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Super-thin basalt fiber

Article Index
Super-thin basalt fiber
Super-thin basalt fiber. Technologies and equipment
Equipment for production of heat-insulating materials
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Super-thin basalt fiber – Materials. Staple-thin basalt fiber - Heat-insulating materials. Properties and benefits.

Super-thin and thin basalt fibres and materials

Базальтовое супертонкое волокноБазальтовое супертонкое волокноSuper-thin basalt fiber (STBF) is a layer of staple fibers of 1 - 3 microns in diameter, tangled and bound with each other taking the form of a felt. This is high quality basalt wool felt.
Staple-thin basal fiber (TBF) is layer of staple fibers of 4 - 9 microns in diameter, and 10 – 80 mm in length.

On the basis of STBF and TBF felts heat- and sound-insulating materials (mats, needled mats, cardboard, soft and rigid plates) are manufacturing.

PropertiesMeasurement unitSTBF feltTBF felt
Fiber diameter μm 1 - 3 4 - 9
Fiber length mm 10 - 50 10 - 80
Density kg/m3 18 - 25 26 - 36
Thermal conductivity, at 300°К W m°С 0,035–0,036 0,037 - 0,041
Application temperature °С –200… +600 –200… +600
 

Advantages of super-thin and thin basalt fibers

  1. Basalt fiber is made exclusively from basalts without admixtures of other minerals.
  2. They have good thermal-insulating properties.
  3. Material is noncombustible, has a high heat resistance. Continuous temperature is up to + 600 °C. Temperature of Low single (short-term) application – up to 1000 °C.
  4. They have a high chemical resistance and long operation life.
  5. High sound-insulating properties and vibration resistance.
 
Sound-insulating characteristics and vibration resistance
Material density – ρ =15 kg/m3; Material thickness – 30 mm. Gap between the material and insulated wall is 0.0 mm.
Frequency range, Hz 100 - 300 400 - 900 1200 - 7000
Normal sound absorption coefficient 0.05 – 0.15 0.22 – 0.75 0.85 – 0.93
Material density – ρ =15 kg/m 3; Material thickness – 30 mm. Gap between the material and insulated wall is 100 mm.
Frequency range, Hz 100 - 200 300 - 900 1200 - 7000
Normal sound absorption coefficient 0.15 0.86 – 0.99 0.74 – 0.99
 
  1. STBF materials are made without using the binding agent or inorganic binders.
  2. STBF materials does not release toxic substances due to heating or exposing to an open flame.
  3. Low hygroscopicity; it is in 8 times lower than that of glass fibers.
  4. High operation life even in humid environments.
 

Staple-thin basalt fibers rank below in quality of super-thin basalt fibers. Their main advantage is low production costs, 3-4 times lower than the cost of STBF production.

Production cost of staple-thin basalt fibers using gas-melting furnaces is quite low compared to other types of furnaces.

Production of materials, such as soft, rigid plates, and cardboard; are performed according to NS-1B binder spraying technique that determines the low moisture of the mat. Therefore, the energy consumption for drying the plates and cardboard is minimal.

The proposed technologies and equipment are determined low production costs of staple-thin basalt fiber, and materials based on such fiber.

Super-thin basalt fiber. Materials

Super-thin basalt fiberSuper-thin basalt fiberSTBF felt
Felts are a layer of tangled super-thin staple fibers bound by force of natural cohesion.
They are intended to manufacture heat- and sound-insulating materials with very high quality for industry and construction.

Needled MBPa and MTPB mats
The mats are made on the base of super-thin basalt fiber enclosed in fiberglass fabric (MTPB) or not enclosed (MBPa) and needled with fiberglass roving or basalt roving.

Application. MBPa and MTPB mats are used as heat insulation in high and low temperatures for pipelines of industrial equipment, shipbuilding and for other means of transportation as well as in construction works for insulation of walls, partitions, floor structures.

Heat- and sound-insulating mats TM-19-20, ATM-10C-20, ATM-10K-20
The mats are made on the basis of ultra - and super-thin fiber on both sides encapsulated in fibreglass or silica fabric and needled with fibreglass or silica yarn.

Sound-absorbing mats BZM
Mats are made on the basis of STBF with acoustic transparent shell made from fiberglass.
Application. Mats are used as sound-absorbing filler in noise-insulating structures of the equipment (aircraft and marine engines) and other devices.

Felt woolen board TK-1, TK-4
The board is made of STBF felts based on the inorganic binder.
Application. The board is used for heat insulation of industrial equipment, household appliances (gas and electric stoves, ovens). It is an effective, environmentally safe substitute of asbestos board.

Heat-insulating plates PMTB
Plates are made of basalt super-thin fiber based on the inorganic binder.
Application. The plates are used for heat, sound insulation of ships, and industrial equipment within the range – 260°C – +700°C, and withstand long-term heat and flame load up to 1100°C.

