Presented By:Presented By:

Shahan AkhtarShahan AkhtarM.Sc. Fiber Tech.M.Sc. Fiber Tech.2008-ag-52.U.A.F.2008-ag-52.U.A.F.

OUT-LINE OUT-LINE

Basalt introductionBasalt introductionManufacturing processManufacturing processKey propertiesKey propertiesApplication ExamplesApplication Examples

IntroductionIntroduction

known as a rockknown as a rock lavalavaOccurance Occurance Basic minerals Basic minerals CheaperCheaperNon-Toxic, Non-Toxic,

Non-CombustibleNon-Combustible

Brief History

First extrudement of filament.First extrudement of filament. Authentic start of research.Authentic start of research.

Golden era of 1960/70’s. Golden era of 1960/70’s.

Research eventually became successful. Research eventually became successful.

It is in Perestroika, the technology was It is in Perestroika, the technology was declassified. declassified.

Chemical composition basalt rock:

Chemical compound % weight of basalt

SiO2 51.58

Al2O3 15.48

FeO 9.43

CaO 8.50

MgO 5.10

Fe2O3 4.42

Na2O 2.10

TiO2 2.08

Chemical Name & Structure

Al

Al

Al

Al

Al

An overview of the basalt fiber manufacturing process is:

Stone crushing

Loading and transportation

Washed out with water & then dry

Material is fed into furnace.

Molten material flows into a fore-hearth.

Platinum alloy “bushing”.

A single strand(7-17μ).

A water-based sizing

Package forming.

The untwisted roving, twisted/plied into a yarn, or chopped to a fixed length.

Cont.Cont.

Manufacturing processManufacturing process

1) Crushed stone, 2)Loading station, 3) Transport system, 4)dry station, 5) Initial melt zone, 6) Secondary controlled heat zone, 7) Filament forming, 8) Sizing applicator, 9) Strand formation, 10) Fiber tensioning, 11) Winding

Microscopic view of Basalt FiberMicroscopic view of Basalt Fiber

PropertiesProperties

High tensile strength (breaking strength)

Low elongation at break

High elastic modulus

Density: 2.7 gram/cubic centimeter

Low thermal conductivity

High sound absorption coefficient

Cont.Cont.

Low moisture absorption

High specific volume resistance

Radiation proof lead equivalent

Permanent flame retardant resistance

Extraordinary high softening temperature (point): >1200 Celsius degree

Operating temperature range: from -260 to 760 Celsius degree

Chemical propertiesChemical properties Low water absorbencyLow water absorbency Good alkaline resistanceGood alkaline resistance Also acid and salt resistanceAlso acid and salt resistance

Chemical stability (loss weight after 3 hours boiled(%))

2N HCl 2.2

2N NaOH 6.0

H2O 0.2

Comparative technical index betweenbasalt fibers & the other mineral fibers

PropertiesContinuous

BasaltE-Glass S-Glass Carbon Aramid

Density (g/cm³) 2.63 - 2.8 2.54 - 2.57 2.54 1.78 1.45

Tensile Strength (MPa)

4100 - 48403100 -

38004020 -

46503500 -

60002900 -

3400

Elastic Modulus (GPa)

93.1 - 110 72.5 - 75.5 83 - 86 230 - 600 70 - 140

Elongation at break

3.1 4.7 5.3 1.5 - 2.0 2.8 - 3.6

Maximum Service

Temperature °C

750 380 300 500 250

Application of basaltApplication of basalt

Basalt Fiber 3-D Sandwich FabricBasalt Fiber 3-D Sandwich Fabric

Basalt Fiber 3-D Sandwich FabricBasalt Fiber 3-D Sandwich Fabric high grade yacht.high grade yacht. speed train.speed train. chemical tanks.chemical tanks. wind turbine.wind turbine. core layers of the core layers of the

Radiation protectionRadiation protection Architectural decoration.Architectural decoration. Heat preservation & sound Heat preservation & sound

insulation.insulation.

Basalt Fiber SheetBasalt Fiber Sheet

Reinforcement forReinforcement for The bridgeThe bridge tunnel structure tunnel structure The wood reinforced The wood reinforced

structure structure beams, colums, beams, colums,

plates.plates.

Basalt Fiber Needled Felt

Advanced air filtration system.Advanced air filtration system.

Poisonous gas and dust filtration systems in Poisonous gas and dust filtration systems in chemical industrychemical industry

Filtration, acoustic absorption, heat insulation Filtration, acoustic absorption, heat insulation and vibration proofing system in electronic and vibration proofing system in electronic industry.industry.

High temperature resistance, environmental High temperature resistance, environmental protection automobile mufflers.protection automobile mufflers.

Heat insulation and acoustic absorption Heat insulation and acoustic absorption system of vessels and ships.system of vessels and ships.

Basalt Fiber Sealing RopesBasalt Fiber Sealing Ropes

Furnace doors, cover board, success Furnace doors, cover board, success opening, had the hole of the high temperature opening, had the hole of the high temperature pressure furnace. pressure furnace.

Applied in sealing material, which owing the Applied in sealing material, which owing the compressibility, the high elastic and the low compressibility, the high elastic and the low friction coefficient.friction coefficient.

Excellent properties of acid alkali resistance Excellent properties of acid alkali resistance in the parts connection or transforming in the parts connection or transforming corrosion media. corrosion media.

Basalt Geo gridBasalt Geo grid

They are made up of natural raw material (natural chemical composition provides chemical stability and resistance).

They are non inflammable and they can carry out distributed load.

The cost is 4-5 times lower than other geo textile material.

ConclusionConclusion

Basalt has excellent set of properties in Basalt has excellent set of properties in thermal, mechanical, chemical and thermal, mechanical, chemical and environmental. Due to low cost they can environmental. Due to low cost they can easily replace many different applications easily replace many different applications of carbon, asbestos, steel, glass fiber.of carbon, asbestos, steel, glass fiber.