tank 8, in which the melt is stored. If necessary, additives can be added to the melt (eg natural rock or waste containing cement) in order to influence or adjust the quality of the melt and thus of the spinning products. With the mixing and buffer tank 8, it can also be ensured that sufficient melt is always stored in order to ensure continuous operation of the device 12 arranged after the mixing and buffer tank 8 for spinning inorganic fibers.

As indicated in Fig. 1, the U-shaped bent pipe section of the siphon remains filled with inorganic melt, so that a passage of gases is prevented. Thus, no hot gas from the homogenization reactor 5 can reach the atmosphere through the siphon. In addition, no air can enter from outside through the siphon in the homogenization reactor.

Fig. 2 shows another exemplary embodiment of the device according to the invention. The same designations as for FIG. 1 are used. The device shown in Fig. 2 also includes a Schmelzabweiser

11. This can be arranged in two different positions A and B and moved back and forth between these positions. In position A, the melt deflector 11 is arranged so that an inorganic melt passed through the siphon 7 is conducted into the mixing and buffer tank 8. On the other hand, in position B, the melt deflector 11 is arranged such that the inorganic melt conducted through the siphon 7 is conducted by the melt deflector 11 into the granulating basin 10 filled with water, where it is shock-cooled. In normal operation, the Schmelzabweiser remains in position A. In special cases (eg in case of emergency or maintenance of the mixing and buffer tank 8 and / or the apparatus 12 for fiber spinning, or even when starting and stopping the thermal line of the melt deflector 11 is temporarily in Position B was driven.

FIG. 3 shows a further embodiment of an exemplary device according to the invention which is based on the device according to FIG. The homogenization reactor 5 of the device shown in FIG. 3 additionally has a bottom-side outlet 5a and a weir 5c. Through the weir can be held in the homogenization reactor melt for a certain residence time there. This allows the improved separation of the inorganic melt contained in the homogenization reactor in a metal-rich and a mineral-rich fraction. Due to the different densities of the fractions (the metal-rich fraction is significantly denser than the mineral-rich fraction), the mineral-rich melt fraction floats on the metal-rich melt fraction. The metal-rich melt fraction thus accumulating in the bottom of the reactor can be discharged from the reactor via the outlet 5a. The outlet 5a is designed in this case in particular closable. The discharged metal-rich melt fraction can be transferred into a granulation bath 5b. The water present in the granulation bath 5b causes a shock-cooling of the metal-rich melt fraction and thus granulation.

The granulating bath 5b may be identical to the granulating bath 10.

FIG. 4 shows a further embodiment of the device according to the invention, which is decisively based on FIGS. 2 and 3. The U-shaped bent pipe section of the siphon 7 has in Fig. 4, a closable opening 9, in which a rupture disk can be integrated. The opening 9 is located at the lowest point of the bent pipe section. After a planned opening of the opening 9 (eg during maintenance) or after an unplanned bursting of the rupture disk (eg with a strong overpressure in the siphon 7), the inorganic melt is passed through the opening 9 from the siphon 7 into a granulating basin 10 filled with water and shock-cooled there.

Claims

claims

Process for the production of inorganic, in particular mineral, waste fibers, comprising the following steps:

a) compressing wastes containing organic and inorganic components,

b) drying the waste compressed in step a) in a degassing duct (2), whereby the organic constituents of the waste are at least partially degassed,

c) treating the wastes dried in step b) in a high-temperature reactor (3) at temperatures> 1000 ° C., wherein the organic constituents of the waste are gasified with oxygen and the inorganic constituents of the waste are melted to obtain an inorganic melt,

d) passing the inorganic melt obtained in step c) into a homogenizing reactor (5) connected in a gastight manner to the high-temperature reactor (3), in which the inorganic melt is thermally refined and homogenized at temperatures> 1600 ° C.,

e) deriving the in step d) thermally refined and homogenized inorganic melt from the homogenization reactor (5) via a with the homogenization reactor (5) gas-tightly connected Schmelzaustragsrohr (6),

f) passing the in step e) from the homogenization reactor (5) via the Schmelzaustragsrohr (6) derived inorganic melt through a siphon (7), which gas-tight with the

Meltaustragsrohr (6) is connected and has a bent pipe section which remains filled with inorganic melt, so that a passage of gases is prevented. g) preparation of the inorganic melt in a heated buffer and mixing tank (8),

A method according to the preceding claim, characterized in that prior to step e) the inorganic melt is separated into a mineral-rich melt fraction and a metal-rich melt fraction and a separated discharge of mineral-rich and metal-rich melt fraction from the homogenization reactor (5), wherein the mineral-rich melt fraction on the Schmelzaustragsrohr (6) will be held.

