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Machinery for production of basalt ultrathin fiber ()

Machinery for production of basalt ultrathin fiber is meant for staple basalt ultrathin fiber made of melt rocks based on duplex technology. According to the technology raw stock undergoes heat treatment twice. The first stage includes heating, melting, homogenizing and outgassing of the crumb. At the second stage the coarse fiber is repeatedly heated and stretched by the high-speed flow into ultrathin staple fiber.

 
Equipment description

Machinery for production of basalt fiber is meant for staple basalt ultrathin fiber made of melt rocks based on duplex technology. According to the technology raw stock undergoes heat treatment twice. The first stage includes heating, melting, homogenizing and outgassing of the crumb. At the second stage the coarse fiber are repeatedly heated and stretched by the high-speed flow into ultrathin staple fiber.

Description of the process

The feedstock for the production is basalt crumb with the fraction size 3-15 mm.

Through the machine food crumb comes to the melting furnace and melts at the temperature t=1400-1500.

The temperature in the furnace is regulated by the amount of fed gas and air. Air comes through metal recuperator, where it is heated due to the use of the heat from gases of combustion.

The melt under the sole weigh goes through the drawing nozzle of the feeder and stretches as a continuous glass filament with diameter 100-200 micron.

The feeder consists of heatproof plate with the drawing nozzles placed between two fridges. In order for the melt to come through the drawing nozzles of the feeder, the feeder is heated with the help of the electric current to the temperature 1300-1390 .

Formed glass filaments are constantly stretched and driven to the blowing. Filaments are stretched due to the pair of rubberized rollers on which the filaments are uniformly spread on the whole width of the nozzle of the blowing chamber of the filaments.

The rollers are driven by the alternating current motor with smoothly regulated speed of rotation.  Speed of rotation of the rollers provides even supply of the fiber to the nozzle.

Glass filaments after passing the rollers get into high-temperature (1500-1600) and high-speed (300 m/s) gas flow, under the influence of which they are stretched and are blown to the ultrathin staple fiber with the diameter from 1 to 2 micrometers.

The fibers in the flow of gases of combustion through the diffuser get to the shaping receiver.

Diffuser represents two metal convergent channels on-the-miter to the general drum conveyor. The main unit of the conveyor is a net. Under the net there is an extension chamber connected to the vacuum fan with a piping. Combustion products under the influence of exhaustion go through the net to the fan, and the fiber rests on the net as a thin layer, which winds on the special drum or goes on the fiber packer.

Headcount

Machinery is operated by one engineer per shift. Working hours of the furnace round the clock, use standard 350 days a year. Every shift except operator there should be service engineer and mechanic. Engineer and mechanic operate couple of machineries united into one production section.

Serviceability

Serviceability of the equipment till re-lining of the furnace is 3 months. Draw plates made of the heat-tolerant alloys need to be substituted once in 20-22 days. Substitution of the high-wear details and component units is performed without substantial spending of time and costs.

Production Time
Production time of the machinery: 2 - 2,5 months.
Installation, pre-commissioning: 0,5 - 1 month.
Constituents of the equipment

Name

Model

Machinery 22

Machinery 42

1

Furnace

2

4

2

Gas and air supply system

2

4

3

Recuperator

2

4

4

Feeder

2

4

5

Transformer

2

4

6

Glass Feeders with suspension bracket mechanism

2

4

7

Extract mechanism

2

2

8

Blowing chamber

2

2

9

System of gas and air supply of blowing chambers

2

2

10

Diffuser

1

1

11

Fiber - settling chamber

1

1

12

Decontamination cells for combustion products

1

1

13

Ventilation of the combustion products

1

1

14

Electrical equipment

1

1

15

Ground

1

1

16

Water-cooling system

1

1

17

Blower machine*

1

1

18

Cooling tower*

1

1

*In case of absence on-site is supplied additionally.

Cost of the Equipment
  • Machinery 22 - 45 000 USD
  • Machinery 42 - 52 000 USD
  • Cost of the machinery includes cost of the equipment ex-factory manufacturer
  • Training of 3 operators, 1 service engineer on the working equipment  in Chernivtsi 3000 USD for one machinery (cost does not include travelling expenses for 4 people)
  • Installation, pre-commissioning at the customers 5000 USD per one installation (cost does not include travelling expenses for 4 people)

Cost does not include:

  • cost of the general water-cooling outfit which can have different productivity depending on the equipment
  • cost of the equipment for providing compressed air. If customer does not have main for compressed air equipment is provided additionally. Cost of the equipment depends on the quantity of the machineries.
  • Cost of the general gas and water main
  • Cost of the air flow guide for ventilation of the combustion products from the fiber - settling chamber if its length is more than 3 meters from the machinery.