1- Technology of production of basalt continuous fiber

Описание  технологического процесса

Before the start of production of continuous basalt fibers on an industrial plant large fraction of basalt rubble jaw crushed to the required fraction which is 5-12 mm. After selection of metal inclusions magnetic separation method, a basalt raw materials represented in the form of fine gravel or chips with average grain size of 5 to 12 mm is sieved off and washed with small impurities (dust, etc.), after which it was dried under normal conditions in the natural air circulation through ventilation or a special drying apparatus (depending on climate conditions of production). With the help of crane or hoist basalt chippings washed periodically loaded into the hopper loader installed on the melter.

The melting furnace is a regenerative continuous tank furnace with direct gas heating of the melting zone. In the furnace basalt raw material melts, and it comes after homogenization the melt in the feeder for the subsequent molding thereof feeders complex continuous basalt filaments. Melting is carried out at a temperature of crumbs (1500 ± 50) ° C in the combustion of the gas air mixture, which consists of natural gas and air. Combustion air is supplied from the high-pressure fan through a heat exchanger-recuperator, where it is heated with heat of exhaust gases to a temperature of 450 - 600 ° C, and the gas supplied from the gas distribution substation (EMG). The melt from the feeder of the furnace fed by gravity to the feeder at the bottom of which there are dispensing devices 6, through which the melt is fed to a platinum rhodium, bushing, where the formation of elementary CBF. The melt from the feeder through a platinum drain device (jet feeder) with electric heating is supplied into a platinum, bushing with electric heating, wherein the spinnerets forming a strand of elementary filaments as the filaments by drawing and winding them to a pulling device. Strand filaments on a roller enters the pulling device, which applies a lubricant after lubricant layer coating its filaments are collected in a multifilament yarn. Integrated thread passes Nita Expanding apparatus wound on his removable spool. As the winding bobbin with the yarn withdrawn from a bobbin of the winding machine and replaced with a new reel. Winding on bobbins apparatus is formed multifilament yarn (CN), which consists of 1200 elementary CBF. Wound bobbin maintained day under normal conditions, and then come to the department for rewinding the roving with the necessary number of additions. After rewinding the roving to the finished coils labeled and wrapped with paper, then packed in wooden crates and enters the composition of the finished product.

 

2- Process  Flow  Diagram: /  Схема   последовательности технологических операций

The technological process of roving consists of the following stages:
       delivery and unloading of crushed basalt fraction 5 ... ..12 mm at the warehouse;

 incoming inspection raw material,

preparation of a lubricant,

 loading crushed basalt in the furnace;

melting of basaltic melt generation in the form of continuous fiber filament yarn;

process control complex basalt yarns,

filament yarn exposure in a plant for 24 hours,

cutting chips;

 fast drying multifilament yarn roving and obtaining a predetermined value of the linear density;

roving drying at 120 ... ..160 ° C for 12 hours (depending on the type driers)

 quality control roving to meet the requirements;

packaging, transportation and warehousing. 

3-Layout:/Схема размещения оборудования (план участка):

 

 

4- Product range, Production capacity/Мощности производства

The preferred production capacity of at least 2,500 tons of basalt fibers per year using eight platinum - rhodium bushings 1200 holes each.
The workshop involves the production of continuous filament yarn linear density of 600 ÷ 800 tex from natural basalt and subsequent processing into roving for various purposes.

 

5- End production application/ Применение конечной продукции

- Aviation Industry (fireproof insulation of engines onboard aircraft parts, sound mufflers in industrial installations, brake pads);
- The radio-electronic industry (manufacture of printed circuit boards having high temperature characteristics, and stable dielectric properties);
- Petrochemical industry (filters for cleaning of process gas, filters for waste water treatment from oil products, technological lines);
- Construction industry (non-flammable solid construction details and design instead of wood, soft and hard roof);
- Engineering industry (depreciation pad presses, coldness insulation of industrial and domestic refrigeration, insulation of tanks with oxygen, nitrogen, etc.);
- A special technique as a container with increased resource exploitation for the storage and transportation of ammunition

6- Product quality specifications:/Технические характеристики, качество продукта

Fiber strength properties  

 

Chemical resistance of fiber

 

7 - Raw material:/Сырье

Basalt rubble as a single component raw material for basalt continuous fibers must be developed to certify career, representative examples of which have been laboratory and pilot tests with a positive result.
Raw materials from rocks is crushed average, basic and ultrabasic rocks metamorphosed volcanic basalt types: basalts, gabrro, amphibolites, diabase, porphyry and others (hereinafter referred to as the raw material).
Raw materials should be radiation-safe. Equivalent dose of ionizing radiation should not exceed 0.30 mSv / h.
The materials must not contain impurities in the form of metal, quartz, sand and clay and other rocks.
The raw material is delivered in the form of a fraction, characterized by the smallest and largest nominal grain size of 5 mm and 12 mm.
The content of grains smaller than 5 mm should not exceed 10% by mass, the grain size of more than 12 mm and should not exceed 10% by weight.

 8-Main Requirements:

 

9- Energy resources: /Энергорессурсы

a) Fuels/топливо

Natural gas for 1 kg of basalt fiber - 1,0 m3

b) Electricity/электричество

Electricity (3 phase), - transformers and power kW and their number, voltage 380 V
Electrical Power kW:
Installed 2 x 630 independent power supply (one is redundant) power consumption - 1 350 for technological purposes
Power consumption kW, 4200 * th. KW
Electricity consumption per 1 kg of basalt fiber 1,7 * kW 

C) Air /воздух

Compressed air for 1 kg of basalt fiber -17.6 m3

 

d) Water/вода

 Flow 270 m3 per day
Distilled water consumption of 1.2 m3 per day

10- Equipments table/Оборудование

 

1. The site preparation basalt

1.1 . Crusher, magnetic separator, loader.
1.2. Spiral classifier for washing and drying, fractional crushed basalt given chemical composition.

   

    

3. The site continuous fiber processing capacity of 2,500 tons / year
3.1. A device for loading crushed basalt in a melting furnace
3.2. Winding machines (6 )
3.3. Transformers UHL4 TCE-75
3.4. Built-in appliances with automatic control of electro - and gas installations generating basalt fiber
3.5.Bushing complete with a feeding tube - 7 pieces, including 1 -Reserve.
3.6. Closed water circulation system for cooling inlets the current supply.
3.7. Carts for transporting spools with fiber.

     

4. The site drying.

4.1. Area natural fiber drying.

4.2. Drying chamber - 1pc. 

 

5. The site rewind and cutting fiber
5.1.Rewinding machines 1 pc.
Precision winding machines- 3 pcs.
5.2. Conning-tower machines 2 pcs.

6. Quality Department
       6.1. Equipment for the chemical laboratory.
       6.2. Universal Testing Machine.
       6.3 Scale Quadrant, unrolling device for determining the linear density of the yarns and rovings - 1 set.