Rock

Basalt Rock Products

Scott Gerhardt

8/11/11

Cover and Contents (1)

Introduction (2)

Test example of Basalt Rebar (2)

Scientific Challenges of Industrial process (3-6)

Oregon (7)

Basalt (8)

Scientific Hurdle outline (9)

I first read about basalt fiber rebar in Dr. Rogge’s CEM 407 class on an assignment for reading an article from ENR, Engineering news record: (http://enr.construction.com/products/materials/2010/0929-RockFiberRebar.asp).  The article is about promising results from a twenty two meter long demonstration replacement bridge project.  Susan Taylor from Queens University in Belfast is championing the new deck design method for improving sustainability, durability, and more efficient use of materials.  Teams tested the finished deck with three times the EU maximum load and found the maximum strains at 11.7% of maximum capacity with half the deflection of comparable steel section.  Their tests listed the BFRP’s (Basalt Fiber Reinforced Polymer’s) tensile strength of about 1,200 mega-Pascal’s, twice steel’s strength at three quarters the mass; while being more resistant to the alkaline conditions commonly found in concrete, with durability ideal for projects with corrosion risk.  “’BFRP production is; very simple’ Ben Williams adds. Unlike glass, he says ‘Basalt is mined, melted and extruded into fibers with no purification steps or additives’.”  (ENR) The article ends with Mohsen Issa’s, a professor of Structural and Materials Engineering at the University of Illinois at Chicago, quotes about the future of BFRP in the US. 

From the website: http://www.b-composites.net/204.html a plethora of information is available comparing BFRP to other composite materials specifically why it can be considered as Green Product, including but not limited to the following reasons:

1. Raw materials for production of basalt fiber are natural rock – basalt.

2. During loading into the melting furnace producers don't use any chemical additives as well as any solvents, pigments or other hazardous materials.

3. Producers use only natural gas and electricity for heating of melting furnaces and bushings.

4. Melting furnaces for production of basalt fiber are environmentally friendly and don't release any industrial waste during production.

5. Final product doesn't include any hazardous materials and fully corresponds to REACH protocol and all hygienic standards.

6. Basalt products have no toxic re-action with air or water, are non-combustible and explosion proof. When in contact with other chemicals they produce no chemical reactions that may damage health or the environment.

7. Basalt fiber diameter exceeds 6 microns and does not enter the human respiration system. Scientifically is proven that the fiber of more than 3 microns in diameter cannot penetrate into human respiration system.

8. In Europe, Japan and the United States, fiber-reinforced PP and PE auto parts are often recycled by incineration. The problem with this is that the glass-fiber reinforcement melts and builds up on the bottom of the ovens, which must be shut down for cleaning. In the same conditions, basalt fiber burns down into a fine powder. The extracted powder can then be used as filler for resins or in road materials. Moreover, this powder is a natural material (basalt powder), not a chemical substance as in case with the E-glass. Thus using reinforced parts made out of basalt fiber instead of the E-glass fiber reinforcement allows car producers effectively meet strict end-of life requirements.

The website: http://www.b-composites.net/203.html also lists a ‘typical’ chemical composition of basalt rock by percentage as:

SiO2 - 52.8

Al2O3 - 17.5

Fe2O3 - 10.3

MgO - 4.63

CaO - 8.59

Na2O - 3.34

K2O - 1.46

TiO2 - 1.38

P2O5 - 0.28

MnO - 0.16

Cr2O3 - 0.06

The left hand bar on the b-composites site (http://www.b-composites.net/ ) lists various applications in advanced composites from woven fibers to applications where steel is currently used but could be replaced by basalt products.  The left hand bar also lists the manufacturers in Eastern Europe, Asia, and China.  These manufacturers can also be verified by Googling for materials providers selling the product overseas: http://www.alibaba.com/manufacturers/basalt-fiber-rebar-manufacturer.html lists the various manufacturers and their prices for verification. 

The B-composite site also give a general overview of the process but leaves out many of the necessary engineering details that would need to be fine tuned for the basalt source(s) that could eventually feed various processes.  The site outlines other alkaline basalt sources than the chemical composition listed above that have higher survivability and durability in alkaline environments depending on the quarry source or chemical control of the crushed stone, or application.

