News

IBE Horizontal Rotor Cascade Centrifuge

New development for high-throughput fiberizing: 0.8–7.2 t/h

IBE Projects GmbH presents a new development: the horizontal rotor cascade centrifuge (spinner), designed for stable, precisely controlled fiberizing across a wide production range. The concept combines a compact, service-friendly layout with high process stability—while retaining the proven blow-off aerodynamics and thermal stabilization used in our vertical solutions.

Core concept

The system is based on a horizontally mounted rotor with a cascade-type fiberizing zone. This arrangement enables:

uniform melt distribution and stable discharge through the perforation,
repeatable fiber parameters and consistent operation,
convenient maintenance and straightforward integration into production lines,
scalable capacity without changing the fundamental process logic.

Capacity and product quality

The centrifuge is engineered for industrial operation:

from 0.8 t/h (pilot / line operation)
up to 7.2 t/h (high-throughput operation)

With properly tuned operating parameters and optimized blow-off settings, the following quality figures can be achieved:

saleable product yield: > 90%
“korolyok” (shot) content: < 4%
In addition: When processing basalt melt, the rotor replacement interval compared to a roller centrifuge has been extended from ~80 to ~340 hours, significantly reducing downtime and operating costs.

Design advantages

1) Precision dynamic temperature (viscosity) control

An intelligent control system provides precision, dynamic control of melt temperature during centrifuging within ±2°C, adjusting it in real time. This ensures stable melt viscosity and, as a result, repeatable fiber quality with minimal variation in fiber geometry—in fiber diameter (thickness) and fiber length.

2) Stable melt feeding

Melt is delivered via a trough with split, two-sided distribution, reducing asymmetry, preventing local overfilling, and improving stability—especially during transient conditions.

3) Bearing zone protection and longer service life

The design includes:

a Ø80 mm spindle shaft for increased stiffness,
water cooling of the shaft to reduce heat transfer to the bearings,
a thermal shield to protect the bearing area from radiant heat and contamination.

This improves reliability, particularly at high temperatures and with intensive blow-off.

4) Thermal curtain and controlled aerodynamics

A thermal curtain is implemented in the blow-off receiver to stabilize temperature in the working zone and reduce the impact of cold air ingress. This helps maintain consistent melt viscosity at the perforation and supports stable fiber formation.

5) Compact and easy to integrate

The horizontal layout is well suited for installation on the shop floor and integration into existing process lines. The modular concept allows adaptation to specific production tasks and space constraints.

Applications

The solution targets production lines for mineral and basalt-based fibrous materials, including:

insulation products (boards, mats),
basalt staple fiber and composite intermediates,
industrial conversion of mineral melts into fibrous fractions.

Next steps

On request, IBE can provide:

technical description and layout documentation,
operating parameter sizing for the required capacity and melt properties,
integration concepts for existing furnaces, blow-off systems, and collection/filtration units,
support for commissioning and process optimization.