USE OF A MINERAL WOOL PRODUCT

Abstract

The present invention describes a mineral wool product comprising mineral fibers bound by a binder resulting from the curing of a binder composition comprising a phenol-formaldehyde-based resin, and/or a carbohydrate containing component; a hydrophobic agent comprising: (i) at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane; (ii) at least one hardener, such as silane, such as alkyltriethoxysilane, such as octyltriethoxysilane; (iii) at least one emulsifier; as insulation of a metallic structure, said structure having an operating temperature between 0-650° C., such as between 25-500° C., such as between 70-300° C., such as between 300-650° C.

Claims

1-35. (canceled)

36. A binder composition for mineral fibers, wherein the composition comprises (A) a phenol-formaldehyde-based resin and/or a carbohydrate containing component; and (B) a hydrophobic agent comprising (i) at least one silicone compound, (ii) at least one hardener, and (iii) at least one emulsifier.

37. The binder composition of claim 36, wherein (i) comprises a silicone resin.

38. The binder composition of claim 37, wherein the silicone resin comprises a reactive silicone resin selected from one or more of a polyalkylethoxysiloxane, a polymethylethoxysiloxane, a polyphenylethoxysiloxane, a polyphenylsiloxane, a polyphenylmethylsiloxane.

39. The binder composition of claim 36, wherein (ii) comprises a silane.

40. The binder composition of claim 36, wherein (ii) comprises an alkyltriethoxysilane.

41. The binder composition of claim 36, wherein (ii) comprises octyltriethoxysilane.

42. The binder composition of claim 36, wherein (B) comprises from 20% to 90% by weight of (i), based on a total weight of (B).

43. The binder composition of claim 36, wherein (B) comprises from 30% to 60% by weight of (i), based on a total weight of (B).

44. The binder composition of claim 36, wherein (B) comprises from 0.5% to 10% by weight of (ii), based on a total weight of (B).

45. The binder composition of claim 36, wherein (B) comprises from 1% to 5% by weight of (ii), based on a total weight of (B).

46. The binder composition of claim 36, wherein (B) comprises from 30% to 60% by weight of polymethylethoxysilane and from 1% to 5% by weight of octyltriethoxysilane, based on a total weight of (B).

47. The binder composition of claim 36, wherein (A) comprises a carbohydrate containing component and the binder composition further comprises one or more of (a) a polycarboxylic acid or a salt thereof and/or an inorganic acid or a salt thereof; (b) a component selected from amines and ammonia; (c) a reaction product of a polycarboxylic acid or anhydride thereof and an alkanolamine.

48. A mineral wool product, wherein the product comprises mineral fibers bound by a cured binder composition of claim 36.

49. The mineral wool product of claim 48, wherein the product comprises from 0.05% to 2% by weight of (B), based on a total weight of the product.

50. The mineral wool product of claim 48, wherein the product comprises from 0.10% to 1% by weight of (B), based on a total weight of the product.

51. The mineral wool product of claim 48, wherein the product is in the form of an insulation product for a thermal insulation of a metallic structure.

52. The mineral wool product of claim 48, wherein the product is in the form of a pipe section or a mat or a wired mat.

53. The mineral wool product of claim 48, wherein the product has a water absorption according to ASTM C1763-16 of less than 4 vol. % and/or has a water absorption according to EN13472 of less than 0.5 kg/m.sup.2 and/or has a water absorption according to EN13472 of less than 1.0 kg/m.sup.2 following storage of the product at 250° C. for 24 hours.

54. A method for producing a mineral wool product, wherein the method comprises contacting mineral fibers with the binder composition of claim 36.

55. A method of insulating a metallic structure, wherein the metallic structure has an operating temperature of from 0° C. to 650° C. and the method comprises insulating the metallic structure with the mineral wool product of claim 48.

Description

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] The present invention is directed to a use of a mineral wool product comprising mineral fibers bound by a binder resulting from the curing of a binder composition comprising a phenol-formaldehyde-based resin, and/or a carbohydrate containing component, a hydrophobic agent comprising (i) at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxy-siloxane, polyphenylsiloxane, polyphenylmethylsiloxane, (ii) at least one hardener, such as silane, such as alkyltriethoxysilane, such as octyltriethoxysilane, (iii) at least one emulsifier, as insulation of a metallic structure, said structure having an operating temperature between 0-650° C., such as between 25-500° C., such as between 70-300° C., such as between 300-650° C.