Method according to one of the preceding claims, characterized in that the inorganic melt in the homogenization reactor (5), in particular due to prevailing temperature and choice of residence time in the homogenization reactor (5) in a mineral-rich melt fraction with a density of <5 t / m ³ , preferably < 4 t / m ³ , particularly preferably <3 t / m ³ and a metal-rich melt fraction having a density of> 5 t / m ³ , preferably> 6 t / m ³ , particularly preferably 7.5 t / m ^{3 is} separated, wherein the mineral-rich melt fraction used in the subsequent steps e) to g) for the production of mineral fibers and the metal-rich melt fraction from the homogenization reactor (5) is discharged discontinuously.

Method according to one of the two preceding claims, characterized in that the mineral-rich melt fraction contains the following main constituents in the stated amounts:

Si0 ₂ : 30 to 70 wt .-%, preferably 40 to 50 wt .-%,

Al ₂ O ₃ : 2 to 30 wt.%, Preferably 5 to 20 wt.

Fe ₂ O ₃ : 4 to 35 wt .-%, preferably 7.5 to 12.5 wt .-%,

CaO: 6 to 20% by weight, preferably 8 to 15% by weight,

MgO: 0.5 to 12% by weight, preferably 2 to 12% by weight. Method according to one of the preceding claims, characterized in that in the preparation of the melt, in particular the mineral-rich melt fraction, in the buffer and mixing tank (8) additives and / or additives are added, in particular natural rock (eg dolomite, spade, diabase, anorthosite ), and / or cementitious recycled material.

Method according to one of the preceding claims, characterized in that the Schmelzaustragsrohr (6), the homogenization reactor (5) and / or the siphon (7) and / or the buffer and mixing tank (8) are heated continuously, preferably to a temperature between 1600 and 2200 ° C, more preferably at a temperature between 1800 and 2100 ° C.

Method according to one of the preceding claims, characterized in that the bent pipe section of the siphon (7) has a closable opening (9), which is preferably located on the underside of the bent pipe section, particularly preferably at the lowest point of the bent pipe section.

Method according to the preceding claim, characterized in that in the closable opening (9) a bursting disc is integrated, which is designed so that it at a predetermined overpressure, preferably at 1 bar overpressure, more preferably at 0.8 bar overpressure, burst so that the inorganic melt, in particular the mineral-rich melt fraction, is discharged through the opening (9) out of the siphon (7).

Method according to the preceding claim, characterized in that after a rupture of the rupture disk, the inorganic melt, in particular the mineral-rich melt fraction, through the opening (9) in a granulation (10) is passed and is shock-cooled there.

Method according to one of the preceding claims, characterized in that the in step f) through the siphon (7) guided organic melt is temporarily passed with the aid of a Schmelzabweisers (11) in a water-filled granulation tank (10) and shock-cooled, wherein preferably the Schmelzabweiser (11) is heated continuously, preferably to a temperature between 1600 and 2200 ° C., more preferably a temperature between 1800 and 2100 ° C.

Method according to the preceding claim, characterized in that the melt deflector (11) can be arranged in two different positions and is moved back and forth in the course of the process between these two positions, wherein in the first of these positions (A) the melt deflector (11 ) is arranged so that the in step f) through the siphon (7) conducted inorganic melt, in particular the mineral-rich melt fraction, without being derived from the melt deflector (11), to a device in which it is spun into inorganic fibers or possibly the buffer and mixing tank (8) arranged in front of the device is directed, and in the second of these positions (B) the melt deflector (11) is arranged such that the inorganic melt from the siphon (7) passed in step f) passes from Melt deflector (11) is passed into the water-filled granulation tank (10) and shock-cooled there.

Method according to one of the preceding claims, characterized in that the spinning of the inorganic melt, preferably the mineral-rich melt fraction, in particular the mineral-rich melt fraction produced in the buffer and mixing tank (8), to inorganic fibers in step h) g} takes place with a spinning process, which is selected from the group consisting of

Drawing process, in particular nozzle drawing process,

Blowing method, in particular nozzle blowing method,

as well as combination thereof. Method according to one of the preceding claims, characterized in that the metal-rich melt fraction after discharge from the homogenization reactor (5) is introduced into a granulation tank (5b, 10) and granulated.

Method according to one of the preceding claims, characterized in that the fibers produced are processed into mineral wool products or loose mineral wool.

