Comparing the technologies used in CBF production

Technology
stage
Generation 1.0 Generation 2.0

Trial production of CBF

Large-scale industrial production of CBF, offered by Basalt Projects company.

Purpose
Basic possibility of CBF industrial production. Basic possibility of producing CBF with target market position and manageable characteristics of fiber.
Raw material extraction
Production at individual quarries, selected largely by chance due to the natural growth of the industry, feedstock for production of staple fiber. Preliminary careful selection of quarries and existence of methods for raw material detection, according to the requirements for obtaining products with given properties; creation of a system for monitoring raw material preparation on the spot.
Raw material preparation
Almost non-existent Raw materials preparation system.
Separate technologies for improving raw materials and additional charging.
Melting process
Low-capacity furnace modules (up to 100 tons of CBF per year).
Refractories: 6 months lifespan, use of refractory materials for the glass industry.
The melt is not prepared; there is only the melting of fusible components without completely destroying the crystal lattice and with gas removal.
Multi-bushing furnace units with capacity of 600-1500 tons/year.
Refractories: up to 2 years lifespan..
Filament formation
Filament stretching: platinum-rhodium feeder bushings with 200 holes manufactured by non-ferrous metal working plants based on drawings by loner engineers on separate orders. Apron feeder used for producing the super-thin basalt fiber of the 70s of the last century serves as the basis of the design.
The lubricant is taken from glass fiber production without adaptation to basalt fiber.
Filament stretching: platinum-rhodium feeder bushings with 1200 holes manufactured under strict control by Basalt Projects, including using 3D printing technology.
Systematic development of lubricants under given product properties.
Process automation
No process automation Significant use of automation and permanent monitoring of the process
Main characteristics of technology
  • 85 units of 1000-ton-capacity equipment, a significant proportion of non-standard equipment;
  • 140 people for 1000-ton capacity plant;
  • Production space 3500 m2 for 1,000 tons;
  • Volatile characteristics;
  • Flexible control of total capacity through input/preservation of individual modules;
  • Complete dependence on individual experts – owners and those who are experienced in the technologies;
  • Requires highly qualified personnel;
  • A lot of waste.
  • 6-10 units of 1000-ton-capacity equipment, a significant proportion of non-standard equipment;
  • 65 people for 1000-ton capacity plant;
  • Production space 2000 m2 for 1,000 tons;
  • Stable characteristics of produced fiber are reached;
  • Reached economies of scale, CBF cost reduction to no more than $1.5/kg;
  • The process doesn’t much depend on personnel.
Инвестиции в производство
$15000 investment for 1-ton capacity $8000 investment for 1-ton capacity
Production view
 Specialists from Basalt Projects developed a pack plan (generic solution) creating a CBF production plant using cutting-edge technologies, comprising the step of pre-project planning, as well as phases of design and construction of large-scale plant of CBF and composites production, which at the current development stage of the market will bring the fastest ROI for the investors.