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Moscow
October, 2011
Internet: www.infomine.ru
e-mail: info@infomine.ru
Continuous Basalt Fiber, Reinforcing Articles and Basalt Fiber Materials Production, Market and Forecast in the CIS
Contents
Summary .................................................................................................................. 9
Introduction ........................................................................................................... 10
Tables
Table 1. The Study assistants
Table 2. Chemical composition of the rocks as single component raw material for
fabrication of different fiber kind
Table 3. Mineral composition of rocks as single component raw material for
fabrication of different fiber kind
Table 4. Basalt rock melts peculiarities
Table 5. Principle characteristics of installations for fabrication of basalt
continuous fibers at SE NPO Bavoma
Table 6. Basalt fiber strength characteristics
Table 7. Basalt fiber chemical inertness, %
Table 8. The fibers comparative characteristics
Table 9. Comparative characteristics of threads from glass and basalt fiber
Table 10. Correlation of tack direct roving with monofilament diameter and filler
feeder quantity
Table 11. Correlation of multifilament yarn number with feeder draw-rings
quantity
Table 12. Key continuous basalt fiber production line and fields of their application
Table 13. Makers of continuous basalt fiber and reinforcement composite articles
in Russia and Ukraine
Table 14. LLC Kamenny Vek made direct roving technical characteristics
Table 15. LLC Kamenny Vek made plied roving technical characteristics
Table 16. LLC Kamenny Vek made twisted thread technical characteristics
Table 17. LLC Kamenny Vek made needle-punched mats technical
characteristics
Table 18. LLC Kamenny Vek foreign distributors
Table 19. JSC IvotGlass made basalt roving nomenclature and technical
characteristics
Table 20. JSC IvotGlass made basalt chopped fiber technical characteristics
Table 21. JSC NZSV made basalt complex fiber technical characteristics
Table 22. JSC NZSV made basalt roving technical characteristics
Table 23. CJSC NTB made baslt roving characteristics
Table 24. LLC TechnoBasalt Invest made basalt-plastic reinforcement technical
characteristics
Table 25. Comparative characteristics of different reinforcement types
Table 26. Comparative characteristics of basalt-plastic and fiberglass
reinforcement
Table 27. Comparative characteristics of steel and basalt reinforcement
Table 28. Comparisson of Liana and steel reinforcement performance
Table 29. LLC UralSpetsArmatura made reinforcement performance
Table 30. Comparative characteristics of Armastek fiberglass reinforcement and
steel reinforcement
Table 31. TG Ekipazh made basalt-plastic flexible fittings technical
characteristics
price, RUR/ rm
Table 61. Comparative characteristic of metallic and composite reinforcement
under equally efficient replacement
Table 62. Composite and metallic reinforcement comparative prices, RUR/m
Table 63. LLC Sudogda fiberglass production price-list
Table 64. Volumes and structure of accomodation commissioning in Russia by
Federal Districs, 2007-2010, m2 million, %
Figures
Figure 1. Structure of fiber-glass and basalt fiber application in the USA
Figure 2. Structure of fiber-glass and basalt fiber application in Europe
Figure 3. Continuous basalt fiber manufacturing unit
Figure 4. Comparative characteristics of basalt fiber and fiberglass at tension
strength, MPa
Figure 5. Comparative characteristics of basalt fiber and fiberglass at elasticity
coefficient, hPa
Figure 6. Block-scheme for the market of continuous basalt fiber and
reinforcement articles (production) in Russia
Figure 7. Continuous basalt fiber production structure in Russia
Figure 8. Balance of materials for fabrication of composote reinforcement at LLC
KNPO UAK
Figure 9. Multilayer building envelop: a) excluding flexible connections; b) with
metal flexible connections; c) with composite materials flexible
connection
Figure 10. Copmosite flexible connections production structure
Figure 11. CJSC Matech made basalt-plastic connections technical
characteristics
Figure 12. Continuous basalt fiber materials and articles exports dynamics in
Russia, 2007-2010 (tonnes, $000)
Figure 13. LLC Kamenny Vek production exports regional structure in 2007-
2010, %
Figure 14. Continuous basalt fiber production exports structure in Russia, 2007-
2010, tonnes
Figure 15. Continuous basalt fiber production exports structure in Ukrain, 2007-
2010 (tonnes, $000)
Figure 16. Continuous basalt fiber Ukrainian plants production exports structure in
2007-2010, tonnes
Figure 17. Continuous basalt fiber principle production export price average annual
dynamics in 2007-2010, $/t
Figure 18. LLC TechnoBasalt Invest and CJSC NTV average annual price
dynamics in 2007-2010, $/t
Figure 19. Comparative charasteristics of basalt-plastic reinforcement articles
prices against analogues made of some other materials
Figure 20. Dynamics of accomodation commissioning by Russia in 2008-2010 and
forecast till 2011-2015 under Special Federal Programme of Home, m2
Figure 21. Regional structure of commissioned accomodation in Russia during
the first 9 months of 2011, %
Figure 22. Regional structure for metal rebar consumption in Russia split by
Federal Districts in 2011, %
Figure 23. Continuous basalt fiber output forecast in Russia, 2012-2015, tonnes
Figure 24. Basalt-plastic reinforcement and flexible connections output forecast in
Russia, 2012-2015, tonnes
Summary
Introduction
The continuous basalt fiber (CBF) is "young enough" and very promising
kind of production.
