BASALT

Our purpose is to present here with all possible applications of basalt roving and all products based on basalt fibers.

2

Research and Production Association Polymer-Composite. Company Limited. is based in Primorsky region, Russia. Our basic activity is research of rocks raw materials and development of new industrial technologies and equipment for production of ultra-, micro-, super-thin-, thin-, thick and continuous basalt fibers and rowing, as well as composites and other basalt products.

Our partners have been in this field for more than 50 years, we are well aware of best technological solutions from the period of Soviet Union till modern implementations of today. Numerous results of our scientific studies and our technological solutions are successfully put into life at more than 40 industrial enterprises.

BASALT ROVING

BASALT ROVINGWe can offer you our cooperation and assistance as follows.

Development of new technologies, modernization and automation of the existing technology of production of continuous, thin and super-thin staple basalt fibers and products made of them.

Development of new basalt fiber materials and technologies of their application for effective fire protection of metal and concrete structures of underground constructions and high buildings.

Testing of raw materials, selection of raw materials for production of various types of basalt fibers as per the requirements to final product.

Analysis, testing and certification of all types of basalt fibers and products made of basalt fiber, mineral wool and glass fiber.

Development, obtaining and approval of specifications, certificates and regulations for basalt materials.

Manufacturing, assembling installation and «turnkey" starting up of plants for production of continuous, super-thin and thin staple basalt fibers and products made of basalt.

Training of specialists. Author's support of the process of production, modernization of equipment in line with new

developments of the Co. Provision for technical standards, know-how, technological and operational documentation. Provision for input to design basalt fiber plants. Technical support and audit engineering at performance of complex design by the project company.

• One third of the Earth’s crust consists of basaltic rocks, most of which are easily available for industrial applications.

• Difference in chemical and mineralogical composition of the basalts affects the properties of their melt, and hence influences the final form of the fibrous material.

• According to analysis of data which had been obtained as a result of our laboratory and technological research of more than 1000 samples from basalt deposits in Russia, Ukraine, CIS , China, Korea, Canada , Japan and other countries, we developed criteria for assessing the applicability of rocks for production of various types of fibers.

• We created our database of rocks from different parts of the world, which can be used for production of basalt fibers. We also developed more than 20 techniques of testing rocks for possibility of their industrial application to produce various types of basalt fibers.

• In basalt fiber production raw material is prepared much easier than raw material for glass fiber production:

- rocks can be stored in the open air without any packaging;

- rocks are crushed into 5-40 mm fractions.

• Basalt is magmatic (formed of deep silica-alumina melts) rock of the basic structure (the maintenance silica SiO2 makes 50 ± 5 %), fallen asleep in the top layers of an earth's crust or on a

surface. • By results of several thousand analyses of rocks of a 16-kilometer layer of the earth's crust

accessible to geological studying, and under the average maintenance of chemical elements in an earth's crust prevalence of breeds in this layer which is expressed in a following proportion is established: igneous rocks - 95 %; metamorphic - 4 %; sedimentary - 1 %.

• On analytical data igneous rocks consist of 2/3 parts of a granite and 1/3 parts of basalt. Thus, the maintenance of basalt in an earth's crust exceeds 30 %.

• The basic minerals of which basalts consist, are: - plagioclase (silica-alumina, sodium and calcium); - pyroxene (chained silicates); - peridots - ore minerals (magnetite, ilmenite) and volcanic glass.

• Basalts contain (on weight): 45-55 % SiO2; 10-20 % Al2O3 and up to 20 % FeO + Fe2O3 and

MgO. Except for the cores oxide basalts contain practically all elements of the table of Mendeleyev, and, mainly, in the form of mineral connections. Completely crystal breeds of similar structure refer to dolerite, the basalts destroyed and changed by secondary processes are known as diabases and basalt porphyry. The deep analogue of basalt carries the name gabbro.

7

CLASSIFICATION OF BASALT FIBERS AND PRODUCTS

A PLAINT OF CONTINUOUS BASALT FIBERS IS CALLED ROVING.

The density of roving is different due to different number of fibers; their thickness varies from 7 to 20 microns in a plait. Rovings are marked as “tex”, which indicates the weight of 1km roving in grams.Roving is supplied in rolls; rolls are hermetically packed in plastic film.

10

COMPARATIVE PHYSICAL AND TECHNICAL PARAMETERS OF BASALT FIBERS AND THEIR ANALOGUES

№

Name of the fiberDensity,kg/m3

Destructive tensile stress,

τр , MPa

Elastic modulus at stretching,Е, MPa

Strength after

thermo-processing,

(1 h, 400 оС)

Resistance at boiling

In water in 2n NaOH in 2n HCl

MPa % of initial

Δ M, mg

% Δ М, mg

% Δ М, mg

%

1 Glass aluminoborosilicate, «Е» type

2550 2200-3450 72400 910 32,0 34,9 99,2 685,4 83 1763,8 53,91

2 High modulus glass, «UМ-31А» type

2890 3450 109630-116000

2240 64,0 11 - 1200-1400

- *153-184

-

3 Quartz 2500-2600

3000-4000 50000-110000 - - resistant - resistant - resistant -

4 Basalt continuous fiber

2750 2200-2500 85000-100000 1750 81,7 34,9 99,2 52,4 88,9 99,4 81,18

CONTINUOUS FIBERS CHARACTERISTICS

• Basalt complex fiber roving is used for fabrics of different structure and density, for thermal insulation of braiding cords, as well as for reinforcement of composite materials and various basalt plastics.

