Low-energy binding agent for stone wool-based products

Introduction. The primary objective of this study is to reduce the energy consumption involved in manufacturing mineral wool products by developing an innovative binder based on modified epoxy compounds. To achieve this objective, the potential use of epoxy compounds as binders and their modification methods were thoroughly investigated. Materials and Methods. The materials used included an epoxy binder, a modifier, and a plasticizer. The mineral wool featured an acidity modulus ranging from 1.8 to 2.1 and fiber diameters approximately 4–5 μm. Adhesion strength and tensile strength tests were conducted using an INSTRON 3382 testing machine. A methodology was developed and implemented to study the formulation and technological parameters for producing the modified epoxy binder. Results. The optimal composition of the modified epoxy binder was identified, comprising 6% modifier (latent component) and 3% plasticizer. The recommended thermal curing temperature was established at 150–154 °C, which is significantly lower than the 240–320 °C typically required for conventional binders. This work helps by creating a digital method to study the technology and showing that, obtained using a latent component and plasticizer, modified epoxy compounds can be used as binders for mineral wool products. Following curing, the adhesion strength to mineral surfaces reached 58.4 MPa, the tensile strength of the binder was 77.4 MPa, and the adhesion strength after climatic testing was 29.1 MPa. Conclusion. Assessment of the properties of mineral wool products demonstrated that their operational durability is comparable to that of products manufactured with traditional binders. Mineral fiber products – including basalt, glass, and stone wool – are among the most commonly used and effective thermal and sound insulation materials. Their application significantly reduces energy consumption for cooling during hot periods and heating during cold seasons. Using the modified epoxy binder cuts energy costs for heating by 50% and lowers overall heat use by 20–30%, which improves the energy efficiency of the products.