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Basalt continuous fibers (BCF). Organization of the industrial production of BCF and BCF primary materials.
The present information is devoted to questions of the organization of industrial production of basalt continuous fibers and marketable primary materials on their basis (BCF roving, chopped fiber, basalt twisted thread). The modern process equipment and a modular principle of design of TE BCF 1500-2000 technological line is offered for organization of BCF industrial production. TE BCF 1500-2000 industrial line it is a complex of technological equipment for BCF production, including BCF modular production units, winding units with control and monitoring equipment, equipment for charging basalt and the system for controlling charge of basalt into melting furnaces, system for recovering heat of exit gases, the smoke removal system; air supply system and the gas supply system; electric equipment of the processing units and the production line; system for controlling process parameters of the processing units and the production line; section for lubricant preparation and the system for feeding lubricant to devices for applying lubricant to basalt fibers; water-cooling system; driers for dry of primary fiber and BCF roving; equipment for rewinding basalt continuous fiber into bundles of basalt fiber roving; equipment for rewinding basalt continuous fiber into bundles of basalt continuous thread; cut machines for cutting of primary fiber and BCF roving; handling trolleys, spool holders and auxiliary equipment.
Basalt continuous fibers (BCF). BCF primary materials industrial production.
BCF roving production
Basalt fiber filament rewind into bundles of basalt fiber roving at the rewinding unit (thrower)
BCF chopped fiber production
The spools with basalt continuous fiber are installed on the spool holders for cutting the fiber at the fiber-cutting unit.
BCF twisted thread production
Twisting units (twister) are used for producing of twisted thread
Multisection twisting unit for production of twisted thread from primary basalt continuous fiber
Fiber cutting unit ( chopper)
By the given plan it is offered to design modern manufacture for producing primary marketable BCF materials, including BCF roving, chopped fiber, twisted thread. The packed basalt fiber roving, basalt chopped fiber and basalt twisted yarn may be used for production of BCF-based finish materials (cloth, meshes, nets and other textile and composite materials).
Necessary conditions for organization of basalt continuous fibers and BCF materials production:
- Presence of engineering communications: natural gas or LPG, the electric power, water;
- Industrial, storage and other subsidiary premises;
- Presence basalt career (with basalt suitable for BCF manufacturing) in nearby district is desirable.
Requirements to industrial premises and engineering communications
Company will give detailed requirements to industrial premises and engineering communications for accommodation of BCF and BCF materials manufacture in addition during negotiations.
It is possible use already available industrial premises for accommodation of TE BCF 1500 – 2000 technological line or to build new premises. The company has experience development project of BCF and BCF-based materials in Ukraine, Russia, Tajikistan, Iran, and China.
Industrial premises for TE BCF 1500-2000 Technological line accommodation
Premises should have following engineering communications:
- As the energy carrier natural gas (NG), liquid petroleum gas (LPG), or associated petroleum gas is using;
- Also electric power (220/380V, 50 Hz) and circulation technical water (in grader).
As an example Industrial premises for the chopped strand mats production made from BCF.
Preparation, Installation, and Commissioning of the ТЕ BCF 1500-2000 Production Line
The works for the preparation, installation, and commissioning of the ТЕ BCF 2000 production line shall be performed in two stages.
The first stage
- Selection of basalt raw materials for the production of basalt continuous fiber;
- Developing of Requirements to production premises and engineering communication, needed to organize BASALT CONTINIOUS FIBER (BCF) and Materials on their basis production, design of BCF project. Author's support and participation in designing and construction of BCF plant;
- Preparation of production facilities and engineering services for installation and commissioning of the equipment. Build a new premises or carry out of reconstruction of already available industrial premises for accommodation of TE BCF 2000 technological line, supply of engineering communication;
- Manufacture, supply, installation, and commissioning of the first priority equipment of the TE BCF 1500- 2000 production line rated at the productivity of 500-1000 ton of basalt continuous fiber per year, and complex equipment for production of the finish BCF products, including: driers for primary continuous basal fiber and basalt fiber roving, rewinding units for BCF roving, and units for cutting basalt fiber roving into chopped fiber;
- Start of BCF production, producing of pilot batch of BCF, train of personnel operate of technological equipment;
Period of completion is 7-8 months if production premises and engineering utilities will be ready to set up equipment.
After launching the first BCF-1 installation the final selection of basalt breed is to be made, and technological modes of BCF production are to be worked out. Technicians and operators are trained on BCF-1 installation as well. At the same time BCF-1 installation allows to begin BCF production. Thus, after 5 months small volumes of BCF can be produced, this time can be used as a preparatory period for marketing. Simultaneously with launch of first priority equipment of the TE BCF 1500- 2000, the company begins spade-works of the second stages.
The second stage
- Manufacture, supply, installation, and commissioning of the second priority equipment of the TE BCF 1500 - 2000 production line rated at the productivity of 1000-1500 ton of basalt continuous fiber per year
- Supply and installation of the equipment for reprocessing primary basal continuous fiber into basalt fiber roving and other marketable materials based of basalt fiber. Training of personnel. Period of completion is 8-9 months.
Upon request from customers the BFMTD delivers equipment and technological lines for BCF materials production, including: twisted thread and BCF articles, such as: BCF rebar, composites of various shape, pipes, rods and others based-BCF materials.
Execution of the design supervision by BFMTD specialists. Creation of the Standard Specification for the production of basalt fiber, BCF roving, and chopped basalt fiber; transfer of others technological and technical documentation required to operate of the equipment and produce marketable BCF products.
Before the installation of the equipment, the customer should prepare production facilities and engineering services required for the production
After commissioning the first production units of the production line start training the operation and maintenance personnel. The first priority production units provide the possibility to start the production of basalt continuous fiber after 5 months from the start BCF project. Technological modules are installed step by step – this approach allows starting production immediately after the module’s installation. The supply and installation of the first priority production equipment shall be accomplished at the first stage of works to be performed for the preparation, installation, and commissioning of the ТЕ BCF 1500-2000 production line. In this case, the installed modular production units will be used for the production of fiber without delay. So, the fiber is produced concurrently with the supply and installation of the second priority equipment. When the second phase is finished , technological line starts to work with total designed output of 1500-2000 tons of BCF per annual.
Experts of the company have wide experience in developing, manufacturing, installation and start-up of equipment for manufacturing of BCF and BCF-based materials.
BFMTD can provide all range of services in BCF production, beginning from technological consultations, developing technological and operation documents, technological regulation documents; and finishing with building the whole projects. BFMTD can develop administrative arrangement of the enterprise, most optimal personnel list of the enterprise which is determined with consideration for the experience gained in the 5-year operation of the enterprise for production of basalt fiber in Ukraine, with productivity of 1200 ton per year, and the new enterprise in Russia and China. BFMTD provides a new manufacturer with legal protection, based on it’s technological and equipment engineering patents.
Integrated solutions
BFMTD’s work model implies providing customer with full means for total cycle production, beginning with getting basalt, which is a raw material, and ending with finished products - BCF materials. This kind of total cycle production model is highly effective and profitable. BCF production is based on application of technological lines TE BCF 1500-2000. TE BCF 2000 lines are the base of BCF production plants with production capacities 3 000 / 5 000 / 10 000 / 15 000 tons a year
BCF and BCF materials production facilities have modular design, which allows quick and effective production organization.
BFMTD offers technological processing equipment for reprocessing of basalt fiber into BCF products, including machines, installations, and technological lines for fabrics, nets, mats, profile plastics, basalt-plastic rebar, composite materials and basalt fiber products manufacturing.
