OJSC Research Institute “Glassplastics and fiber” has long experience (more than 40 years) in designing and developing of equipment for producing various fibers from rocks including basalt.

For the first in the USSR it was our Institute, which designed and developed equipment for producing:

·              Staple super ultra fine and continuous basalt fibers;

·              Heat-resistant articles from silica fibers on inorganic binder, which are used in latest cosmic technologies (specifically “Buran” spaceship was equipped with articles, manufactured according to technology and on the equipment of Institute);       

·              Glass plastic serving stripe for needs of electrical engineering, where use of this stripe reasonably reduces non-ferrous metals consumption and expenditure of labour for making equipment;

·              Weft knitted with additional filling and knitted materials in the form of sleeve from glass and basalt fibers, that are used in aircraft construction, ship building and other branches of engineering;

·              Warp knitted thickened and netted cloths from threads of any origin including carbon, metallurgical and Kevlar ones;

·              Silica cords, stripes, blanks, nets etc;

·              Geo textile materials from synthetic and basalt fibers;

·              Premixes, semi-finished items for pressing different articles, including bout’s bodies, flanges, window frames, traffic signs, technical equipment’s moulding etc;

·              Glass paper (it is used when producing glass plastics, gas and liquid filters, soft roofing materials etc);

·              Mates (cloths) from chopped glass threads.

Our organization has scientific and technical potential for designing technologies and equipment (for the whole process of manufacture) and working of basalt and glass fibers, glass plastics.

Institute’s structure includes research laboratories, designers’ office, pilot production of glass fibrous and heat-insulating materials and also mechanical shop for experimental and industrial machinery manufacture as well.

Equipment

                        

 I.  BSTV plant

1.      Output of BSTV-20 plant, t/year – 120-130;

kg/h – 16-18;

2.      Raw materials intake:

basalt crumb (fraction 3-8mm) – 16,25 kg/h

3.      Natural gas intake:

78 m³/ h; gas pressure – 0,027 – 0,3 MPa.

4.      Compressed air intake:

-         10 nm³/min (600 nm³/h);

-         air pressure – 0,2 – 0,25 MPa.

5.      Service water intake, m³/h – 18,

including softened water – 0,55 m³/h.

6.      Regulation loads’ power, kW – 65.

7.      Securing of manpower.

Routine working time of workers, who service

plant to production BSTV with regard for time

 for the rest is 6 hours. So, for computation of the number

of staff it’s necessary to take 4 shifts, 6 hours each.

 

8.      Overall dimensions of one plant:

-         length – 8375 mm;

-         width – 5220 mm;

-         height – 3760 mm;

-         mass – 8800 kg.

 

 

II. Stitch plant MP-100

 

Stitch plant MP-100 is of cyclic action,

cloth is laid out manually. Stitched mate

is cut to pieces of size is needed, treads’

ends are knotted or glued.

1.      Output when speed of cloth feed

is 2 m/sec and thickness is 80 mm, m/h - 8,5

2.      Conveyer speed, m/min -  1.0; 2.0;3.0;

3.      Сloth width , mm                        1000;

4.      Stitch thickness, mm                 40-100;

5.      Needle space, mm                          100;

6.      Stitch length, mm                              80

7.      Regulation power, kW –                 2,2

8.      Overall dimensions, mm

length – 7670

width – 2510

height – 2300

 

 

III. Technical data of equipment for producing plates δ=40÷60 mm

1.      Output at δ=40 mm (300 work days a year), m³/year – 5760;

2.      Overall dimensions of plate:

-         length, mm – 1200;

-         width, mm – 1200;

-         thickness, mm – 40+3.5; 50+4; 60+4;

3.      Regulation power, kW – 156;

4.      Fuel – natural gas;

5.      Gas intake, nm³/h – 250;

6.      Gas pressure, kgp/m² – 0.5;

7.      Air pressure, mm of water column - 150÷200;

8.      Overall dimensions of the line*:

-         length, mm – 64210;

-         width, mm – 6200;

-         thickness, mm – 6880.

*Overall dimensions are given regardless for work bay, where binder is to be prepared.

Notes: to ensure the operation of the line 6 modular BSTV plants are required.

The list of main nonstandard equipment to manufacture plates and its approximate cost is given in the table 1.

Table 1

 

№	Name	Mass of equipment unit, kg	Approximate cost of processing, USA dollars.	Number of units in the line	*approximate cost of one unit, USA dollars.	Total approximate cost, USA dollars.	Notes
1	Ball mill V=3400l, Germany	Standard
2	Device for producing binder	4600	4.7	2	21620	43240
3	Hydro breaker	3250	-	2	15275	30550
4	Device for hydro mass	2900	-	2	13630	27260
5	Collector	1630	2.5	2	4075	8150
6	Slight presser	1300	3.2	1	4160	8320
7	Plant for drying and heat treatment	60000	2.5	1	150000	15000	Without lining
8	Vacuum extrusion machine	14000	4.7	1	65800	65800

 

 

*Final prices are determined by actual expenditures with regard for 20%

rofitableness coordinated with Customer.

 

Articles’ data

Index	Heat-insulating pressboard	Heat-insulating plate
Use temperature, oC	up to 700	-200 up to +700
Heat conductivity, not more than, W/mK	0.040 – 0.45	0.046
Density, kg/m3	100 - 280	not more than 300