Generation 2.0 of basalt fiber technology

Large-scale industrial production of continuous basalt fiber (CBF).
Basic possibility of producing CBF with target market position and manageable characteristics of fiber.
With this technological solution of Generation 2.0, it is possible to create more powerful plants with a capacity to produce 10,000, 20,000 and more tons of CBF per year. The relevant calculations and documentation are being prepared separately based on available information.
One of the most attractive parts of production is its resource «asceticism»:
CBF production technological scheme can be expressed by a «stone + energy = fiber» formula. Initial raw materials is basalt rocks and it makes a third of all igneous rocks.
Demand for CBF and basalt-based composites in all areas of the industry is growing, but large-scale production is hopelessly lagging behind, relying mainly on first-generation plants. These plants were established based on experimental prototype technology, whose aim was only to confirm that CBF production is possible, but not for industrial large-scale production. But latest-generation plants (Generation 2.0 of CBF technology) currently account for only 20% of the current capacity of worldwide CBF production.

Today, there are significant advances in all the fundamentals of basalt production: the technology has stepped forward considerably, laboratory tests have allowed to select raw materials to obtain basalt fiber with specifically set properties, and the global industry is ever ready. Moreover, new construction materials with better physical and mechanical properties are required.
Our company's main activity is to create effective plants for production of continuous basalt fiber (CBF) using cutting-edge technologies. Basalt products coming out from such plants have highly competitive advantage thanks to optimal price/quality ratio. The products also enjoy high demand in the market.
Comparison of existing technological solutions.
Generation 1.0
Trial production of CBF

Generation 2.0
Large-scale industrial production of CBF, offered by Global Basalt Engineering Co.
Purpose
Basic possibility of CBF industrial production.
Basic possibility of producing CBF with target market position and manageable characteristics of fiber.
Main equipment
Up to 8 (eight) furnace modules are needed for a production capacity of 1000 tons/year.
The 1 (one) furnace unit are needed for a production capacity of 1000 tons/year.
Melting process
Low-capacity furnace module with capacity up to 140 tons of CBF per year.
The melt is not prepared. There is only the melting of fusible components.
Multi-bushing furnace unit with capacity of 1000-1500 tons of CBF per year.
The melt is prepared. There is completely destroying the crystal lattice.
Raw material extraction
Production at quarries, selected largely by chance, and based only on the results of a chemical analysis of rocks.
Preliminary careful selection of quarries and existence of methods for raw material detection, according to the requirements for obtaining products with given properties. There is system for monitoring raw material preparation on the spot.
Raw material preparation
Almost non-existent. Or not able to filter unfit raw material qualitatively.
Raw materials preparation system. Separate technologies for improving raw materials and additional charging.
Filament formation
Filament stretching: standart platinum-rhodium feeder bushings with 200 holes.
Filament stretching: modern platinum-rhodium feeder bushings with 800, 1200 or 2000 holes produced specifically for work with basalt melt and under strict control by our company.
Lubricant
The lubricant is taken from glass fiber production without adaptation to basalt fiber.
Systematic solutions of lubricants with only adaptation to basalt fiber under given to end product properties.
Process automation
No process automation.
Significant use of automation and permanent monitoring of the process.
Stability and quality of fiber
The stability of the fiber obtained in all furnace modules is a critical factor and unattainable on this technology. Each furnace module has its own chemical and temperature process and when a refractory component enters the melt, it makes a significant change in the property of the fiber.
Stable characteristics of produced fiber are reached due to the melting process with completely destroying the crystal lattice of raw materials in one furnace unit using automated process control system. Refractory components do not affect the melting process with such a volume of the melt.
Main economic characteristics
Up to 140 people for 1000-ton capacity plant.
Requires highly qualified personnel.
A lot of defects and waste.
Up to 65 people for 1000-ton capacity plant.
The process doesn't much depend on personnel.
Defects and waste is minimal.
Technology investment
(without construction)
$12000 investment for 1-ton capacity.
The rate does not decrease for large capacities of facility.
Up to $8000 investment for 1-ton capacity.
The more capacity of facility, the lower the rate.
Production view
Photo gallery of Generation 1.0
Photo gallery of Generation 2.0
Location of facilities using technology
Ukraine, Russia, China, Georgia, Uzbekistan, Ireland
Russia
The cost of building industrial buildings and structures is calculated based on local prices for construction and installation works and materials.

Phases of creation of production on release of continuous basalt fiber (CBF) and products on based basalt fibre

Specialists from Global Basalt Engineering Company make use of the latest design methods based on an integrated approach, separately thrashing through each stage extensively – from the basalt raw materials base to obtaining the final composite product.
1
PHASE 1
Before-project planning
Front-End Engineering allows to lay a solid foundation of the success of the future enterprise with minimal risk and reasonable cost. That is why we conduct two studies simultaneously – survey of basalt raw materials and economic calculations and modeling.

