Engineering of basalt fiber and composite

International projects for the construction of plants for the production of continuous basalt fiber and composites
Specialization
The main activity of the company is creation of effective productions on release of continuous basalt fiber (СBF) with technologies of the last generation and composites on the basis of СBF (Basalt Fiber-Reinforced Polymer Composites as BFRP).

Basalt products of such enterprises have great competitive advantages due to the optimal ratio of price to quality, as well as high demand in the market.
Experts of Global Basalt Engineering LLC apply a comprehensive approach, individually working through each stage – from the raw material base to the final composite product.
The company provides a full range of services and works on the construction of plants "on a turn-key basis":

  • Research of raw materials, economic justification and formation of a high-yield line of the final product;
  • Pre-project engineering and market research;
  • Complex of design works;
  • Construction and installation works;
  • Supply and commissioning of equipment;
  • Adjustment of all technological processes;
  • Employee training;
  • Technical and designer supervision;
  • Technical support and technological franchise;
  • Operational management of the enterprise until the payback period.

The concept of continuous basalt fiber manufacture and basalt based composites

When planning the production of CBF, the raw material base and the line of final composite products are selected, taking into account its prospects, profitability and demand in the market
Raw material
Rubble
Rocks of basalt composition
Processing
CBF
Smelting of the gravel and obtaining of the continuous basalt fiber
Processing
Semiproduct
Manufacture of roving fibres, yarns, fabrics or prepregs
Finished product
Composite
Demanded product line on the market
Each stage of processing the initial raw materials (basalt rubble) increases the added value of the final product.
The product of each preceding stage is the supplier of raw materials for the next stage.

Pricing product principle

Typical solution of basalt fiber plant

Our company has developed several typical solutions for the creation of large-capacity production on the latest generation of technologies for the production of CBF and composite products, which leads to the fastest payback on the enterprise and return on investment.
5000 tpy
Optimal capacity in the production of products for the construction market
4 Ha
The required area to accommodate the production
~5 years
Discounted payback period of the enterprise
>150 pers
Number of jobs
Production of one of such typical enterprises is focused on the construction market: rebar, geotextiles (mesh/grid), structural and construction profile, cutting fiber, each local construction market has its own characteristics, for example, in a number of countries the entire volume of metal rebar is imported, which makes this enterprise attractive for investments.
Due to the use of basalt-plastic reinforcement of smaller diameters compared to metal (in equal ratio), reducing the cost of transportation and installation (9 times lighter than stainless steel) savings of up to 20% can be achieved.
The project for the construction of a plant with a capacity of 5,000 tons of continuous basalt fiber per year will produce final products in the form of construction materials, for example:
  • Up to 43,000,000 rm of re-bars (Ø10mm), or
  • Up to 18,000,000 rm of construction profiles (50x50x5), or
  • Up to 6,500,000 m2 of geogrids (100x100x3), or
  • Up to 5,000,000 m2 of road mesh (200x200x8), or
  • Up to 5,500 ton of fabrics, or
  • mixed products.
These standard solutions are designed to understand and evaluate the investment attractiveness of CBF production.

Are you interested in basalt fiber technology and organizing your own production of composites based on basalt fiber?

In addition to typical solutions, we are pleased to help you choose a line of final products and technological solutions for its production.
Befor Project Stage
A more accurate range of products is formed at the stage of creating a pre-Feasibility study for the project, based on analytical data on the demand for a particular product in the region of the CBF production facility, market price, competitive products, etc., and the strategic goals of the project.
One of the most essential parts of a pre-Feasibility study is Raw material supply. It is important to determine if the local basalt quarries are suitable for CBF production.
Befor Project Stage
A more accurate range of products is formed at the stage of creating a pre-Feasibility study for the project, based on analytical data on the demand for a particular product in the region of the CBF production facility, market price, competitive products, etc., and the strategic goals of the project.
One of the most essential parts of a pre-Feasibility study is Raw material supply. It is important to determine if the local basalt quarries are suitable for CBF production.
Pre-Project Stage
Development of a conceptual design of the plant and feasibility study for investments (feasibility study). The conceptual design allows you to visually present the project to investors, as the appearance of buildings, the layout of the premises, the convenience of unloading raw materials and loading finished products, the arrangement of the production area directly affect the investment attractiveness of the facility. A feasibility study will allow investors to financially evaluate the project concept, its investment attractiveness, market potential and return on investment.
Complex engineering surveys at the planned site in parallel with the development of a conceptual design and a feasibility study. This will allow you to immediately place the buildings and infrastructure of the production site, taking into account the terrain, geology and network connections, as well as make more accurate calculations of construction and installation works and the cost of connecting to energy resources. The result of the engineering survey will be the essential information for the construction company to calculate the cost of the civil construction works.
Engineering
Equipment supply

Stage of implementation
of the continuous basalt fiber project

Each of CBF projects is unique, but all of them go through standard stages of its implementation. To reduce the project realization time and necessary resources, part of the stages can be performed in parallel.
1
Before-project stage
Two studies are conducted — the study of rocks of basalt raw materials and preliminary economic calculations (business plan).
2
Pre-project stage
Carrying out complex engineering surveys on the proposed site and development of the Conceptual design and feasibility study of investments (feasibility studies)
3
Engineering
Drafting process of project documentation: Schematic design (stage "P") and Detailed design (stage "R").
4
Equipment supply
Ordering and manufacturing of technological equipment. Delivery of equipment to the site.
5
Construction and installation
Construction work on the site for the construction of buildings and laying of communications. Installation and commissioning of process equipment and life support equipment.
6
Employee training
Preparation of methodical training base, training of engineering and technical personnel of the enterprise.
7
Commissioning
Achievement of the planned production indicators and transfer of the facility into operation.
Constant research and development, as well as market knowledge allow us to offer enterprise management services.
Technology franchise
Periodic upgrade of technological units and processes is carried out to help keep the enterprise at the modern technological level.
Operations management
Management of operational activities of the enterprise before its self-sufficiency, including the organization of sales, promotion of products to the market and advertising events.

The concept of composite production

When planning Basalt Fiber-Reinforced Polymer (BFRP) Composite production, a line of technological equipment is selected for the production of products in demand on the market, which allows to reach the self-sufficiency of the enterprise in the shortest possible time.
Raw material
Fiber
Basalt fiber, glass fiber and carbon fiber
Finished product
Composite
Demanded product line on the market

Stages of implementation of the composite project

The stages in the organization of production at the existing industrial site, when only the supply of equipment is required, are described.
1
Project works
Development of only section TX (Technology) of the project documentation of the object: schematic project (stage "P") and detailed project (stage "R").
2
Selection and production of equipment
The quality and efficiency of the equipment are the key to the production of products of the highest standards with an optimally low cost.
3
Installation and commissioning
The work performed ensures the efficiency of the equipment and training of employees to work with the technology.
In the case of a full cycle of production organization, including the construction of the workshop, it is required to carry out a full range of works similar to the works on the organization of production of CBF.
For production of such mass product in the construction market as reinforcing production (rebar, geogrid, fiber) we offer pultrusion lines of own production.

Pultrusion equipment

One of the key focusof the company is the production and supply of modern energy-efficient production lines for the manufacture of final composite products by pultrusion (rebar, grid, fiber).
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
+971 50 667 5445
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.
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