PROCESS TECHNOLOGY

JSC Thermosteps-MTL uses 2 automatic basalt fiber insulating material fabrication lines by STM Tenova (Italy) and Gamma Meccanica SpA (Italy).

Total capacity of these two lines is 65 thousand metric tons of fiber per year. These machines perform all process operations starting from melting and ending with final packaging. Each of the lines starts with a «hot block» to melt basalt rock and transform it into fine fiber. Then the source material is polymerized and processed into sheets.

The end products are moved to the end section of the line where they are packed and pre-stacked.

Fiber
fabrication
Carpet
forming - 1
Carpet
forming - 2
Finished
product processing

The first stage of rockwool production is stacking and melting of material. Rockwool is made from molten basalt rock.

JSC Thermosteps-MTL uses the following rocks for their rockwool facilities: basalt and porphyry from the Urals and Karelia, dolomite as a reducing agent and coke to support melting. The materials are delivered at the production site by railroad, then are unloaded and stacked in the storage area, and after that are transported to loading hoppers on trucks. There the rock is sieved, weighed and batched. After that it is fed to a foundry by a number of interconnected belt conveyors.

The foundry utilizes coke energy to support melting. An integrated molding system separates molten rock and transforms it into fiber. Molten mass pours out from the funnels and onto the rollers of the rotating machine that molds it into fine fiber. Then the fiber is impregnated with a binder to make it more durable and moldable.