[0021] Hydrophobic Agent

[0022] The present inventors have surprisingly found that by the use of the very specific hydrophobic agent described herein, corrosion problems in form of corrosion under insulation can be avoided. Without wanting to be bound to any specific theory, the present inventors assume that the corrosion problems associated with the previously-known use of insulation elements for metal structures are connected to the so-called wicking-effect of such insulation products. This wicking effect of the insulation products causes moisture, once it has entered the system, to be retained for a prolonged period of time at the surface of the metal structure. Accordingly, such insulation materials prolong the time during which the surface of the metal structure is kept in contact with water which contributes to an increased rate of corrosion, in particular at higher temperatures.

[0023] Without wanting to be bound to any specific theory the present inventors assume that the use of the very specific hydrophobic agent described herein allows a quicker dry out time which allows an inhibition of corrosion.

[0024] It has now surprisingly been found that by use of mineral wool products prepared from a binder containing the hydrophobic agent described herein, excellent insulation characteristics can be attained while at the same time the corrosion under insulation is effectively inhibited.

[0025] In one embodiment, the hydrophobic agent comprises (i) in an amount of 20 to 90 percent by weight, in particular 30 to 60 percent by weight, based on the weight of the hydrophobic agent.

[0026] In one embodiment, the hydrophobic agent comprises (i) in form of polymethylethoxysiloxane.

[0027] In one embodiment, the hydrophobic agent comprises (ii) in an amount of 0.5 to 10 percent by weight, in particular 1 to 5 percent by weight, based on the total weight of the hydrophobic agent.

[0028] In one embodiment, the hydrophobic agent comprises (ii) in form of octyltriethoxysilane.

[0029] In an alternative embodiment, the silicone compound component (i) also serves as the hardener component (ii) of the hydrophobic agent. Accordingly, in this alternative embodiment, the hydrophobic agent comprises at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane, and at least one emulsifier.

[0030] Accordingly, in one embodiment, the hardener is another compound than the silicone compound. In an alternative embodiment, the hardener is comprised in the silicone compound as a curable system. In this alternative embodiment, the hardener may be the feature that is effected by an intra-molecular hardening of the silicone compound.

[0031] In one embodiment, the hydrophobic agent comprises (i) in an amount of 30 to 60 percent by weight, (ii) in an amount of 1 to 5 percent by weight, based on the total weight of the hydrophobic agent, the remainder being (iii) and optionally other components and trace amounts of ethanol.

[0032] In one embodiment, the hydrophobic agent comprises polymethylethoxysiloxane in an amount of 30 to 60 percent by weight, octyltriethoxysilane in an amount of 1 to 5 percent by weight, based on the total weight of the hydrophobic agent, the remainder being (iii) and optionally other components and trace amounts of ethanol.

[0033] In one embodiment, the binder composition comprises the hydrophobic agent in an amount of 0.05 to 2 percent by weight, such as 0.10 to 1 percent by weight, such as 0.15 to 0.8 percent by weight, based on the weight of the aqueous binder composition mineral wool product.

[0034] In one embodiment, the binder composition comprises a carbohydrate-containing binder component, wherein the binder component further comprises (a) a polycarboxylic acid component or any salt thereof and/or an inorganic acid or any salt thereof, and/or (b) a component selected from the group consisting of amine compounds, ammonia; and optionally, and/or (c) a reaction product of a polycarboxylic acid component or anhydride thereof and an alkanolamine component.

[0035] In one embodiment, the mineral wool product is a pipe section or a mat or wired mat.

[0036] Binder Composition

[0037] The present invention is also directed to a binder composition for mineral fibers comprising: a phenol-formaldehyde-based resin, and/or a carbohydrate-containing component; and a hydrophobic agent comprising: (i) at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane, (ii) at least one hardener, such as silane, such as alkyltriethoxysilane, such as octyltriethoxysilane, (iii) at least one emulsifier.

[0038] This binder composition, which comprises a specific hydrophobic agent, allows the production of mineral wool products which can be used as insulation of a metallic structure having very good insulation characteristics and at the same time allows the inhibition of corrosion under insulation.

[0039] In one embodiment, the hydrophobic agent comprises (i) in an amount of 20 to 90 percent by weight, in particular 30 to 60 percent by weight, based on the weight of the hydrophobic agent.

[0040] In one embodiment, the hydrophobic agent comprises (i) in form of polymethylethoxysiloxane.

[0041] In one embodiment, the hydrophobic agent comprises (ii) in an amount of 0.5 to 10 percent by weight, in particular 1 to 5 percent by weight, based on the total weight of the hydrophobic agent.

[0042] In one embodiment, the hydrophobic agent comprises (ii) in form of octyltriethoxysilane.