Staple thin basalt fiber. Heat-insulating materials. Heat-insulating plates

TBF feltsTBF felts TBF plates based on NS 1 inorganic binderTBF plates based on NS 1 inorganic binder Board. Suspended ceilings. TBF platesBoard. Suspended ceilings. TBF plates

Staple thin fiber felt.  Needled felts.  

Soft plates PTMB NS 50 – 70.
Rigid plates PTB NS 100 – 140. Board Tk-10 NS, Tk – 12NS, Tk-15NS.

Specification of materials based on staple basalt fibers
SpecificationMeasurement unitSize
Elementary fiber diameter μm 4 - 8
Fiber length, min. mm 30 - 90
Volume density kg/m3 26 - 36
Thermal conductivity (at 25°С) W m°С 0,037 - 0,041
 
Soft plate PTMB NS 50 – 70
SpecificationMeasurement unitSize
Volume density kg/m3 45 - 70
Compressive strength at 10% of deformation MPa 0.0042
Thermal conductivity:      at 25°С
                                      at 125°С
                                      at 300°С
W m°С 0,041 - 0,055
0.07 – 0.076
0.8 – 0.09
Long-term application temperature, up to °С 600
Plate size mm 500 х 1000
Plate thickness mm 40 - 60
 
Rigid plate PTB NS 100 – 140
SpecificationMeasurement unitSize
Volume density kg/m3 100 - 140
Compressive strength at 10% of deformation MPa 0.012
Thermal conductivity:      at 25°С
                                      at 125°С
                                      at 300°С
W m°С 0,044 - 0,054
0.07 – 0.076
0.8 – 0.09
Long-term application temperature, up to °С 600
Plate size mm 500 х 1000
Plate thickness mm 40 - 60
 
Board Tk-10 NS, Tk – 12NS, Tk-15NS
SpecificationMeasurement unitSize
Volume density кг/м3 150 - 160
Compressive strength at 10% of deformation МПа 0.025
Thermal conductivity:      at 25°С
                                      at 125°С
                                      at 300°С
Вт м°С 0.045 - 0.054
0.07
0.09
Long-term application temperature, up to °С 700
Plate size мм 500 х 1000
Plate thickness мм 40 - 60
 

Materials based on basalt fibers and inorganic binders NS-1B are noncombustible in heating and exposing to an open flame, and do not release harmful substances, and smoke.

Thin and super-thin basalt fiber. Scope of application

Scope of application of heat-insulating materials made of staple thin basalt fibers.

Due to the low production costs, the staple thin basalt fiber materials are widely used.
Industrial civil engineering – insulation of walls, ceilings, roofs, facade heat insulation of buildings.
Fire protection systems buildings, metal constructions.
Insulation of steam lines and heating mains.
Industrial insulation - furnaces and thermal equipment.

Application of super-thin basalt fiber and STBF materials

Power engineering – nuclear, thermal power plants, turbines, heating plants, steam boilers, heating mains; heat and sound insulation of thermal equipment.

Fireproof materials for fire protection systems: firewalls, protection of critical metal structures, fire doors, passages, etc.

Manufacture of ceramics, porcelain, building materials – insulation of furnaces and equipment in manufacturing the ceramic and porcelain products (dishes, vases, sanitary products, etc.), furnaces for brick manufacture, ceramic tiles.

Machine-building – insulation of thermal equipment, heating and hardening furnaces, heating mains.

Aircraft industry – heat- and sound-insulating mats, enclosed in waterproof fabric for heat and sound isolation of engine and fuselage. STBF is used for "Soyuz" spaceship. The high quality of materials has been proven. 

Shipbuilding – heat-insulating panels based on the inorganic binder for heat and sound insulation of ship plants, equipment, ship hulls, bulkheads.

Cryogenic machinery and equipment – insulating material in production of liquefied gases, liquid oxygen, etc.

Metallurgy – materials for insulation of different kinds of process furnaces and thermal equipment, regenerators, recuperators, pipelines, and communications.

Chemical and petrochemical industry – insulation of thermal equipment, heating furnaces, drying chambers, steam boilers, steam pipelines, heating mains; nonflammable, fire-resistant materials for fire protection of the equipment and facilities.

Production of constructional materials and structures – heat insulated panels for prefabricated buildings and structures, floorings; suspended ceilings, fire walls, fire doors, constructional plastics.
Filters. STBF is widely used for manufacture of filtering materials and products, fine filters for air and liquids, high-temperature filters.
STBF made at 1400 - 1500°С is an excellent material for hydroponics in cultivating the bacterial cultures, seedlings of plants, etc.

Household appliances - heat insulation of gas and electric stoves, gas and electric ovens.

More information see
Technology and equipment for production of super thin fiber
Processing equipment for manufacturing of heat-insulating plates



 
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