“Production of basalt continuous fiber (CBF) and basalt plastic reinforcement”
Main goals of project
Creation of industrial production of basalt continuous fiber (CBF) using modern high-tech equipment and a full technological cycle of production of materials from CBF.
Implementation of schedule project
Location of the project
city of Bukhara, st. Alpomish 5, based on JSC “Bukharaenergomarkaz”
Information about participants of the project:
– co-executor (the lead sectorial of Ministry/authority/Department)
Ministry of Housing and Communal Services
Total costs of project
15.0 million USD
Prospective source of financing:
– own funds
1.0 million USD
2.0 million USD
– the required volume of direct foreign investments
12.0 million USD
Composition of main costs
Acquisition of equipment – $ 13.7 million, construction and installation work – $ 1.3 million
Predictable of profitability
Predictable of payback period
12.5 million USD
Characteristics of the planned to production
Basalt continuous fiber (roving) is the main feedstock for production of composite materials: valves, pipes, road nets, fabrics, high-pressure cylinders, etc. to replace metal counterparts and has the following characteristics: High strength. The specific strength of basalt continuous fiber is 2.5 times the strength of alloyed steels and 1.5 times the strength of fiberglass. Heat resistance. The temperature range of long-term use of CBF is 200 + 600 degrees. Short-term exposure to temperatures up to 700 degrees, single exposure to temperatures up to 1000 degrees. High chemical resistance to water, salts, alkalis and acids.
Compared to metal, CBF is corrosion resistant. Compared with fiberglass, CBF is an alkali-resistant material. BNV have high corrosion and chemical resistance to corrosive media: solutions of salts, acids and especially alkalis. High compatibility of BNV with other materials: metals, plastics, plastics, adhesives, the ability to produce materials and products based on BNV using various technologies for molding, winding, pultrusions, spraying and other “cold technologies”. Basalt-plastic fittings with a low specific weight (10 times lighter than metal) have high strength (2.5 times higher than metal and 1.7 times higher than glass fiber), a long service life, are not susceptible to corrosion, and to aggressive media.
-BPA can be sold at least 10-30% cheaper than steel reinforcement, with a profitability of at least 100%.
Capacity of project/productivity
2-2.5 thousand tons / year basalt continuous fiber and 420 tons per year basalt plastic reinforcement
Contribution to the project by the initiator
USD 3.0 million (including a bank loan of USD 2.0 million)
Current status of project
The company “Basalt Fiber Materials Technology Development” (Ukraine, the head of Dr.Sci.Tech. Osnos S.P.) jointly The project initiator collected information on the basalt deposits of the Republic of Uzbekistan; six basalt deposits were studied and local basalt deposits in the Samarkand and Navoi regions were selected as feedstock for the production of basalt continuous fibers. Developed a business plan and technical documentation of the project.
Information about the initiator of the project
Full name of the enterprises
Requisites, email, contacts
G. Bukhara, Alpomish 5. Tel: +99865 2228059 Mob: +99890 715-05-44 (Karaev Anvar Shodievich, Director of JSC “Bukharaenergomarkaz”); Mob: + 998 93 960 2801 (Rakhimov Bakhodir Bakhshullaevich, chief engineer of JSC “Bukharaenergomarkaz”); Mob: + 998 91 4497997 (Narzullaev Ulugbek Muhitdinovich specialist JSC “Bukharaenergomarkaz”)
Date foundation of enterprises
Statutory fund and
749.5 million soums
Structure of founders and distribution of shares
State share – 52% of shares.
Individuals – 21% of the shares.
Legal entities – 27% of the shares.
