The MAgAzine of The gerMAn BASALT fiBre induSTry

2013 / 2014 edition 1. revised version | www.bafanet.com
BASALT
the Magazine of the german Basalt fibre industry
cover story:
turning stone into fibre
the process
applications
NETwork
Forum Technologie & Wirtschaft e.V.
MeixstraSSe 5
01326 Dresden
germany
[email protected]
www.BAFANET.COM
©
www.sternkopf.biz
is a business network for the research and development of basalt fibre
and its applications in textile manufacture, in lightweight structures, in
the construction sector and in various other industries. Responsibility for
managing the network falls to Forum Technologie & Wirtschaft e.V. This
association coordinates research and development in the textile sector
and identifies areas of potential collaboration between different fields.
By establishing and supporting networks and research collaborations, the
Forum is playing a key role in consolidating the regional economic structure in Central Germany.
Funded by:
(German Federal Ministry of Economics and Technology)
following a resolution passed by the
German Federal Parliament
2
COMPETENCE MATRIX
EDITORIAL
Competence matrix
An industry on the move
BASALT – The Magazine of the German Basalt Fibre Industry.
Yarn and fabric production
Filament, chopped strands, equipment
DBF
UD tapes, scrim
CETEX
Sewing and
embroidery yarn
Alterfil
3D fibre structures
Fiber Engineering
Non-woven fabric
Norafin
Fibtex
Spinning, core yarn
Hoftex
Yarn finishing, thread
Alterfil
Knitted fabric
STS
Knitted/ crocheted
fabric
Woven fabric
STFI
Netting
STFI, Karl Mayer
Karl Mayer
Tapes, rope
Barthels-Feldhoff
finishing, coating
Finishing,
functionalisation
Thorey
Coating,
lamination
VIS
Additives and auxiliary
products for fabrics
Lefatex Chemie GmbH
Surface
functionalisation
Innovent
Bonding
AB-Tec
service
Research,
testing,
certification,
surface formation,
equipment
STFI
Research,
technology,
engineering
CETEX
Analysis
Project management
with Forum TuW
e.V.
Research,
analysis,
surface treatment,
functionalisation
Research,
development,
lightweight structures
Development,
construction,
engineering services
Research,
analysis,
ceramic
materials
Innovent
TU Chemnitz
EBF Dresden
KI Keramikinstitut
This is the ambitious title we have given to this publication, now
into its second edition. The German basalt fibre industry – is there
really such a thing? And what should we include under this heading? When you Google for the term, the references you find are
generally academic articles on the quarrying of basalt. But that’s
not what our magazine is about. Because basalt is much more
than rock; it is more like spun gold. Melted basalt produces fibres
that open up completely new technical possibilities. The nature
of these possibilities is the theme of our magazine published on
behalf of the German basalt fibre industry.
Basalt fibre is a truly innovative material. Although the underlying science has been the subject of research since the 1960s, it
is only now that basalt fibre is on the threshold of an industrial
breakthrough. We are certain that a huge new sector of the economy is about to mushroom from the first pioneering projects.
The basalt fibre industry is an industry on the move. These fibres
spun from stone have tremendous potential for a variety of applications, ranging from the automotive industry to mechanical
engineering and from construction to textile manufacturing.
Forward-looking enterprises and research institutions that have
recognised the potential of basalt fibre and wish to exploit its
economic benefits have joined forces to form BASALTFASERNETZWERK (Basalt Fibre Network). Together, they intend to
explore the possibilities for the technical application of basalt
fibre, to resolve the issue of reliability in quality and to develop
new applications.
We hope that the visionary projects we report on in this edition
will excite and inspire you. We are already looking forward to
the next issue in which we will update you on the latest developments surrounding basalt fibre.
From left to right:
Torsten Kunz (Project Coordinator)
Mirko Jacob (Project Coordinator)
Torsten Bäz (Project Leader)
Peggy Wunderlich (Project Administration)
In 2013, the two established networks COMBAFI
and TEXSALT banded together to form BASALTFASERNETZWERK. TEXSALT focuses on textiles made
of basalt, while COMBAFI specialises in basaltfibre-reinforced composites. By joining forces, the
members of this new association aim to benefit
from synergies and to develop new approaches to
the exploitation of basalt fibre.
