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Super-thin basalt fiber - Super-thin basalt fiber. Technologies and equipment

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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. Technologies and equipment

In brief, conventional technology of STBF production consists of the following processes:
  • Loading crushed basalt rock in the furnace;
  • Basalt melting and melt homogenization in the furnace;
  • Production of basalt melt from furnace feeder through a bushing assembly in the form of continuous primary fibers ( filament);
  • Blowing of primary fibers with burner into staple super-thin fibers;
  • STBF felt formation at the corresponding conveyor.
 

STBF production installationSTBF production installation Melting furnace of the STBF installationMelting furnace of the STBF installation

 

Pulling of the primary fibers from bushing assembly of the STBF installationPulling of the primary fibers from bushing assembly of the STBF installation Fiber blowing chamber of the STBF installationFiber blowing chamber of the STBF installation

 

Forming chamberForming chamber STBF fiber felt at the receiving conveyorSTBF fiber felt at the receiving conveyor

STBF production technology - by extracting the primary fibers and blowing them with high-temperature gas flow. For a long time, STBF installations work at many plants. Structure of conventional STBF plants is developed more than 30 years ago and during that time, it has not been changed.

The Company experts developed a new generation of STBF plants with enhanced performance, and low power consumption.

 

Company’s offer - a new generation of STBF plants

Supply, installation, and commissioning of the equipment for production of STBF and STBF materials.
BCTF 20M plants. The plants series BSTF is operationally proven and modified based on operating experience.

Technological equipment of new generation - the plants of series BSTF - BSTF 20 and 40. BSTF plants provide a significant reduction of energy consumption.

BSTF 40 – the plant with improved performance and low power consumption. Performance of BSTF 40 plant is increased twice compared with the conventional plants.

Equipment for production of STBF and STBF materials.

BCTF 20M plants.
BCTF 20M plant is proven its reliability for more than nine years of operation.

Some peculiarities of BCTF 20М plant. Considering operating experience BCTF 20M plant was modified as follows: rock-melting furnace, the unit of bushing assembly installation, gas burners, the fiber blowing chamber and recuperator.
* The bushing assembly is made from heat-resisting steel.

BCTF 20M plant main specification
SpecificationMeasurement unitValue
1. Plant capacity kg/hour
tons/hour
16 -18
140 - 160
2. Natural gas consumption, max., depending on the gas calorific value m3/hour 55 – 60
3. Electric power consumption:
installed capacity,
consumed power, max.

кВА
кВт/час

90
45
4. Compressed air for fiber blowing, pressure MPa 0,1–0,15
5. Cooling water (circulating), flow m3/hour 0,5
6. Parameters of forming felt:
width
density

mm
kg/m3

1000
18 - 23
7. Overall dimensions:
length / width / height;
m 8 / 6 /4.5
 

Specific consumption of energy resources to produce 1 kg of STBF: natural gas - 3.1 m3, electric power - 2.4 kW/hour.

The plants of a new series BSTF: BSTF 20 and BSTF 40

Установки BSTF 20 и BSTF 40 предназначены для производства холста БСТВ.

BSTF 20 and 40 BSTF plants are designed to produce BSTF felt.

The main features of the new generation BSTF plants is usage of new proved developments and technical solutions: gas burners and blowing chambers, rock melting furnace and its feeder, recuperator, bushing assembly, water cooling system. To manufacture the plant, modern components and systems were used: transformer of bushing assembly, high-pressure fan, fiber extractor, control and monitoring equipment. Plant configuration was changed that provides better efficiency of the operators, smaller dimensions, and weight of the plant.

Basic technical solutions have been tested practically and showed good results. BSTF 20 plant was successfully tested, confirmed its performance during operation.

Main technical characteristics of BSTF plant are given in Table.
BSTF 40 plant represents two paired BSTF 20 plants installed on the same production site and working to the one receiving conveyor. The capacity of one BSTF 40 plant can replace two conventional BSTF plants.

BSTF plant main specification
SpecificationMeasurement unitBSTF 20 ValueBSTF 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.

BSTF 20 and BSTF 40 peculiarities

During plant development, some innovative technical solutions were made allowing in comparison with conventional BSTF production plants:

  • 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 ensure the quality of the produced STBF.
 

BCTF 20M, BSTF 20, BSTF 40 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.

Manufacturing process management of STBF and its material

Общий вид установок БСТВ г.НытваОбщий вид установок БСТВ г.НытваIt is economically feasible to organize a site (shop) with a completed STBF production cycle and manufacture of materials from STBF. Economic calculations show that in the future the number of BSTF 20M, BSTF 20 plants in the shop should be not less than five, and BSTF 40 – not less than three. The table presents the STBF production volume at BCTF 20M, BSTF 20, BSTF 40 plants.             

General view of the installations STBF, Russian Federation, Nytva town.

 
Объемы производства БСТВ
Plant IdentityNumberPlant capacity,
kg/hour
Plant capacity, kg/dayPlant capacity, tons/year
BCTF 20М 1 16 -18 410 140 - 160
BCTF 20М Line 5 80 2050 700-800
BSTF 20 1 18 -19 440 150 - 170
Линия BSTF 20 5 90 2200 750-850
BSTF 40 1 36 -38 870 290 - 300
BSTF 40 Line 3 100 - 110 2600 900
 

As distribution area of the products is increased, it is possible to place a larger number of the plants.

Production equipment of STBF materials
STBF process equipment

Produced material

UPKh-10 plant for felt production Heat insulation felts
MP - 10 machine for needled mat production Needled heat-insulating mats
Special sewing equipment Enclosed heat- and sound-insulating mats
Board production process line Board, thickness of 5 to 10 mm
Slab production process line Heat-insulating slabs
 

Production facility requirements

Basic requirements to production facilities on site location (shop) of STBF production.
Placement of five BSTF 20M, BSTF 20 or three BSTF 40 plants: width - 20 m, length - 40 m (placing the plants in a line), height - not less than 7.5 m, required shop height is 8 m.

Utilities:

  • middle pressure gas (0.03 - 0.04 MPa or 0.3 - 0.4 kg/cm2), flow rate - 350 m3/h;
  • electricity 3x380V, 50 Hz; installed capacity is 600 kVA (including two-fold reserve);
  • compressed air – 60m3/min, pressure – 0.12 MPa (1.2 kg/cm3);
  • water supply – up to 5 m/h (recycling supply from cooling towers), water pressure – 0.3 MPa;
  • sewerage for domestic needs of the staff.
 

Production facilities should be equipped with aeration lantern, plenum system, overhead-track hoist or other lifting devices to install equipment and lift basalt raw materials. Weight-carrying capacity of overhead-track hoist – 400 - 1000 kg. The site should have a number of utility areas: a basalt raw material storage area of 100 - 200 m2, storage area for finished products - 300 - 400 m2. The manufacturing site should be equipped with household premises for personnel, premises for technical personnel (section foreman, production foreman, electricians, and automation technicians), repair room (should have fitter work place, welder work place). Minimum distance to the nearest dwelling houses is 200 meters.

Production management of STBF materials

Installation and commissioning of STBF plants on the site will be carried out by stages: installation and commissioning of the first plant, then the next plants – in every 2 - 3 months each.

Installation and commissioning of process equipment for STBF production and its materials are carried out on turnkey basis including commercial production batch, customer’s personnel training.

The customer is responsible for preparation of the manufacturing areas to place the equipment and supply the communications (gas, electricity, compressed air, water), for mounting smoke exhaust system (air ducts, smoke stack).



 
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