At the present time in the world there are two main variants of technologies and equipment for basalt continuous fiber production. There are big melting furnaces with long feeder (feeding installation), and technological lines consisting from modular units. BFCM Company possesses both types of techniques, has patents for its technologies and know-how, as well as for the most part of special equipment. Last years BCF production based on modular units is more perspectives.
All those operations are quite simple, especially if you consider that primary fusion, homogenization and enrichment of basalt initial raw material was made by ancient volcanoes, i. e. by nature. Aimtechnologies: to ensure a good quality of BCF, production stability and the required level of production cost.
All those technological features determine the particular qualities of equipment and bushing assemblies, which are used for BCF production. The experts emphasize that, while BCF production technologies seem to be simple, in practice they are quite complex and require a great deal of know-how.
To secure achieving the goal of industrial production of high-quality BCF, the whole range of technological features in their complexity are ought to be considered, and special equipment needs to be designed to match the goal.
The basalt raw material is reduced to fractures 5 ~ 20 mm in dimension the basalt fractions are fed by the charging conveyer (1) to the melting furnace (2) the charged basalt is melting at a temperature of 1400 ~1600 C the melted basalt passes through the die holes of the bushing (3) from the bushing, the basalt continuous fibers 9 ~ 15 mm in diameter (4) are fed to the unit (5) for applying lubricant the winding unit (6) performs the operation of winding the continuous basalt fibers on the spools (7) the basalt continuous fibers from the spools are rewound into the bundles (9) of basalt fiber roving.
BCF industrial production has a short history of only 25 years. The initial BCF industrial equipment was very expensive, and energy-hungry. To be able to realize the perspectives of development of BCF production, one should clearly understand that BCF technologies are still on the initial stage of their development and that their real perspectives are enormous. At last years BFCM completed the earlier started researches of fusion processes of various basalts types, thermo-chemical reactions during active basalts melting and homogenization of basalt melts, workability and characteristics of melts during continuous fibers production, developing of bushing assemblies. All these scientific researches were implemented in practice in the new series of technological equipment.
At the present time the new generation of BCF equipment provides the possibility to reduce consumption of energy, includes: natural gas at 3 times and electricity at 7 times (against the feeder melting furnaces, it was equipment of more earliest design ), increase productivity at 2 times, and, accordingly, the production cost of high quality basalt fiber was reduced significantly.
The first samples of BCF were received in Ukraine of the Soviet Union in 1959- 61. The first basalt continuous fibers of satisfactory quality were produced with laboratory equipment in 1963. A great deal of work followed to develop BCG production techniques and equipment for, to study fiber characteristics; to develop of samples of BCF materials and to study their potential fields for application.
In the middle of 1980-ies the first industrial installation for BCF production was designed and launched in a factory near Kiev. Within several years some other plants with annual output of 350 and 500 tons were launched. Those installations were equipped with furnace for basalt melting with two feeding installations, which had platinum alloy bushings. The bushing assemblies consisted of stream feeders (heating tubes) and special bushing plates. Feeding installations were a significant step forward in development of basalt technologies.
But this kind of equipment had some shortcomings, such as high energy consumption on unit of production, great weight of bushings and rather low productivity. In Soviet time the main consumer of basalt materials was the defense industry (the armaments industry), so there was no attention paid to the high cost of BCF production.
In the end 1990-es a new generation of BCF production technologies and equipment based on a modular approach were designed, it was made in order to decrease energy consumption, lower equipment costs and minimization of the bushing weight. On the basis of new modular techniques in 2000-2002 the Ukraine-Japanese joint venture for BCF production was built, new BCF Plant produced heat-resistant fibres used in Toyota's car mufflers. In Ukraine, in 2003 year, the new BCF plant was established using new techniques.