Torsten Bäz
Project Leader BASALTFASERNETZWERK
[email protected]
TEXTILe applicatons
Geotextiles, textiles for
the construction industry
IGG
Filtration
IGG, Norafin
Textile Architecture
Abrasion-resistant
conveyor belts
VIS
Geomats, filters,
non-woven liners
Norafin
Textile products
for marine
applications
Beka Mare
Solutions
High-temperature
applications
Automotive
BMW
Norafin,
Fibtex
Soundproofing
IGG,
Fibtex
Application field: composite materials
Woven prepregs
Barthels-Feldhoff
Automotive
BMW
Facade elements
FIBER TECH
Ceramic composite
components
KI KERAMIKINSTITUT
Profiles, plates,
rods, prepregs
CG Tec
Asphalt reinforcement,
geotextiles
Tensar
Tubes,
pressure tanks,
power systems,
plant engineering
Roth Industries
Fibre composite
products for marine applications
Beka Mare
Solutions
Prefabricated buildings,
building, construction
materials
CONTENTS
4 / 5
6 / 7
8 / 9
10 / 11
TURNING STONE INTO
FIBRE
The process
FEELING EuphoriC
Interview with Christoph
Osterroth, CEO of Deutsche Basalt Faser GmbH
revolutionary fIBRE
Applications and
benefits
NETWORK PARTNERS
Zapf
Plant technology, fibre
injection technology
Fiber Engineering
Competence matrix of the networK: The diagramme illustrates how companies and research institutions have pooled their diverse
skills and resources by collaborating in the network. The entire multi-faceted value chain from filament production to recycling is represented here,
facilitating a variety of applications and solutions.
COMPETENce MATRIX | EDITORIAL
2 / 3
process 4 / 5
Interview 6 / 7
applications
8 / 9
Network
10 / 11
3
4
PROCESS
PROCESS
5
TURNING STONE INTO FIBRE
THE PROCESS
HOW DO YOU SPIN STONE INTO THREAD? A LOOK INTO THE FURNACE:
FACTS & FIGURES
10%
1,450°C
2,000 m/min
THE proCess
The diameter of a basalt thread is 10%
of a human hair.
1,450°C is the temperature at which basalt rock
starts to melt.
2,000 metres per minute: the speed at which the thread is spun.
THE PRODUCTS
Rovings:
A basic thread consists of 250 filaments. Several threads are bundled as yarn and bundled
up into a roving which in turn serves as the
starting material for textile production. Rovings
are the raw material for twisting, spinning or
weaving.
1
2
Lumps of basalt rock, 5cm
to 10cm in diameter, are fed
through a funnel into the
furnace. The precisely controlled temperature inside the
furnace ranges from 1,300°C
to 1,450°C. The basalt is
‘plasticised ‘, i.e. smelted and
liquefied.
The yellowish-red molten basalt is then extruded through
the flow feeder (a heated
tube) into the bushing. The
flow feeder builds up a precisely regulated melting pressure.
The molten basalt is drawn
off through the nozzles in the
bushing, forming hair-thin basalt fibres.
‘
3
4
In order to ensure optimum
processability, the filaments
are coated with sizing which
allows them to be treated
like a textile and serves as a
bond-ing agent between fibre and matrix. The sizing has
been specially developed for
this process and is adapted for
specific applications.
Next, the fibres are drawn by a
winder and wrapped around a
‘ The
so-called ‘spinning cake’.
fibre is now ready for delivery
to the customer.
COMPLEX SYSTEMS
CAUTION, HOT!
It may sound straightforward, but in fact it is a highly
complicated technical process. Pressure, temperature
and extrusion speed at the nozzle plates are precisely
regulated, with extremely low tolerances. Within these
parameters, the viscosity of the melt is controlled, thereby enabling the thickness of the drawn thread to be regulated. Consistent filament thickness is a crucial factor
for later applications and an essential quality feature.
The temperatures at which the furnace is
run are exceptionally high. This requires
appropriate technical adjustments. Consequently, the nozzle plates are made from
special noble metal, as temperatures of this
magnitude would melt steel.
CHOPPED STRANDS:
50 continuous fibres running in parallel are
drawn into a coating machine. After coating,
they are dried, which causes the coating to be
polymerised. This ensures high strand integrity.
The fibres are then chopped into 1cm lengths
which are characterised by their high strength
and satisfy the most stringent quality requirements. Their high frictional properties, low wear
and high temperature stability make them ideal
for a number of uses, such as the manufacture
of brake linings.