[0043] In an alternative embodiment, the silicone compound component (i) also serves as the hardener component (ii) of the hydrophobic agent. Accordingly, in this alternative embodiment, the hydrophobic agent comprises at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane, and at least one emulsifier.

[0044] Accordingly, in one embodiment, the hardener is another compound than the silicone compound. In an alternative embodiment, the hardener is comprised in the silicone compound as a curable system. In this alternative embodiment, the hardener may be the feature that is effected by an intra-molecular hardening of the silicone compound.

[0045] In one embodiment, the hydrophobic agent comprises (i) in an amount of 30 to 60 percent by weight, (ii) in an amount of 1 to 5 percent by weight, based on the total weight of the hydrophobic agent, the remainder being (iii) and optionally other components and trace amounts of ethanol.

[0046] In one embodiment, the hydrophobic agent comprises polymethylethoxysiloxane in an amount of 30 to 60 percent by weight, octyltriethoxysilane in an amount of 1 to 5 percent by weight, based on the total weight of the hydrophobic agent, the remainder being (iii) and optionally other components and trace amounts of ethanol.

[0047] Mineral Wool Product

[0048] The mineral fibers employed for the production of the mineral wool products may be any of man-made vitreous fibers (MMVF), glass fibers, ceramic fibers, basalt fibers, slag fibers, stone fibers and others. These fibers may be present as a wool product, e.g. like a stone wool product.

[0049] The present invention is directed to a mineral wool product comprising mineral fibers bound by a binder resulting from the curing of a binder composition comprising a phenol-formaldehyde-based resin, and/or a carbohydrate-containing component, a hydrophobic agent comprising: (i) at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane, (ii) at least one hardener, such as silane, such as alkyltriethoxysilane, such as octyltriethoxysilane, (iii) at least one emulsifier.

[0050] In one embodiment, the hydrophobic agent comprises (i) in an amount of 20 to 90 percent by weight, in particular 30 to 60 percent by weight, based on the weight of the hydrophobic agent.

[0051] In one embodiment, the hydrophobic agent comprises (i) in form of polymethylethoxysiloxane.

[0052] In one embodiment, the hydrophobic agent comprises (ii) in an amount of 0.5 to 10 percent by weight, in particular 1 to 5 percent by weight, based on the total weight of the hydrophobic agent.

[0053] In one embodiment, the hydrophobic agent comprises (ii) in form of octyltriethoxysilane.

[0054] In an alternative embodiment, the silicone compound component (i) also serves as the hardener component (ii) of the hydrophobic agent. Accordingly, in this alternative embodiment, the hydrophobic agent comprises at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane, and at least one emulsifier.

[0055] Accordingly, in one embodiment, the hardener is another compound than the silicone compound. In an alternative embodiment, the hardener is comprised in the silicone compound as a curable system. In this alternative embodiment, the hardener may be the feature that is effected by an intra-molecular hardening of the silicone compound.

[0056] In one embodiment, the hydrophobic agent comprises (i) in an amount of 30 to 60 percent by weight, (ii) in an amount of 1 to 5 percent by weight, based on the total weight of the hydrophobic agent, the remainder being (iii) and optionally other components and trace amounts of ethanol.

[0057] In one embodiment, the hydrophobic agent comprises polymethylethoxysiloxane in an amount of 30 to 60 percent by weight, octyltriethoxysilane in an amount of 1 to 5 percent by weight, based on the total weight of the hydrophobic agent, the remainder being (iii) and optionally other components and trace amounts of ethanol.

[0058] In one embodiment, the mineral wool product comprises the hydrophobic agent in an amount of 0.05 to 2 percent by weight, such as 0.10 to 1 percent by weight, such as 0.15 to 0.8 percent by weight, based on the weight of the mineral wool product.

[0059] In one embodiment, the binder composition comprises a carbohydrate-containing binder component, wherein the binder composition further comprises (a) a polycarboxylic acid component or any salt thereof and/or an inorganic acid or any salt thereof, and/or (b) a component selected from the group consisting of amine compounds, ammonia; and optionally, and/or (c) a reaction product of a polycarboxylic acid component or anhydride thereof and an alkanolamine component.

[0060] In one embodiment the mineral wool product is in form of an insulation product for thermal insulation of metallic structures.

[0061] In one embodiment the mineral wool product is in form of a pipe section or a mat or wired mat.

[0062] Pipe sections are pre-formed (formed in the factory) insulation materials used for the insulation around pipes.

[0063] A typical embodiment of such a pipe section is a mandrel wound pipe section.

