Zubko Y. Optimization of production processes and use of fibers, microfiber and microspheres obtained by superheated basalt melts

The presented thesis is devoted to the creation of energy-efficient single-stage industrial technology based on the superheated melt method to produce high-quality basalt micro products in the form of staple and continuous fibers, microfibers and microspheres. The peculiarities of technological processes of obtaining these products and some composite materials based on them have been studied. The method of superheated melts involves overheating of the basalt melt to a temperature of 2300−2600 °C, which significantly exceeds the temperature inside the gas bath furnace. This high-temperature melting mode allows to significantly improve the homogenization of the melt at the outlet of the melting furnace and to achieve complete (100%) amorphous of basalt products obtained by processing this melt. The modeling of the thermal insulation process of external high-temperature pipelines and units is made taking into account the temperature dependence of the thermal conductivity of the fiber. The average ambient temperature and average wind speed in Ukraine are also taken into account. On the basis of the calculations, tables of recommended thicknesses of thermal insulation depending on the temperature of the carrier and the diameter of the pipeline are compiled. These tables can be used in the development of internal corporate energy saving standards for enterprises in the chemical and energy industries of Ukraine. The technology of manufacturing a special type of basalt super-thin fiber (BSTF) with an average fiber diameter of 1-1.5 microns has been developed, which has a reduced fiber length and can be used for pneumatic blowing without granulation. This made it possible to create effective methods of heat, sound insulation and fire protection of houses made on the basis of wood frame or light steel frame. The developed material showed high insulation efficiency, which significantly exceeds the results obtained with traditional thermal insulation materials. The technology of production basalt super-thin fiber modified with zirconium silicate has been developed. Studies have shown that such a fiber exhibits significantly higher chemical stability in alkaline and acidic media compared to baseline samples. It can be used in thermal insulation works in chemical pro Keywords: basalt fibers, basalt microspheres, basalt microfiber, basalt microfillers, basalt roving, thermal insulation materials, induction melting.