This intermediate product will
be further processed in various applications, and Deutsche Basalt Faser GmbH supplies it in two versions: rovings
and chopped strands.
THE BIRTH OF THE FIBRE:
The molten mass is ready for extrusion through the nozzles and
forms a funnel-shaped head. The fibre is created by extracting it
at such a high speed that the molten material has no time to crystallise; it solidifies in an amorphous state. In this way, basalt rock is
turned into flexible fibres with fascinating properties.
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INTERVIEW
INTERVIEW
„FEELING EuphoriC“
Interview with Christoph Osterroth,
CEO of Deutsche Basalt Faser GmbH
christoph Osterroth
WHAT DOES INVESTMENT IN SUCH INNOVATIVE PROJECTS MEAN FOR YOU PERSONALLY?
The personal appeal for me is the element of challenge.
As an engineer and businessman, I see these innovative
development projects as having immense potential.
HAVE YOU REACHED ALL YOUR GOALS WITH
THE DEVELOPMENT YET?
HOW WOULD YOU ASSES THE FUTURE OF THE
GERMAN BASALT FIBRE INDUSTRY?
What you see here today is just the beginning. The basalt fibre industry is in the initial phase of a completely
new technology that opens up undreamed-of possibilities. We have pursued a high-risk strategy and overcome
many legal and regulatory hurdles along the way. I see a
huge potential. Various well-defined projects are about
to show concrete results. A commercial breakthrough for
basalt fibre is within our grasp.
hOW WELL EQUIPPED ARE YOU TO COPE WITH
THE PRODUCTION ASPECTS OF THE IMMINENT
BOOM?
We have approval for ten furnaces and are about to expand our production in line with demand. Our first furnace designed and built in-house is more than just a pilot.
It is already a fully functional production unit which is
capable of operating at a profit. We now intend to build
several more.
HOW DID YOU GO ABOUT DEVELOPING THE
TECHNOLOGY FOR THE PRODUCTION OF BASALT FIBRES?
The furnace in which we smelt the basalt was built completely by ourselves. With the support of the experienced
professionals at our affiliated company in Georgia, we have
fine-tuned the process to ensure optimum and consistent
quality of the basalt fibre. Thanks to our in-house development, we have acquired an in-depth technical understanding of the entire process. As simple as it looks, the
technology is actually highly sophisticated. But we have
this technology fully under control. It fills us with a sense
of pride that we have managed to get the technology up
and running, producing basalt fibres of consistent quality
and functioning at a high level of reliability.
No, but that’s the exciting thing about it. For example,
if you were researching sheet metal at this point in history, you might be able to achieve an improvement of
a few percentage points. But you see, basalt is a very
young material. With just a moderate amount of R&D,
you can achieve significant improvements. Each time we
come up with a new product, we can still expect farreaching improvements in its technical characteristics.
There is enormous potential here that we are constantly
aware of. So my assessment of the current situation is
that we’ve already achieved some magnificent results
but that there are many more to come.
BASALT IS ACTUALLY A CRYSTALLINE PROdUCT, SO WHY DOES IT LEND ITSELF TO PROCESSING AS A FIBRE FOR TEXTILES?
In its natural state, basalt rock is indeed crystalline, just
like sugar. During the natural process of formation, basalt takes a certain time to acquire its crystalline structure. We can’t afford to give it this amount of time in our
production process. We solidify the amorphous structure
of the basalt. This is what makes it susceptible to processing for textile purposes.
BASALT IS A NATURAL PRODUCT, SO HOW DO
YOU ENSURE CONSISTENCY IN THE QUALITY
OF THE FIBRES?
The two factors that are crucial in ensuring consistently
high quality are reliability of process and raw materials
that do not vary in their properties. We have our own
quarry in Georgia, and the rock there is characterised by
a particularly favourable chemical composition. The quarry
has sufficient reserves to assure uninterrupted supplies
over many decades to come, even when production
really takes off.
WHAT IS THE SPECIAL FASCINATION OF BASALT
FIBRE FOR YOU PERSONALLY?
