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Insulation

Market Leader Metadynea

Due to constantly growing energy prices, environmental concerns and in future reducing fossil energy resources, state legislators and public in general as well request improved insulation of buildings. In this development Metadynea is a key player in Russia with its advanced insulation binders.

Metadynea is the market leader in Russian insulation resins markets. This is based on R&D and years of experience of Metadynea’s strategic partner Dynea around the world. And Metadynea’s 10 years’ presence in the Russian markets.

At present about 50% of domestic energy use in Russia is used for heating up buildings. Energy has to be saved and the solution is high quality insulation materials in all building roofs, walls and floors. Also the requested fire safety favours mineral wool based insulation, either stone or glass.

Mineral wool based insulation materials in general are used in thermal insulation, against cold and heat, and to improve fire safety in buildings, in different industrial equipment like pipes, tanks etc. In home appliances like refrigerators, in transportation vehicles, ships and so on. The main feature of an insulation material is the high porosity or large content of air inside the structure of the material. This combined with required mechanical, moisture, flammability and other specified properties bring the low density and low thermal conductivity. And in case of stone or glass wool these specific properties are made possible with a Metadynea binder developed for the purpose.

Mineral wool, as stone or glass wool, is made as raw wool. This is then formed into required form of mats, pipes or slabs with different densities by a binder, normally a phenol-formaldehyde resin.

Technology

Mineral wool production with synthetic binder includes following processing steps

  • Charge preparation
  • Binder solution preparation
  • Silica melt preparation
  • Formation of fiber from melt flow of glass or stone
  • Mat formation from the individual fibers
  • Binder spray to the fibers/mat
  • Heating and curing of mineral wool mat
  • Cooling of the mat
  • Cutting into desired forms and sizes and packaging

To achieve the desired properties of the final product an important step of the process is the spraying of the binder. This binders adheres the loose fibers to bond together into a form with specified mechanical properties.

Choice of the binder affects among other things insulation wool’s humidity resistance, VOC emissions of the manufacturing process. With the appropriate binder also emissions from the insulation material in its use can be radically reduced or eliminated. And the choice of binder type is depending also on the end application of the wool, its density and other properties.

Resin Requirements

A synthetic resin, which is used as the core component of the binder, shall fulfill several requirements

  • High adhesion to silicate fibers to bring and fulfill high strength properties to the insulation
  • Good solubility to water for the formation of optimal particles for the spray emulsion
  • High reactivity for curing and solidification
  • No toxicity, lowest possible emissions
  • High heat stability
  • Moisture resistance in cured form
  • Good aging properties for the long, problem free usable life time of the insulation

Metadynea has a wide portfolio of resins to meet the requirements of modern insulation material. On top of different core resins from Metadynea, wool producers use additives like hydrophobic emulsions, silanes to promote adhesion, dusting preventing emulsions etc.

On top of state-of-the-art resins Metadynea has the resource and skills to provide technical service and support from consulting or problem solving to product and process development, or to assist our customers in their product and productivity development. Metadynea resins come with service.

We are glad to answer your questions and provide required binder solutions and technical service to our customers.

Customers have different manufacturing processes in use and various products in the portfolio. Metadynea can offer you resins made to fit your product, and processing requirements.

In general terms the resins, used for binding glass or stone wool fibers, can be divided in two groups. The choice is depending on economical, processing technology and product related requirements. The two groups of resins – which are both offered by Metadynea – are characterized as follows

  • resins, which require the addition of urea by wool producer at their production process = unmodified by urea
  • resins, which are “premixed” by Metadynea and do not need a urea addition by customer = urea modified resins, also called RTU (Ready To Use) – resins
Unmodified by Urea
PRIMERE 72 6646M
This resin has very wide temperature range of storage between +5-+20C. Storage time – up to 3 weeks. Low level of free phenol – not more than 0,6 w-% – lowering stack emission levels. Using ammonium sulphate is not necessary at customer’s plant. Solid content (130C;2h;0,6g) of this resin is high – above 51w-%.
Technical Data Sheet - PRIMERE 72 6646M
PRIMERE 72 6203M
High solid content – above 53,5 w-% with storage time about 14 days. The wool products, produced with this resin will have highest storage stability at open area during cold or rainy conditions. This is a good solution for customers’ warehousing.
Technical Data Sheet - PRIMERE 72 6203M
PRIMERE 72 6301M
This resin has long storage period – up to 28 days. Free phenol level is less than 1w-%. Customer should use ammonium sulphate during binder preparation. The resin is developed for high performance and quality of glass wool products.
Technical Data Sheet - PRIMERE 72 6301M
PRIMERE 72 5508M
The resin has low level of free phenol – less than 0,6w-%. Using ammonium sulphate is obligatory during binder preparation. Storage time – up to 3 weeks.
Technical Data Sheet - PRIMERE 72 5508M
PRIMERE 72 J110
Technical Data Sheet - PRIMERE 72 J110
PRIMERE 72 J320
Technical Data Sheet - PRIMERE 72 J320

 

Modified by Urea
PRIMERE 72 6450M
Free formaldehyde level below 0,5w-%, solid content above 49,5w-%. It’s desirable to use ammonium sulphate for binder preparation with this resin.
Technical Data Sheet - PRIMERE 72 6450M
PRIMERE 72 6452M
This resin has high solid content – above 53w-% combined with reasonably low free phenol level – not more than 0,8w-%. The resin is well proven in modern production of stone wool and hydro-mass process. Use of ammonium sulphate can be used in binder preparation.
Technical Data Sheet - PRIMERE 72 6452M
PRIMERE 72 5264M
Resin is more stable than 6452M in winter storage: lower temperature limit is +13C. Use of ammonium sulphate is not required. Solid content of this resin is above 48%.
Technical Data Sheet - PRIMERE 72 5264M
PRIMERE 72 5513M
This resin has the lowest level of free phenol and formaldehyde (less than 0,5w-%) – that means low emission levels of hazardous matters in exhauster-chimneys. The resin is favored by customers with plants located close to living areas. Solid content above 50w-%. Storage time is up to 2 weeks with +17-+20C. Use of ammonium sulphate is required during binder preparation.
Technical Data Sheet - PRIMERE 72 5513M
PRIMERE 72 5514M
The resin is analog of 5513M, but 5514M is more stable in winter time: storage temperature limit is +12C. Use of ammonium sulphate is required during binder preparation.
Technical Data Sheet - PRIMERE 72 5514M
PRIMERE 72 J100
Technical Data Sheet - PRIMERE 72 J100
PRIMERE 72 J230
Technical Data Sheet - PRIMERE 72 J230

 

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