Number and types of jobs created
Total – 146 including:
– AUP- 8
– ITP – 5
– auxiliary service 13
main production personnel 120
Environmental impact statement (project EIS), which includes expected types and volumes of wastes, places of their utilization
At the development stage
Information about the land plot for the construction of the enterprise
The existing building NKHVO (880 m2) in the territory of JSC “Bukharaenergomarkaz”
road, railway, water, gas, electricity, sewage and others
The required infrastructure
Upcoming construction and installation works
Overhaul of the NKHVO building with connection lines (gas, electricity, water, sewage)
Design and estimate documentation
Power requirement (kWh), installed capacity (kWh or megawatt hour)
Basalt continuous fiber 6,0-7,5 million dollars. USA, basaltic platikovoe fittings – 3,0 million dollars. USA
Demand for raw materials (per year)
Stones of basalt rocks 2000-2500 tons
Provision of raw materials
The demand for CBF materials from year to year increases significantly. The volume of the market of composite materials BNV is estimated in the coming years at 100 thousand tons per year. The existing capacity of manufacturers in the CIS is 40 thousand tons per year.
Expected market share
Manufacturing companies of BNV and composite materials are located in Russia, Ukraine and China
Main competitive advantage
Low cost of production, proximity to the raw material base
Main target groups of consumers
Construction and road construction companies, engineering enterprises energy, chemical and petrochemical industry, automobile industry, utilities, construction of earthquake-resistant buildings and structures, fire prevention materials
The structure of sales according to target groups of consumers
At the first stage, construction and road construction companies, energy, chemical and petrochemical industries, utilities, construction of earthquake-resistant buildings and structures, fire prevention materials.
The price of 1 ton of basalt continuous fiber is US $ 3000-3500, the price of basalt plastic reinforcement is 10% lower than steel reinforcement.
Cost structure of the final product
The cost of 1 ton of BCF – US $ 975 including: – Raw materials and materials – 9.5% – Energy – 8.5% – Overhead costs – 53.8% – Salary – 24.6% – Other expenses – 3.6%
Availability of patents, licenses, certificates in accordance with the current legislation
Technological equipment of the production of CBF and the main components are protected by patents for inventions that have global priority (the author and owner of patents, Ph.D. Osnos S.P.): 77861 UA “Method and device for the production of fibers from basalt rocks.” 90065 UA “Method of production of basalt continuous fibers from and basalt rocks and device for its implementation.” 48338 UA “A device for the production of basalt continuous fibers with feeder furnace”.86186 UA «Slot-hole die feeder for the production of fibers from basalt rock melts».
2321408 RU “Method for the production of basalt continuous fibers from and basalt rocks and device for its implementation.”
2412120 RU “A device for the production of basalt continuous fibers with feeder furnace”.
ZL 2004 1 0101966.0 CN “Method and device for the production of continuous fibers from basalt rocks.” ZL 2005 1 0008181.3 CN “Method and device for melting basalt rocks in the production of fibers”. 99794 UA “Method for the production of composite reinforcement and device for its implementation.” Also, the replacement of steel reinforcement with composite basalt plastic reinforcement has GOST standards for applications in Ukraine, PRC, and standards of the EU, the USA and Canada are being prepared for approval. All patents and certificates will be unified with the legislation of the Republic of Uzbekistan
The presence of a formed database of potential customers with a confirmed willingness to purchase products
Being worked on
Presence of marketing research
Marketing research conducted by the project developer Dr. Sc. Osnos S.P.
Presentation component of the project
– Rising prices for energy, materials and transportation
– untimely manufacturing of goods
– distance from product exports to Europe and from ports for export to the USA, Japan and Korea
Production technology and parameters of main equipment
Depends on the investor’s preferences
Type of equipment
equipment series TE BCF 2000 (installation of intensive melting of basalt, installation of spinnere feeders, installation of the extract of continuous fibers, installation for the production of basalt-plastic reinforcement)
Country of origin
2-2.5 thousand tons / year of basalt continuous fiber and 420 tons of basalt-plastic fittings
13.7 million USD
320-350 kW / h
Overall size of equipment
Weight of main equipment
Node of main equipment (lines)
Stone melting furnaces with spinneret feeders of platinum radium alloy
Number of working hours per year
Round-the-clock in 3 shifts
Periodicity of the planned –warning repair (design and preparation works)
Once in 4 years
Number of people involved in the production process and their functions
STEP-BY-STEP, DESCRIPTION OF PRODUCTION TECHNOLOGY