Apparatus for producing inorganic fibers from waste, contained tend

a device (1) for compressing waste,

a heatable degassing duct (2) for drying compressed waste,

a high-temperature reactor (3) which can be heated to temperatures> 1000 ° C,

a homogenization reactor (5), which is gas-tightly connected to the high-temperature reactor (3) and which can be heated to temperatures> 1600 ° C,

a melt discharge pipe (6), which is gas-tightly connected to the homogenization reactor (5),

a siphon (7) which is gas-tightly connected to the Schmelzaustragsrohr (6) and having a bent pipe section, and

a buffer and mixing tank (8) for working up the inorganic melt for mineral fiber production,

a device (12) for spinning inorganic melt, in particular a mineral-rich melt fraction, to inorganic fibers, in particular mineral fibers.

Device according to the preceding claim, characterized in that the buffer and mixing tank (8) has at least one possibility for adding additives and / or additives.

17. The device according to one of the two preceding claims, characterized in that the homogenization reactor (5) has a bottom side arranged drain (5a), which in a granulation tion bath (5b, 10) opens.

18. Device according to the preceding claim, characterized in that the bent pipe section of the siphon (7) has a closable opening (9), which is preferably located on the underside of the bent pipe section, particularly preferably at the lowest point of the bent pipe section.

19. Device according to the preceding claim, characterized in that in the closable opening (9) a rupture disk is integrated, which is designed so that it at a predetermined overpressure, preferably at 1 bar pressure, more preferably at 0.8 bar pressure , the device preferably comprises a granulation basin (10) which is arranged so that after bursting of the rupture disk, the inorganic melt, in particular the mineral-rich melt fraction, through the opening (9) from the siphon (7) into the granulation basin ( 10) can be directed.

20. The device according to one of claims 15 to 19, characterized in that the homogenization reactor (5) has a weir (5c), which provides an accumulation of metal-rich melt to a maximum height and on reaching this level a fractional withdrawal of the metal-rich melt over a bottom side arranged drain (5a) allowed, which opens into a granulation bath (5b, 10).

21. Device according to one of claims 15 to 20, characterized in that in front of the device (12) for spinning a buffer and mixing tank is arranged, may be added to the additives and / or additives.

22. Device according to one of claims 15 to 21, characterized in that it contains a Schmelzabweiser (11), which in two Ver¬ can be arranged at different positions and between these Po positions is movable back and forth, wherein in the first of these positions (A) of the Schmelzabweiser (11) is arranged so that a by the siphon (7) conducted inorganic melt, especially the mi neralreiche Melt fraction, without being diverted from the melt deflector (11), to a buffer and mixing tank (8), and in the second of these positions (B), the melt deflector (11) is arranged so that one through the siphon (7 ) guided inorganic melt, in particular the mineral-rich melt fraction, from the melt deflector (11) slides and passed into a granulation tank (10) and is shock-cooled there.

Device according to one of claims 15 to 22, characterized in that the Schmelzaustragsrohr (6,) of the siphon (7), the Schmelzabweiser (11) and / or the buffer and mixing tank (8) consist of a material which at a temperature of 1800 ° C, before given to 2000 ° C, more preferably 2200 ° C, over a period of at least 8000 h heat resistant, wherein the material vorzugswei se is selected from the group consisting of refractory metal, ceramic, lining, and mixtures and combinations thereof ,

Method according to one of claims 1 to 14, characterized in that it is carried out with a device according to one of claims 15 to 23.

Inorganic, in particular mineral fiber, produced by a process according to one of Claims 1 to 14 or 24.

Inorganic fiber according to the preceding claim, containing the following main constituents in the stated amounts:

Si0 ₂ : 30 to 70 wt .-%, preferably 40 to 50 wt .-%,

Al ₂ O ₃ : 2 to 30 wt.%, Preferably 5 to 20 wt.

Fe ₂ O ₃ : 4 to 35 wt .-%, preferably 7.5 to 12.5 wt .-%,

CaO: 6 to 20% by weight, preferably 8 to 15% by weight, MgO: 0.5 to 12% by weight, preferably 2 to 12% by weight.

27. Mineral wool products formed from fibers according to one of the two preceding claims.

28. Use of a mineral wool product according to the preceding claim as a thermal insulation material, acoustic insulation material, building material, flame retardant or as an artificial substrate for the cultivation of plants.

29. Use of a melt, which can be produced according to steps a) to c) of a method according to one of claims 1 to 14, as a substitute for natural rock in the production of mineral fibers and / or mineral wool products.