1.     Sizing Tank

2.     Furnace

3.     Bushing (technical advantage)

4.     Sizing applicator

5.     Gathering shoe

6.     Sizing collection tray

7.     Winder

8.     Cake

9.     Sizing tank recycler

As well as slightly more detailed process algorithms that still protect the proprietary technology.  The entire process is full of potential engineering solutions spanning the spectrum of engineering colleges at Oregon State University.   An important control variable is temperature which used to control viscosity at the bushing, making the consistency of the energy flow through the system, and consistency of the source rock integral to the process success.  Another major technical issue is the high crystallization ability of basalt melt and narrow temperature range of the production process. Pulling speed is another control variable for monofilament diameter.  And monofilament diameter is a controlling variable for the final product; in that reducing the diameter increases the fibers elasticity, but is more difficult to obtain due to narrowing constraints at that point.   Most manufacturers use one end roving for production of assemblies and twisted yarn with the relationship of greater number of rovings the greater the catenary of the final product; a characteristic necessary for a green, locally sourced, rebar alternative.   Below is an example industrial furnace for basalt fiber production:

1.     furnace

2.     Feeding pipe

3.     Bushing

4.     Gathering shoe

5.     Winder

Most manufacturers attempt to increase the number of holes in the bushing to decrease monofilament diameter.  The average is 200 to 400 holes per bushing and only Kamenny Vek in Russia works with bushings of 400 to 1000 holes. 

Natural Gas prices continue to fall, feel free to check again today, regardless, the temperature can be maintained up to 2000 degrees Celsius by the combustion of natural gas, more than enough for the 1400-1500 degree range necessary for basalt fiber production.  Large amounts of Electricity would also be required for the various processes, for fine control of the temperature, and for the various support and operational functions necessary to maintain such an industrial process.  Property value, rail lines, access to water transportation, and proximity to source basalt are also necessary inclusions to the decision matrix for a successful statistical analysis. Given the Oregon’s economic history this could be a viable and integral industry.  Many options exist that meet these needs along the Columbia corridor, many of which are abandoned Aluminum facilities, sites that already have the necessary utilities, rail lines, water access, and some still have buildings.  The area has never fully recovered from the faux energy crisis a decade ago that drove the Aluminum industry out, due primarily to the cost of electricity.  The Goldendale site reclamation began just this year: http://www.yakima-herald.com/stories/2011/04/09/the-goldendale-aluminum-plant-the-death-of-a-way-of-life The Minerals, Metals, & Materials Society has summarized the decline of the aluminum industry across the country and along the Columbia corridor in: http://www.tms.org/pubs/journals/jom/0202/binczewski-0202.html outlining other abandoned Alcoa plants and reduced facilities in The Dalles and farther east along the river, as have the local governmental agencies.  Many of which could be retrofitted to process basalt hauled cheaply down river, with the cheapest site being closest to the source, luckily many abandoned sites are available, for sale, and the resourceful local people are in need of employment that can support families and send children and grandchildren to college. 

The Columbia River Gorge cuts like a knife along the border of Oregon and Washington with tributaries spreading throughout the Columbia River Flood Basalt Province that forms a plateau of 164,000 square kilometers between the Cascade Range and The Rocky Mountains; In all there are more than 300 distinct individual basalt lava flows with an average volume of 580 Cubic KM.  (from: http://volcano.oregonstate.edu/vwdocs/volc_images/north_america/crb.html ) This does not consider the Basalt deposits by other smaller volcanic events around Mt. St Helens, Mt. Hood, MT. Adams and other geographic monoliths that pepper the area.  The highland basalts are separated into regions such as the Chief Joseph dike swarm vents for the flows in the Imhaha, Grand Ronde, Wanapum Formations, and the basalt of the saddle Mountains; the Grand Ronde and Cornucopia dike swarms are within the Chief Joseph swarm.  While the monument Dike Swarm was the vent for Picture gorge Basalt.  And the Paso Basin is nearer the confluence of the Columbia and Snake rivers.  A much, much more detailed map is due out soon from: http://www.oregongeology.org/sub/ogdc/ that is supposed to be finished, from my understanding the government contracted it out to private contractors who are dragging their feet and asking for more money.  From this map areas could be targeted for testing, and from that data, or existing data an informed decision could be hypothesized. The reality is that from wherever the basalt is quarried the geochemical composition will be distinctly different, and have potentially prohibitive transportation costs. Any decision/reality at any point will profoundly impact general feasibility; Perhaps none more than location and cost to quarry source stone material.  Which is why the GEOROC database (http://georoc.mpch-mainz.gwdg.de/georoc/Entry.html) maintained by the Max-Planck Gesellschaft in Mainz is invaluable.  GEOROC is a compilation of 572,000 geological analyses of 322,000 geological samples from 11,147 peer reviewed geological papers.

This report under ten pages out of respect for your time, I have researched more and am willing to research more.  Thank you for your time!

·        Economic Analysis

o   Site selection

o   Quarry selection

o   Facility retrofit

o   Operational costs

o   Marketability

o   SWOT analysis

·        Scientific Assessment of Operations

o   Operational design specifics

o   ASTM A931 - 08 Standard Test Method for Tension Testing of Wire Ropes and Strand

·        Wire rope tests are generally to be performed on new rope. The use of wire rope in any application can reduce individual wire strengths due to abrasion and nicking that will result in the wire rope strength being reduced. Damage to the outer wires will also lower the maximum strength achieved during tension testing.

