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“Production of basalt continuous fiber (CBF) and basalt plastic reinforcement”

Investment proposal
  

Name of the project

“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.

Sphere /industry

Industry

Implementation of schedule project

2019-2020

 

Location of the project

city ​​of Bukhara, st. Alpomish 5, based on  JSC “Bukharaenergomarkaz”

Information about participants of the project:

– initiator

JSC “Bukharaenergomarkaz”

– co-executor (the lead sectorial of Ministry/authority/Department)

Ministry of Housing and Communal Services

– creditor

 

Total costs of project

 15.0 million USD

Prospective source of financing:

– own funds

 1.0 million USD

– credits

 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

105 %

Predictable of payback period

38 months

 

Cash flows

 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

JSC “Bukharaenergomarkaz”

 

 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

1979

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.

 

General information
  

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”

 

Existing infrastructure

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

Developed by

Power requirement (kWh), installed capacity (kWh or megawatt hour)

320-350 kW / h

 

Demand for water (cub/m)

4-4.5 m3 / hour

 

Gas demand (cu/m)

120-140 m3 / h

Market analysis, productions definition (works, services),marketing researches
  

Type of product

Basalt continuous fiber and basalt plastic reinforcement

Annual production (ton. year)

Basalt continuous fiber 2000-2500 tons, basalt reinforcement fittings – 420 tons

Prospective markets sales and their shares:

Inner

20 %

Export

80 %

Coasts of products

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

 

Market volume

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

2-2,5 %

Arch-rivals

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.

Pricing strategy

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

Have

Additional information

 

Project risk

– 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

Ukraine

Performance

2-2.5 thousand tons / year of basalt continuous fiber and 420 tons of basalt-plastic fittings

Cost

 13.7 million USD

Energy consumption

320-350 kW / h

 

Installed capacity

 

Overall size of equipment

6,5/40/7,5

Weight of main equipment

190 tons

 

Node of main equipment (lines)

Stone melting furnaces with spinneret feeders of platinum radium alloy

Number of working hours per year

8400

Duty cycle

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

146

STEP-BY-STEP, DESCRIPTION OF PRODUCTION TECHNOLOGY

(Show schematically)