A new modular laboratory and industrials installation with low energy consumption was developed and commissioned for two BCF plants in PR China. Experience of BFCM technical experts in China gave a new impetus to the developments of basalt technologies. New types of basalt were tested for BCF production, new energy saving equipment were developed and launched. Dr.Osnos S.P., the leading specialist of the company, carried out all the basic scientific and engineering development works according to the state program No. 863 of Chinese Peoples Republic, "Continuous Basalt Fiber and Composite Materials on its Basis". Two BCF factories in China were established use new modular techniques designed by Dr. Osnos. One in Chengdu city, Chengdu Aerospace Tuoxin Science & Technology Co., LTD later renamed in Sichuan Aerospace Tuoxin Basalt Industrial Co., LTD; and another in Shanghai Shanghai Russia Gold Basalt Fiber and Zhejiang province Hengdian Group Shanghai Russia Gold Basalt Fiber - GBF(Gold Basalt Fiber). In 2008-2009 BFCMs experts established a new BCF plant NPO Vulkan in Russia Federation.
Beginning from 2000 year, experts of our company have extensive experience of organization of production on the basis of basalt fiber to use of new technologies on a modular approach. Their portfolio includes seven plants for BCF and STBF projects in Ukraine, Russia and China.
Our Company is a designer and manufacturer of process equipment for the production of basalt continuous fiber (BCF) and materials on their basis, and also thermal insulation materials based on thin and super thin basalt fibres.
For achievement high economic efficiency and quick investment payback it is most rationally to organize industrial production on the process line TE BCF 1500 - 2000 with productivity of 2,000 -2,500 tons per year of BCF.TE BCF 1500-2000 processing line is designed for industrial production of BCF. The line with 16 units (bushings) has a productivity of 1,500 tons a year, the line with 22 units 2000 tons a year.
BCF-1GM- Modular gas-electric installations with single bushing-assembly; its main application is working though the operating modes of BCF production, researching of fusion processes of various basalts types and selection of basalt raw material, training of personnel operate of the equipment.
BCF-2GM- Modular installations use for industrial BCF production. BCF 1500 2000 processinglineiscomplicatedbymainandauxiliaryequipmentforproducingofmarketableBCFproducts(BCF roving, BCF chopped fiber, twisted thread), including: site for lubricant preparation, dryers, equipment for rewinding of the primary BCF into roving, chopping machines, laboratory QC, accessories and others Under the clients requirements, TE BCF 1500 2000 technological line can be complicated by machines for twisted thread producing.
BCF industrial production with annual output of 2,000 -2,500 tons is economically advantageous and cost-effective manufacture, and has enough short terms return on investment . BCF manufacturers with annual productivity of 4,000, 6,000, 10,000 tons of BCF are created on the basis of the TE BCF 2000 processing lines.
Joint production of BCF and materials based on BCF is most expedient; it allows to orient the production of BCF materials and products to final consumers and make the BCF enterprise even more profitable.
STBF-800Companys offer Process equipment for manufacture of heat - insulating materials: - Process lines for production of heat-insulating slabs with density of 50 -180 kg/m3 made from staple thin basalt fiber. Main specifications of the process lines are presented in section Staple thin basalt fiber - Equipment for production of heat-insulating materials - Process equipment of new generation for production of super thin basalt fiber and materials of their basis - heat- insulating felts and punched mats. Main specifications of the process equipment are presented in section Equipment for production of STBF and STBF materials - BCTF 20M, BSTF 20, BSTF 40 plants.
Equipment of application of energy-saving technologies in industry includes recuperators, heat-exchangers, heat recovery and recycling systems, controllers of gas and water supply, gas burners, system of automation and control of technological processes, and other equipment. The equipment will be made, completed and delivered in accordance with the reconstruction design of the existing furnaces and thermal equipment, or bundled with the delivery of new furnaces. High temperature fibrous materials are used for fettling of the heating furnaces. Thus these materials combine properties refractory and thermal-insulating materials concurrently. Usage of equipment, energy-saving system, new fettle materials in complex allows to reduce of energy consumption by 20 50% for heating and kilning furnaces.