Basalt is a revolutionary fibre. In terms of cost-efficiency
and performance, it builds a bridge between carbon fibre
and glass fibre. Basalt opens the door to numerous projects for which glass fibre cannot be used and for which
carbon fibre would be too expensive. And the most exciting thing is that countless totally new areas of use are
opening up, some of which might seem like a distant
dream today, for example constructing motorway bridges
without steel reinforcement and metals which develop
completely new property profiles by the addition of basalt fibres. And why must cars be made of sheet metal
anyway? Almost every day, I have new ideas about what
can be done with this fibre.
WHAT VOLUME OF SERIOUS ENQUIRIES ARE
YOU RECEIVING FOR FURTHER PROJECTS?
We are seeing an industry on the move. At the moment,
a lot of enquiries and concrete projects are coming in,
and that gives me a feeling of euphoria.
7
8
APPLICATIONS
APPLICATIONS
„A REVOLUTIONARY FIBRE“
Applications and benefits
Euphoria. Visions. Optimism.
This is the impression left by every conversation with companies
and engineers who are busy developing applications for basalt
fibre. Let’s take a look at some of these opportunities below.
APPLICATION-SPECIFIC BENEFIT PROFILES
It is significant for the industrial use of basalt fibre that different applications derive benefit from
different characteristics. For example, high temperature resistance, which generally ranks high on
the list of benefits, is of minor importance during the lifetime of products made from composite
materials, because the melting point of the plastic is well below that of the basalt fibre content. But
when the time comes to recycle the product, this factor works in its favour, as the plastic can easily
be separated from the basalt by melting. By contrast, for applications involving insulation, fire protection or concrete reinforcement, this high temperature resistance is essential.
For each potential application, a specific benefit profile can be identified which exploits the special
characteristics of basalt fibre to the maximum.
REINFORCEMENT OF TEXTILE SURFACES USING BASALT FIBRES
Woven fabrics, non-wovens, knitted and crocheted fabrics, scrims, ribbons, tapes and ropes
– all of these applications are examples of textiles that can be reinforced with basalt fibres. In
the following technical applications, current research has shown that the use of basalt fibres
would be appropriate, and this has already been partially confirmed in practice:
• for filters used in high-temperature environments, e.g. incinerators, cement factories
• for stabilisation of road embankments or hillsides in ski resorts
• as a scrim in textile-reinforced concrete instead of steel grid
• for eye-catching designs
• for fire protection applications
• for renaturalisation of surfaces
• for non-woven materials used for technical insulation, drainage material, soundproofing
and agriculture
Potential benefits of Basalt fibre
Current research has identified a number of specific advantages that are characteristic of basalt fibre.
These initial findings will be explored in depth by means of targeted research and development projects
within the BASALTFASERNETZWERK network.
1
High temperature resistance
2Excellent mechanical properties,
such as tensile strength
COMPOSITES
Basalt fibres can be incorporated into a fibre matrix structure as constituents of compounds.
Wind turbine blades, aircraft fuselages and yacht hulls are already being manufactured from
epoxy resin in combination with carbon or glass fibre. Basalt fibre is also conceivable for all
of these applications; in a number of parameters, it would be more cost-efficient and
deliver better performance.
One groundbreaking development associated with basalt fibre is the
organic sheet, which is a combination of natural basalt fibre with polyamide plastic
film to produce a freely malleable lightweight material for industrial manufacturers.
In combination with mineral substances, basalt fibre is used to reinforce concrete.
fire protection
composites
3Chemical resistance
filter textiles
4Corrosion resistance
concrete applications
5Excellent vibration damping
6Natural product
7Antifouling properties
8UV resistance
acoustic insulation
good recyclability
eliminating growth of
algae and/or moss
geotextiles
9
10
NETworK
Network
one network – many options
Visionary companies and research institutions that have recognised
the potential of basalt fibre and wish to exploit its economic benefits have joined forces to form BASALTFASERNETZWERK (Basalt
Fibre Network). Together, they intend to explore the possibilities for
the technical application of basalt fibre, to ensure reliable qualities
and to develop new applications.
