Generation 2.0 of basalt fiber technology

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.

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.

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.

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).

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.