Chemical analysis of rock samples is not sufficient to conclude the suitability of raw materials for the production of continuous basalt fiber! The presence of our own unique techniques allows us to conduct studies of rocks on their raw material suitability with high accuracy, result-oriented.

These studies exclude the possibility of obtaining low-quality continuous basalt fiber and breakage of expensive equipment, which leads to financial damage to the enterprise. The final stage in the study of rocks is pilot-industrial melting at the operating enterprise and the production of the resulting fiber of the finished product, such as rebar.

Pre-Feasibility Study – this is one more important stage in the creation of enterprises that pay off quickly and offer short-term profits. We make all the necessary estimates for a specific location where the basalt enterprise is to be established. The estimates are based on the amount of local taxes, land use tariffs, main roads, ports, cost of laying the necessary engineering utilities, etc.

The client is provided with detailed estimates of costs of production and logistics (even in cases where raw materials will be supplied from other countries). The estimates factor in the economic dynamics with respect to production and as a whole. All these estimates are made for a particular country and economic model for a period of 4-5 years, factoring in all possible risks.
2
PHASE 2
Design
The phase consist of two stages: Pre-project stage and Engineering.

Pre-project state. Carrying out complex engineering surveys on the proposed site and development of the Conceptual design and feasibility study of investments (feasibility studies).

Engineering stage. Drafting process of project documentation: Schematic design (stage "P") and Detailed design (stage "R")

We prepare all the technical and architectural documents, including other necessary documentation, taking into account involvement of local contractors or performance of work by us.

All the necessary documentations, including examination of industrial and environmental safety, are drafted according to international standards in English language but in compliance with local regulations. Besides, we translate the documentations into the language of the client's country.
3
PHASE 3
Supply of equipment
Our company works according to the principle of individual approach to every client. This method lets us to get success in problems of all levels.

At the design phase, technological solutions are laid for production of composite products based on the produced CBF.

Equipment purchase costs account for about 70% of all investments. All equipment can be divided into three main parts:
  • technological custom equipment (furnace modules and units with bushing assemblies) for the production of CBF, which is designed and mounted based on the deep knowledge and know-how of our engineers;
  • technological special industry-specific equipment to handle fibers (winding machines, doubling machines, twisting machines, weaving looms and other machines);
  • technological composite industry equipment for working with fibers (pultrusion lines, weaving lines, winding lines, SMS/BMC lines, etc.);
  • the technological equipment ordered on the basis of design decisions of our company (conveyor lines, lines of preparation of raw materials, etc.);
  • auxiliary equipment that ensures the efficiency of the entire complex of technological equipment;
  • automated software complex (SCADA) with control system of all technological process from raw materials to final product.
4
PHASE 4
Construction
Structural and architectural works and connection to the infrastructure will be carried out by contractors or by our company. Options are considered and negotiated at the economic calculations stage during which a different plan can be justified, for example, construction of large-capacity enterprise.

Construction of a CBF production plant will be implemented in three phases, which reflects one of the main features of the technology – flexible and modular scaling of production.

The first line of the enterprise starts production at the construction stage of the second and third lines. Such scheme is to increase production capacity to the planned level.

The total cost of the project and equipment is determined at the stage of preliminary economic calculations (preliminary feasibility study).
5
PHASE 5
Support & Maintenance
Global Basalt Engineering Company provides complex technological support for production and full control over on-site maintenance of equipment. We use modern automated software systems for process and technical management. In our support and maintenance services, our specialists are always ready to promptly provide clients with the necessary spare parts and components.

Constant design and project work, improvement of technological processes, as well as increased demand in the basalt industry are contributing to development of basalt technologies.

As part of process management, we are ready to upgrade process nodes and processes to help keep the enterprise at current technological level.
Are you interested in the technology and do you want to organize CBF production facilities?
Leave us your contact details and we will contact you to discuss cooperation.
Contacts and Representations
We are always ready for constructive dialogue.
Russian Federation
HeadQuarters
+7 499 113 2019
contact@basalt.global
United Kingdom
Sales Office
+44 208 089 9092
europe@basalt.global
United Arab Emirates
Branch Office

mena@basalt.global
About the company
Global Basalt Engineering LLC is a full-cycle engineering company implementing international projects for the production of continuous basalt fiber and composite materials based on CBF.
Focus areas
The study of rocks
Equipment supply
Design and construction
International projects of engineering, production and application of basalt fiber and composites.