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New developments. Equipment

New generation BCF-G and BCF-GМ series of process equipment for the production of basalt continuous fiber (BCF).

Специалистами компании выполнены разработки установок серии BCF-G, BCF-GM для производства БНВ.

Our specialists developed equipment for the BCF production of a new generation BCF-G, BCF-GM series .

Distinctive features of the new series of installations (BCF -1G, BCF-1GM, BCF-2G, BCF-2GM) are reduction of energy consumption: natural gas and electricity, and increase of productivity.

 

Comparative characteristics of technologies and processing equipment for BCF production
Type technology and equipment Diameter of filament fibers, d (micron) Unit discharge for 1 kg of BCF.
Diameter of filament fibers, d (micron) Natural gas,   m3 Electric power, kWt/hour Weight  of one basalt spool of filament, g Weight of bushing
assembly and quantity of draw dies of the bushing, not less than
Modular installation НБВ–10  (d = 15 - 17 µ) 1.0 – 1.1 6.0

1000 - 1300 1800gram, 200 holes
Modular installation CBF-1G (d = 10 - 12 µ) 0.9 2.8 2500 - 3500 1650 gram, 200 holes
Modular installation BCF-1GM (d = 9 - 13 µ) 0.65 1.5 2500 - 3500 1680gram,200 holes
Modular installation
BCF-2GM (d = 9 - 13 µ)
0,5-0.6 1.2 3000 - 3500 1680 gram, 270 holes
 

Application of new technical solutions in the design of process plants of new series (BCF-G and BCF-GM) allowed to reduce gas and electricity consumption per unit of the BCF production. This is especially important with rising of energy costs in the world.

In general, the use of energy-saving technologies and new generation equipment of BCF-G and BCF-GM series gives it possible significantly to lower the BCF production cost.

Production of composite basalt-plastic materials and products. Basalt-plastic rebar. Section materials. Pipes.

There are three types of the process equipment (pultrusion lines) for production of basalt-plastic rebar and section materials. Supply of the pultrusion lines is carried out for BCF factories.

Standard pultrusion line for the production of basalt -plastic rebar and section materials is presented on the photos.

Bobbin carrier for basalt fiber roving and the section for installing the bobbin carriers for feeding basalt fiber roving to the pultrusion process lineBobbin carrier for basalt fiber roving and the section for installing the bobbin carriers for feeding basalt fiber roving to the pultrusion process linePultrusion process line for the production of basalt-plastic section materials and rebarPultrusion process line for the production of basalt-plastic section materials and rebar

Process line for manufacturing of basalt-plastic rebar

Basalt-plastic rebar of two types and basalt-plastic rods

Development of the production of BCF and basalt-plastic rebar (BPR) is such that the sales cost of BPR by 10 - 20% below than the price of steel reinforcement A3. Basalt-plastic rebar, due to their advantages and lower cost, will gradually replace the traditional steel reinforcement. In the coming years volumes of BPRebar production will grow exponentially. More information see in Article  Appliance of basalt fiber based materials in building and anti-seismic constructing.

Specimens of basalt-plastic tubes, suspension rods, and oil pump jack rods made from  Basalt continuous Fiber and Glass fiberSpecimens of basalt-plastic tubes, suspension rods, and oil pump jack rods made from Basalt continuous Fiber and Glass fiberBasalt-plastic cores of overhead conductors for high-voltage power transmission linesBasalt-plastic cores of overhead conductors for high-voltage power transmission lines

Plants of a new series BSTF: BSTF 20 and BSTF 40 for the production of STBF and STBF materials

The plants of new series BSTF are a new development of our company and are designed to produce BSTF felts. Compared with the conventional plants for STBF production, the new generation - the plants of series BSTF - BSTF 20 and BSTF 40 plants provide reduction of specific consumption of energy resources to produce 1 kg of STBF at 2 times; performance of BSTF 40 plant is increased twice.  

 
BSTF plant main specification
Specification Measurement unit BSTF 20
Value
BSTF 40
Value
1. Plant capacity kg/hour
tons/hour
18 -19
150 - 170
36 -38
290 - 300
2. Natural gas consumption, max., depending on the gas calorific value m3/hour 35 – 40 70 – 80
3. Electric power consumption:
installed capacity,
consumed power, max.

kVA
kW/hour
76
40
130
75
4. Compressed air for fiber blowing, pressure MPa 0,1–0,15
(1- 1.5)
0,1–0,15
(1- 1.5)
5. Cooling water (circulating), flow m3/hour 0,2 0,4
6. Parameters of forming felt:
width
density

mm
kg/m3
1000
18 - 23
1000
18 - 23
7. Overall dimensions:
length / width / height;
m 8 / 4 /4.5 8 / 5.5 / 4.5
 

 

Specific consumption of energy resources to produce 1 kg of STBF is:
natural gas – 2.0 - 2.1 m3; electricity - 2.1 kW/hour.

In comparison with conventional BSTF production plants, BSTF 20 and BSTF 40 plants allow:

  • to halve the electricity and gas consumption;
  • to reduce by 1.5 - 2 times labor costs per unit production;
  • to reduce by several times the cooling water consumption and, thus, thermal losses;
  • to improve stability and performance of the plant;
  • to reduce content of non fibrous inclusions and  correspondingly to improve the quality of the produced STBF.

BSTF 20, BSTF 40  plants are equipped with monitor and control systems of process parameters, providing the production process stability as well as the usability of operators and maintenance personnel at the plant.

Fiber blowing chamber of the BSTF installationFiber blowing chamber of the BSTF installationSTBF fiber felt at the receiving conveyorSTBF fiber felt at the receiving conveyor

 

 
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BASALT FIBER MATERIALS TECHNOLOGY DEVELOPMENT
Room 1803, 18F, Lucky Centre, #139-171 Wan Chai road, Wanchai, KL.