·        The modulus of elasticity of wire rope is not considered to be a standard requirement at this time. The determination of this material property requires specialized equipment and techniques.

·        Rope to be tested should be thoroughly examined to verify that no external wire damage is present. If present, it should be noted. When possible, a new undamaged sample should be obtained for testing.

·        End attachments and their installation can directly affect breaking force achieved during testing. Any attachment that can be used to directly achieve the required rope breaking force can be used. Standard testing with a poured socket, using zinc, white metal or thermoset resin, has been considered the most efficient. Proficiency in attachment of any fitting can have a direct effect on the final test results.

·        1. Scope

·        1.1 This test method covers the tension testing of wire ropes and strand at room temperature, specifically to determine the measured breaking force, yield strength, elongation, and modulus of elasticity. Methods described in this standard are not intended for other purposes.

·        1.2 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.

·        1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. Specific precautionary statements are given in Note 1 and Note 2.

A586 Specification for Zinc-Coated Parallel and Helical Steel Wire Structural Strand
A603 Specification for Zinc-Coated Steel Structural Wire Rope
A1023/A1023M Specification for Stranded Carbon Steel Wire Ropes for General Purposes
B6 Specification for Zinc
E4 Practices for Force Verification of Testing Machines
E6 Terminology Relating to Methods of Mechanical Testing
E8 Test Methods for Tension Testing of Metallic Materials

ISO Standard

·        ISO17558 Specification for Steel Wire Ropes - Socketing Procedures - Molten Metal and Resin Socketing

ASTM A1023 / A1023M - 09 Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

·        Abstract

·        This specification covers stranded steel wire ropes of various grades and constructions manufactured from uncoated or metallic coated wire and cord products manufactured from metallic coated wire. Dimensional characteristics include the diameter and lay length of the rope. Mechanical property requirements include: rope breaking force, spinning loss factor, and stretch; and wire torsions, tensile strength, tensile grade, and level. Cores of stranded ropes shall normally either be of steel or fiber composition. All wire ropes shall be lubricated and impregnated in the manufacturing process. Wire finish may be final-galvanized rope or drawn-galvanized (zinc coated) rope. Rope workmanship and finish; testing and compliance; acceptance tests; and packaging and identification are also detailed.

·        This abstract is a brief summary of the referenced standard. It is informational only and not an official part of the standard; the full text of the standard itself must be referred to for its use and application. ASTM does not give any warranty express or implied or make any representation that the contents of this abstract are accurate, complete or up to date.

·        1. Scope

·        1.1 This specification covers the general requirements for the more common types of stranded steel wire ropes. Included in this specification are wire ropes in various grades and constructions from ¼in. [6 mm] to 2³/₈ in. [60 mm] manufactured from uncoated or metallic coated wire. Also included are cord products from ¹/₃₂ in. [0.8 mm] to³/₈ in. [10 mm] manufactured from metallic coated wire. For specific applications, additional or alternative requirements may apply.

·        1.2 The values stated in either inch-pounds or SI units are to be regarded separately as standard. Within the text, the SI units are shown in brackets. The values stated in each system are not exact equivalents; therefore, each system shall be used independently of the other. Combining values from the two systems may result in nonconformance with the specification.

·       
2. Referenced Documents (purchase separately) 

·        ASTM Standards

·        A931 Test Method for Tension Testing of Wire Ropes and Strand
A1007 Specification for Carbon Steel Wire for Wire Rope

·        ISO Standards

·       ISO3108 Steel Wire Ropes for General Purposes--Determination of Actual Breaking

o   Industrial process algorithm development

o   Bushing design research

o   Temperature control/Pulling speed relationship derivation

o   Equipment assessment/Design

o   Product development

o   Quality assurance algorithms

·        Environmental Impact Survey

·        Geological Site location

o   Quarry or Quarries

o   Specific chemical composition of various basalts

http://www.uvm.edu/~transctr/pdf/netc/netcr63_03-7.pdf

http://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=4&cad=rja&sqi=2&ved=0CEcQFjAD&url=http%3A%2F%2Fwww.sapub.org%2Fglobal%2Fshowpaperpdf.aspx%3Fdoi%3D10.5923%2Fj.textile.20120104.02&ei=cWbrUbaUOsagiAKQ2IGwAQ&usg=AFQjCNE1OYjCfnXArRVtLu3yBkDlkdHLvw&sig2=paXAfkOIVdQS88WmOh_oOQ&bvm=bv.49478099,d.cGE

http://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&sqi=2&ved=0CDMQFjAB&url=http%3A%2F%2Fwww.platinummetalsreview.com%2Fpdf%2Fpmr-v21-i1-018-024.pdf&ei=cWbrUbaUOsagiAKQ2IGwAQ&usg=AFQjCNH4j1O6VdKjuMnTAx62JKs0Fdv4gQ&sig2=JGzAr0cMiBO8p-vtAIyW0g&bvm=bv.49478099,d.cGE