Zapf GmbH
Roth Industries GmbH & Co. KG
Manufacture of prefabricated buildings,
prefabricated garages and elements for
major building projects, production of
construction materials
Development and production of energy
systems, plumbing systems, pipe technologies and pressure reservoirs, as well as
composites and plants for the manufacture thereof
www.zapf-gmbh.de
www.roth-industries.com
Sächsisches Textilforschungsinstitut e. V.
www.deutsche-basalt-faser.de
Fiber Engineering GmbH
Barthels-Feldhoff GmbH & Co. KG
Development and manufacture of
technical textiles, braiding, tape weaving,
plus the manufacture of yarn, coating and
finishing, assembling
Development and manufacture of equipment for the production of fibre-reinforced
components with a 3D contour based on
the Fibre Injection Moulding (FIM)
technology developed in-house.
www.barthels-feldhoff.de
www.fiber-engineering.de
Fibre processing and recycling plus
production of chopped strands and
development of non-woven fabrics used
in fire protection, acoustic insulation and
composite material
Research and development of technical
textiles and non-wovens, accredited test
centre for textiles and for the certification
of personal protective equipment
(Notified Body 0516)
KI Keramikinstitut GmbH
Production of basalt fibre in the form
of rovings and chopped strands,
development of basalt fibre for specific
applications
FIBTEX GmbH
(SAXON TEXTILE RESEARCH INSTITUTE)
www.stfi.de
DBF
Deutsche Basalt Faser GmbH
Basalt-fibre-reinforced profiled rebars
www.fibtex.eu
BEKA Mare SOLUTIONS GmbH
Development and marketing of corrosion
protection systems for marine applications
and composite materials in the marine
engineering sector
www.bekamaresolutions.de
INNOVENT e. V.
www.tensar.de
www.norafin.com
Chemnitz university of
technology, department of
lightweight structures and
polymer technology
hoftex coretech gmbh
Research and development of composites,
technologies and equipment for lightweight structures in the fields of plastics
and building materials
Development and production of classic
yarns, threads and fabrics, as well as
specialised technical textiles; partner for
cutting-edge production and technology
skills
www.leichtbau.tu-chemnitz.de
www.hoftex.de
ALTERFIL Nähfaden GmbH
Thorey Gera Textilveredlung
GmbH
Development, manufacture and distribution of innovative sewing and embroidery
yarns and technical yarns; operating its
own dyeing plant
Textile finishing of woven, knitted, crocheted or non-woven fabrics to the highest
quality standards
www.alterfil-shop.de
www.thotex.de
EBF Dresden GmbH
Engineering services and consulting for the
development and design of machinery and
equipment; wear materials and construction materials
www.innovent-jena.de
www.cg-tec.de
www.ebf-dresden.de
AB-Tec GmbH & Co. KG
VIS GmbH
LEFATEX CHEMIE GMBH
Trading in geotextiles made from natural
fibres and synthetics, gabion and embankment support systems
Production of thermoplastic, heat-activated adhesive non-wovens in Germany,
and Europe-wide marketing of these
products under the name TecWeb
Manufacture of conveyor belts and drive
belts, e.g. for the textile, food, machine
tool, logistics, tobacco, paper and printing
industries
www.igg.de
www.ab-tec.com
www.visbelting.eu
IGG
Internationale Geotextil GmbH
Manufacture of high-grade material structures, composites and special non-wovens
for filtration, work clothing, the medical
sector, automotive manufacturing and the
construction industry
Cetex – Institut für Textil- und Verarbeitungsmaschinen gGmbH
Research, development and transfer for
surface engineering, biomaterials, analysis,
as well as testing of materials and organisation of conferences
www.keramikinstitut.com
Norafin Industries GmbH
Development, manufacture and application of geogrids and geosynthetic
materials, e.g. in base layer stabilisation, in
the reinforcement of steep slopes and retaining structures and in the reinforcement
of asphalt surfaces
CG TEC GmbH
Development and production of profiles
and plates made from CFRP carbon fibre,
glass-fibre reinforced plastic (GRP) and
fibreglass and basalt-fibre reinforced
plastic (BRP), prepreg winding technology,
prepreg moulding technology, pultrusion
Development of ceramic materials, products and technologies, special and highperformance ceramics, quality assessment
and certification of ceramic raw and basic
materials
TeNSAR INTERNATIONAL
Manufacturer of dispersions and emulsions
www.lefatex.de
www.zschimmer-schwarz.com
German research institute for new technologies and machinery for the production of
textile-based semi-finished products, functional components and high-performance
structures
Basalt-reinforced spacer fabric
STS Textiles GmbH & Co.KG
Development and production of fabrics
for home textiles and for automotive and
technical applications
www.sts-textiles.com
www.cetex.de
BMW Group
Automobile manufacturer
www.bmwgroup.com
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