At present just a handful of countries in the world, including Russia and
Ukraine, possess production process for fabrication of continuous fiber with basalt.
Meanwhile, availability of raw materials to manufacture CBF, expansion of
application of this material triggers increasing interest to CBF production. One of
the main priorities in application of continuous basalt fiber is manufacturing of
composite materials.
The output and the scope of application for reinforced fibers within
polymeric composites have been gradually expanding all over the world. In
comparison with conventional materials, fiber composites boast a number of
advantages corrosion resistance, chemical inertness, low factor of heat
conductivity, high specific mechanical properties, small specific weight, high
operating temperature, long wearing life, low cost of design installation.
Output of the closest analog of CBF continuous fiber glass in the world
makes about 3-3.5 million tpa.
While in early 2007 world production of a continuous basalt fiber amounted
for 5.000-6.000 tpa, it stands for 10.000 tpa now.
The largest world consumer of composite plastics are the USA 44%,
followed by Europe 26%, Asia 24%, the other countries of American continent
3.4%, Russia 1.4%, the other CIS countries 1.2 %. Major consumers in
Europe are Germany and Austria over 30%, Italy over 20%, France about
18%.
Distribution of continuous fiber in terms of consumption in Europe differs
from that of in the USA significantly smaller part is being applied in the field of
reinforcement (Fig. 1, 2).
Japan, Germany, the USA and the Netherlands attained the greatest
successes in application of polymeric composites at manufacturing of concrete
reinforced designs.
Besides various composite materials that are being applied in all branches of
mechanical engineering, effective heat-and-sound-proof as well as fireproof
materials are made on the basis of continuous basalt fibers. One of new kinds of
CBF production needle-punched materials is fabricated without any binders
that is a conclusive advantage over conventional heat-proof materials.
For the purpose of this Work we used materials of Federal State Statistics
Service (RF FSSS), Federal customs service of the Russian Federation (RF FCS),
the branch official statistics of railroad transportation of OJSC RZhD, the branch
and regional press-reports, annual and quarterly accounts of emitters of securities
as well as Internet sites of the CBF manufacturers.
(Perm)
LLC NPF
UralSpetsArmatura
(Perm)
LLC Manufacturing
enterprise Market
(Udmurtia)
CJSC Mineral 7
(Ukraine, Lvov Region)
LLC Sudogda fiber-
glass (Vladimir Region)
Source: InfoMine data
Basalt fibers are divided into two big groups: continuous fiber and discrete
fiber (cotton wool, staple fiber), also known as basalt fine fiber (BFF).
Method for generation of discrete fibers was invented over five decades
ago and it has been well perfected, while CBF production technology is young
enough and being improved further.
Interest to continuous fibers emerged in the mid-XX century when rocket,
nuclear and electronic sectors demanded materials with peculiar properties such as,
for example, strength of alloyed steel while much lighter and heat-proof.
Properties of fiber glass, which industrial production had been already
adopted in 1940th, failed to meet requirements of specialist applications.
Carbon fibers are the best in terms of strength, durability and temperature
range of application, but they are the most expensive also.
Basalt made continuous fibers were considered to be a material that
exceeds fiber-glass in terms of majority of technical characteristics, and at the
same time is comparable in terms of production cost and price.
Ukraine has been developing CBF technology for as long as several
decades. Under some assessments, this business consumed near 70-60 million
rubles; the sum was large enough in the Soviet era. According to experts, the
success in CBF generation was attained thanks to adequate funding of research and
development during protracted period giving the chance to pick up necessary
parameters of manufacturing method with experience.
The first specimens of CBF were obtained in 1961 by a branch research
institution. These specimens were rough, hardly elastic, several meters long.
By 1971, they accumulated certain experience in research of basalts, of
their chemical compositions, melts characteristics; in study of CBF characteristics
in terms of strength, chemical and heat resistance; in areas of their application.
They invented certain methods as well as pilot electric and gas-electric CBF
fabrication plants; they obtained specimens of materials on the basis of CBF.
In 1974, Laboratory of basalt fibers was created to deal with theoretical
and practical aspects of fine and extra-fine basalt fibers and materials on their
basis. One of its principle themes was invention of methods and equipment for
manufacture of CBF.
The first industrial-scale CBF plant was constructed in Ukraine at Belichsky
"TeploZvukoizoliatsiya factory (Kiev Region).
The plant appeared to be stone-melting kiln equipped with two feeders
(feeder mounts). The feeders were equipped with platinum-rhodium jet draw ring
feeders composing warmed tube of jet feeder and actually draw ring feeder.
Feeder mounts provided manufacture of high-grade fibers of 8 to 13 microns
in diameter fit for textile process. The equipment suffered certain drawbacks high
energy consumption per unit of production, big mass of draw ring feeders and
comparatively low efficiency.