Construction stages
Pre-project work for the construction of a basalt fiber plant
Before starting the project, at the first stage, our team selects samples of basalt rocks from the Client’s fields to conduct research on their chemical composition and the possibility of obtaining fiber. Research is carried out in the best laboratories in the world. Next, the samples selected as a result of the study are melted in a laboratory installation and the fiber is drawn. The fiber is tested to determine its physical and mechanical properties.
Basalts are a type of igneous rocks formed from a deep, high-temperature aluminosilicate solution. The suitability of basalts for processing into fiber is determined by the properties of the original magmatic fluid: degree of homogeneity, viscosity, melting and crystallization temperatures, chemical composition.
Basalt is an aluminosilicate system with rock-forming elements: O, Si, Al, Mg, Ca, Fe, Na, H, Ti, K and so on. The possibility of achieving uniformity of secondary basalt glass depends on the mineral composition of basalts due to its influence on the temperature and duration of the melting process.
Professor N.E. Ablesimov «Continuous basalt fibers»
Work preceding the project
The next stage of work preceding the project is pilot industrial smelting of basalt rocks from the Client’s deposit, selected on the basis of research. Melting takes place at an existing basalt fiber production plant. This is the main source of data for determining the optimal production flow diagram and further development of design estimates for the construction of production facilities of a plant for the production of continuous basalt fiber.
Preparation of a preliminary feasibility study for a plant for the production of basalt fiber with a design capacity determined by the Client. The document will include a full financial model and market research
1. Introduction
2. Fiber market analysis.
3. Description and features of the production of fibrous products.
4. Marketing and sales
5. Supply of raw materials
6. Logistics
7. Production plan
8. Logistics strategy
9. Personnel
10. Security
11. Financial plan and investment indicators
12. Risk analysis and risk management.
Pre-FEED — basalt fiber plant concept
Pre-FEED is the preliminary stage of a project that represents the initial concept. Its goal is to further create a detailed design, define the project’s goals and deliverables, and develop a plan that serves as a roadmap for the entire project life cycle. This stage includes determining the technical and economic feasibility of the project.
Determination of the scope of the project by defining goals, objectives and requirements. This step includes defining the scope of work, identifying critical components, and developing a detailed project definition that describes the overall concept of the project
Process design is the stage in which engineers assess the technical feasibility of a project and determine the necessary equipment, systems, and processes needed to achieve the project’s objectives. During this phase, engineers design process technological schemes, define equipment, and establish process requirements.
A feasibility study is conducted to assess the economic feasibility of a project, taking into account available resources, project cost, and potential risks and opportunities. During this stage, engineers assess the profitability of the project, identify any potential risks, and develop mitigation strategies The cost estimate involves developing a comprehensive cost estimate for the entire project, including capital costs, operating costs, and potential risks and contingencies. This step provides the basis for the project budget and is essential in determining the financial feasibility of the project
Project planning is the last step in Pre-FEED in which a detailed project plan is developed. The plan includes the project schedule, resource requirements, and milestones
At the end of the stage, the Customer receives:
- Process design basis
- Material & Energy Balance (M&EB)
- Process Flow Diagrams (PFDs)
- Dimensional and Layout Block Drawings
- Process descriptions
- Utility Requirements and Utility Flow Diagrams (UFDs)
- Preliminary Piping & Instrumentation Diagrams (P&IDs)
- Process control description
- Preliminary instrument list
- Process equipment list
- Space requirements for each process/section
- Overall Building Requirements
- FEL 2 Level Cost Estimate Class 4 (Cost Estimate Accuracy: L: -15 to — 30%, H: +20 to +50%)
- Rock yard: Inspection, grading and washing
- Rock conveying system from yard to furnace
- Rock feeding system into the furnace
- Furnace(s) dimensional design to accommodate specified melting capacity
- Steelworks design
- HVAC system for fiber forming level
- Process water system
- Gas combustion system
- DI Water System
- Compressed Air
- Electrical line diagrams
- Sizing Equipment and delivery system
FEED — project of a plant for the production of basalt fiber
FEED or front-end engineering design is an important step in large industrial or infrastructure projects. It is carried out after the Pre-FEED to evaluate the technical specifications, subsequent costs and procurement required for the project. FEED is required for the next stage of the project — detailed design.
- Organizational structure of the project
- Project Scope
- Safety and Ergonomics Research
- Preliminary 2D and 3D models
- Equipment layout and installation plan
- Development of an engineering design package
- List of main equipment
- Strategy and depth of automation
- Technological diagrams, diagram of pipelines and devices
- Project implementation timeframe
- Project financing
One of the stages of pre-design work is layout work. Our team forms a scheme of the master plan for production, the location of the entire complex of equipment in production facilities, taking into account the efficiency of the production workflow and auxiliary work.
Detailed and technical engineering design
Detailed and technical engineering design containing detailed diagrams and drawings for construction, civil works, instrumentation, control system, electrical equipment, supplier management, work schedule, costs, equipment procurement, economic indicators.
- Detailed design containing detailed diagrams and drawings for construction, civil works, instrumentation, control system, electrical equipment, supplier management, work schedule, costs, equipment procurement, economic indicators
- Estimated documentation, tender documentation, participation in the tender commission, selection of suppliers, specification of materials and equipment
- Standards and Guidelines – Every industry has standards and guidelines, and many industries are regulated. Any equipment, manufacturing facilities, production lines, etc. designed for these industries must comply with these standards and regulations and may have a significant cost/time-to-completion impact
- Assumptions, exceptions and potential problems. Identification of potential issues, assumptions, or exceptions that may affect the project during its execution. It is possible to include stages of future expansions
At the end of the stage, the Customer receives:
- Explanatory note
- List of environmental protection measures
- Automatic fire extinguishing
- Architectural solutions
- Automated process control systems
- Water supply and sewerage
- Air supply
- General plan
- Gas supply (internal devices)
- Outdoor gas pipelines
- Storm/Rain drain
- Reinforced concrete structures
- Reinforced concrete structures. Foundations
- Metal structures
- External water supply networks
- External sewer networks
- External low voltage networks
- External power supply networks
- Heating, ventilation and air conditioning
- Security alarm
- Fire alarm
- Firefighting
- Radio communication, broadcasting
- Access control system, Burglar alarm
- Structured cabling
- Engineering systems monitoring system
- Communication systems
- Video surveillance system
- Refrigeration
- Lightning protection
- Power equipment
- Outdoor electric lighting
- Electric lighting (internal)
- Power electrical equipment and lighting
- Fire safety
- Energy efficiency
- Construction organization project
- Recycled water supply
- Preparation and sorting of raw materials
- Water treatment
- Industrial waste water
- Lubricant preparation system
- Fiber technology
- Technology
- Exhaust gas removal system
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