[0064] A mandrel wound pipe section is a pre-formed, full-round cylindrical pipe insulation product which is produced by wrapping an uncured mineral wool blanket around a mandrel in spiral manner for forming and subsequent curing. The cylindrical pipe sections are split and hinged for easy snap-on assembly. Mandrel wound pipe sections can be both faced and un-faced with aluminum foil.

[0065] FIG. 1 shows how such a mandrel wound pipe section is typically produced. In this method the pipe section is wound from a thin web 9 of mineral wool, preferably stone wool. The web 9 is wound around a perforated mandrel 10 as it is known when producing wound pipe sections. After winding hot air is conventionally blown from inside the mandrel and through the wound pipe section for curing of the thermoset binder.

[0066] An alternative embodiment of a pre-formed pipe section is shown in FIG. 2.

[0067] FIG. 2 illustrates a block (1) bonded mineral wool and a cutting string (4) by means of which pipe sections (5) having a tongue/groove-joint (6) and a T-shaped hinge slit (7) are cut out of the block in the transverse direction of the block and parallel to the main surface planes of the block. After cutting out each pipe section 5 is removed from the block.

[0068] A further embodiment of a pipe insulation is shown in FIG. 3 which shows a mat of mineral wool provided with transversely extending V-grooves. Due to the V-grooves the mat can be wrapped around a pipe on site as indicated in the version shown at the front in FIG. 3.

[0069] An alternative embodiment is a mineral wool product in form of a wired mat. FIG. 4 is an illustration of such a wired mat.

[0070] FIG. 4 illustrates in perspective view such a wired mat according to the invention where an insulation layer 1 in terms of a mineral fiber web is provided with a chicken wire 10 which is fastened to the insulating layer 1 by means of an iron thread 14 stitched through the insulating layer. A fixation means 5 in terms of a galvanized iron wire may be in zigzag configuration and placed under the chicken wire 10. In an alternative embodiment, no such fixation means are included.

[0071] In a further alternative embodiment, mats are used without any wiring. In this alternative embodiment, the mineral wool product is in form of a mineral wool mat—sometimes also called a slab.

[0072] FIG. 5 shows how a wired mat according to FIG. 4 is mounted on a pipe as insulation material.

[0073] FIG. 5 illustrates an embodiment of the insulating product according to the invention mounted on a pipe 16, where the product comprising insulating layer 1 is adapted to fit the circumference of pipe 16 and fixation means 5a and 5b extending around the mounted product secures the product on the pipe 16 by knots 15a and 15b. The fixation means 5c has not yet been extended to protrude beyond the adjoining end surfaces of the product to enable the fixation thereby.

[0074] In one embodiment the mineral wool product has a water absorption according to ASTM C1763-16 of less than 4.0 vol. %, such as less than 2.0 vol. %, such as less than 1.5 vol. %.

[0075] In one embodiment the mineral wool product has a water absorption according to EN13472 of less than 1.0 kg/m2, such as less than 0.8 kg/m2, such as less than 0.5 kg/m2, such as less than 0.3 kg/m2.

[0076] In one embodiment the mineral wool product has water absorption according to EN13472 of less than 1.0 kg/m2, such as less than 0.8 kg/m2, such as less than 0.5 kg/m2, such as less than 0.3 kg/m2, following storage of the mineral wool product at 250° C. for 24 hours.

[0077] In this embodiment, in which the water absorption according to EN13472 is measured following storage of the mineral wool product at 250° C. for 24 hours, the following protocol for exposing the product to 250° C. for 24 hours is followed: [0078] Pre-heat a laboratory furnace to 250° C. which is placed under a fume hood. [0079] Place the samples in the furnace for a period of 24 hours. [0080] The ventilation of the furnace shall be off, except from the last 30 minutes of the heating when the ventilation shall be on in order to remove fumes from the furnace in a safe way. [0081] Remove the samples from the furnace and let them cool down to ambient temperature. [0082] After that proceed with the requested test program for water absorption.

[0083] In one embodiment, the mineral wool product according to the present invention has a density of 20 to 150 kg/m.sup.3, such as 40 to 130 kg/m.sup.3, such as 60-120 kg/m.sup.3.

[0084] A Method for Producing a Mineral Wool Product

[0085] The present invention is also directed to a method for producing a mineral wool product which comprises the steps of contacting mineral fibers with a binder composition comprising a phenol-formaldehyde-based resin, and/or a carbohydrate-containing component, and a hydrophobic agent comprising (i) at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane, (ii) at least one hardener, such as silane, such as alkyltriethoxysilane, such as octyltriethoxysilane, (iii) at least one emulsifier.