• Roving is a continuous strand with a predetermined number of multifilament yarns, running parallel to each other. In the process of production special lubricant is applied to the multifilament yarn.

• Nominal linear density of the multifilament yarns in roving depends on the nominal diameter of the filaments and their number makes (38 ± 6,5) tex for RB-9 type and (55 ± 10) tex for RB 12 type accordingly.The nominal linear density roving is defined as product nominal linear density of a complex string and quantity of complex strings in roving.

Parameter name Standards for various

types

RB-7 RB-9 RB-12 RB- 16

Filament diameter, mkm 7 9 12 16

Specific tensile strength, minimum

400 375 280 250

Mass fraction of moisture for lubricants, maximum:- "paraffin wax"- № 76

1,01,5

1,01,5

1,01,5

1,01,5

Mass fraction of substances, removed during incandescence, %, minimum

1,0 1,0 1,0 1,0

Tensile strength of filaments, MPa, minimum

21001800

1550 1400

BENEFITS OFCONTINUOUS BASALT FIBERS

• Basalt fibers (BF ) have a universal set of characteristics which distinguishes them from other fibers used in the composites industry . Properties of basalt fibers are significantly superior to those of E-glass and approach the properties of special fibers, such as: S- glass, chemically resistant glass, quartz and carbon fibers.

• High strength

   Specific strength of basalt fiber is 2.5 times higher than the strength of alloy steel and 1.5 times higher than the strength of fiberglass.

• High thermal stability

     BF can be used for a long term within temperature range from -200 ° C to + 600 ° C. They can be exposed to temperature up to 700 ° C for a short period of time. Single impact of temperature up to 1100 ° C is possible.

• High chemical resistance to water, salts, alkalis and acids

       Compared to metal BF do not corrode at all. Compared to fiberglass BF are not affected by acids. BF have high corrosion and chemical resistance to aggressive environments: solutions of salts, acids and especially alkalis. Chemical resistance of basalt fibers.

• Compatibility with other materials

       Continuous BF have good compatibility with all plastic materials, adhesives , glass and carbon fibers. There is possibility of production materials and products based on BF using different technologies of molding, filamentwinding, pultrusion, spraying and other «cold technologies».

Basing on roving it possible to produce a wide range of materials, including:

basalt twisted yarns; profile compositional products; basalt plastic reinforcement; basalt plastic pipes and tanks; geotextiles (grid and fabrics) for reinforcement of road surfaces, strengthening mounds and embankments; needle felts, fabrics and cords for composite materials and thermal installations.

Composite BCF materials have unique properties:

small specific weight, they are 4-6 times lighter than composite materials with steel reinforcement; 1.5 times stronger than fiberglass products; 10 times cheaper than the materials made of carbon fibers; weight reduction of the constructions comes to 1.5 - 2 times, the complexity of their manufacture is much less,

they can substitute nonferrous metals and stainless alloys; their application allows to increase reliability and durability performances of constructions in aggressive

environments and so on.

 TECHNOLOGICAL STEPS OF CONTINUOUS FIBERS PRODUCTION ARE

AS FOLLOWS

• delivery to the warehouse and unloading of crushed

8-15 mm basalt fraction ;

• incoming inspection of raw material ;

• preparation of lubricant; loading of crushed basalt into the oven ; melting of basalt;

• continuous fiber filament yarn manufacturing, technological control of the process

• keeping of multifilament yarn in the shop for 24 hours ;

• chopping and drying the yarn;

• winding of multifilament yarn to get roving with a predetermined value of linear density ;

• drying the roving at temperatures of 120 ... 1600 C for 12 hours (the time depends on the dryer type );

• quality control of roving for compliance with TS requirements; packaging; transportation and storage at the warehouse..

Feeder

Forming units

Warehouse of material

Winding device

Rewinding machine

Finished product

warehouse

 

Boot device

Melting furnace

Lubricating device

Fiber drying

Packing

Washing of raw material

Lubricant preparation

unit

Factory lab

DATA LINE TECHNOLOGY

Performances BCF

1 Fiber diameter, microns 7 – 20

2 Productivity, MT/year (kg/h) 100 -160 (10-18)

3Energy consumption- natural gas, m3/hr (m3/kg) - electric power, W/h (kWh/kg)

25 -30 (1,3 -2,2)30 -35 (1,8- 2,7)

4 Lubricant specific consumption, l/kg 0,6

5 Number of mass feeder sets 2

6 Diamensions, m (with platform) 8 x 8 x 8

ChinaUkraine

BASALT ROVINGcomposite materials

Composite basalt rebar Basalt and plastic pipes

Basalt geogrids

17

High pressure cylinders

 

The purpose of this presentation is to show the possibility of application of continuous basalt fibers and their products.

 

www.technobasalt.com

Contact us:

Research and Production Association Polymer-Composite. Company Limited.

DV Polymer-Composite Co. Ltd. Chalapchiy Aleksandr Chief Strategy Officer

tel.: 8924435245089207867000skype: alexchalapchiye.mail:alexbasalt@gmail.comchalapchiy@mail.ru