[0086] In one embodiment, the hydrophobic agent comprises (i) in an amount of 20 to 90 percent by weight, in particular 30 to 60 percent by weight, based on the weight of the hydrophobic agent.

[0087] In one embodiment, the hydrophobic agent comprises (i) in form of polymethylethoxysiloxane.

[0088] In one embodiment, the hydrophobic agent comprises (ii) in an amount of 0.5 to 10 percent by weight, in particular 1 to 5 percent by weight, based on the total weight of the hydrophobic agent.

[0089] In one embodiment, the hydrophobic agent comprises (ii) in form of octyltriethoxysilane.

[0090] In an alternative embodiment, the silicone compound component (i) also serves as the hardener component (ii) of the hydrophobic agent. Accordingly, in this alternative embodiment, the hydrophobic agent comprises at least one silicone compound, such as silicone resin, such as a reactive silicone resin, such as a reactive silicone resin chosen from the group of polyalkylethoxysiloxane, polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane, and at least one emulsifier.

[0091] Accordingly, in one embodiment, the hardener is another compound than the silicone compound. In an alternative embodiment, the hardener is comprised in the silicone compound as a curable system. In this alternative embodiment, the hardener may be the feature that is effected by an intra-molecular hardening of the silicone compound.

[0092] In one embodiment, the hydrophobic agent comprises (i) in an amount of 30 to 60 percent by weight, (ii) in an amount of 1 to 5 percent by weight, based on the total weight of the hydrophobic agent, the remainder being (iii) and optionally other components and trace amounts of ethanol.

[0093] In one embodiment, the hydrophobic agent comprises polymethylethoxysiloxane in an amount of 30 to 60 percent by weight, octyltriethoxysilane in an amount of 1 to 5 percent by weight, based on the total weight of the hydrophobic agent, the remainder being (iii) and optionally other components and trace amounts of ethanol.

[0094] In one embodiment, the mineral wool product comprises the hydrophobic agent in an amount of 0.05 to 2 percent by weight, such as 0.10 to 1 percent by weight, such as 0.15 to 0.8 percent by weight, based on the weight of the mineral wool product.

[0095] In one embodiment, the binder composition comprises a carbohydrate-containing binder component, wherein the binder composition further comprises (a) a polycarboxylic acid component or any salt thereof and/or an inorganic acid or any salt thereof, and/or (b) a component selected from the group consisting of amine compounds, ammonia, and optionally, and/or (c) a reaction product of a polycarboxylic acid component or anhydride thereof and an alkanolamine component.

[0096] In one embodiment the method is a method for producing a mineral wool product in form of an insulation product for thermal insulation of metallic surfaces structures.

[0097] In one embodiment the method is a method for producing a mineral wool product in form of a pipe section or a mat or wired mat.

[0098] The present invention is further illustrated by the following examples:

EXAMPLES

[0099] Different insulation products were tested with regard to water absorption properties according to the standard ASTM C1763-16 test method. The results of tests are stated in Table 1.

TABLE-US-00001 Mass, Water Recovery Recovery Mass, after recondition Abs. WA, WA, Density Volume Mass, immersion (after (WA) 2 hr 48 hr Sample kg/m.sup.3 cm.sup.3 initial g (2 hr) g 48 hr) g vol. % vol. % vol. % Roxul SL960, 92 4532 415.69 658.47 415.82 5.4 4.9 0.003 mat E-glass, 234 2755 646.09 3166.03 2599.29 22.9 22.6 17.73 pipe section Roxul, 73 2162 158.14 183.88 158.93 1.2 0.5 0.037 pipe section with Silicone resin BS45 Mineral wool, 145 2427 350.88 832.86 438.04 5.0 4.8 0.898 pipe section Roxul PS980, 183 1776 325.90 806.37 556.76 6.8 6.6 3.249 pipe section Mineral wool, 80 7582 606.86 2040.20 1269.98 18.9 18.2 8.746 mat

[0100] Pipe sections were tested with regard to water absorption properties according to the standard EN13472. The pipe sections were manufactured as a mandrel wound pipe section and are from the ProRox product series and the tested specimen had a thickness of 50 mm.

[0101] The tests were done on both untreated products and products that were aged (250° C./24 h).

[0102] SILRES BS 45 silicon resin from Wacker had been added to the products in amount of 0.41 wt. %.

[0103] The results from a triple-determination are stated in Table 2.

TABLE-US-00002 TABLE 2 Water Absorption level Water Absorption level according to the according to the EN13472 standard, EN13472 standard, Initial Aged (24 h, 250° C.) Sample kg/m.sup.2 kg/m.sup.2 ProRox 960 0.09 0.08