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Georgia, Tbilisi
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Production of Basalt Fibre Products
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Title |
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Production of Basalt Fibre Products.
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Objectives |
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- To built plant to produce up to 1,000 tons of basalt fibre per year.
- To create 22 permanent jobs, including 13 jobs for SIPT staff.
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Background |
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The purpose of this project is to enable the Ilia Vekua Sukhumi Institute of Physics and
Technology (SIPT) in Tbilisi, Georgia, to establish a facility to manufacture and sell basalt
fibre and Foam-Fibre-Concrete. The comparatively low softening temperature (1250C) of basalt
makes it possible to manufacture basalt fibres and articles made from it. Because of the
availability of the technology, the practically unlimited reserves of raw material, and the
importance of the applications of basalt materials, basalt technology is used in many countries.
Fibre is obtained by stretching basalt threads drawn from a spinneret by a special device
which reels the threads onto a drum. Fibres are then chopped to the required length. The chopped
fibre is then incorporated into foam concrete blocks or into concrete as a reinforcing element.
The fibre can be used for reinforcing a number of materials, including concrete, foam concrete,
asphalt concrete and polymers. Concrete structures with basalt fibre approach the performance of
structures reinforced with steel mesh, but basalt concrete has higher strength because the
basalt fibre is much more highly dispersed in the reinforced material. Furthermore, basalt
fibres with a diameter of 18-60 micrometres, unlike metallic mesh, do not change their strength
during a long period in an aggressive environment such as hardening cement. The second proposed
product, Foamed Fibre Concrete (FFC) blocks, will be used for reconstruction of old buildings,
construction of individual houses and agricultural premises. Blocks can be used for building
structural walls, floors, and partitions, in structures such as garden houses and garages. FFC
is characterised by high thermal and sound insulation, high strength, ecological compatibility
and incombustibility, high frost-fire resistance, ease of laying and processing and low
labour-intensiveness.
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Plan |
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The plan involved designing and building a plant capable of producing up to 1,000 tons of basalt
fibre per year with a view to achieving sales of £ 300,000 in 2011. The factory would develop
original know-how for clients to improve the use of basalt fibre in enhance the properties of
composite materials and parts. The proposed fibre products should be able to compete in internal
and regional markets on the basis of lower price. The main products we to be basalt fibres for use
in anti-corrosion marine paints and flexible containers made form basalt fibres. The plan involved
starting with 12 staff from SIPT, to set up the administration of the company within the Institute,
design and procure the necessary equipment, train up the operating and administrative staff. To
complete the production team they plan to recruit a further 10 staff during the first year.
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Leadership |
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The proposed work is being carried out at SIPT in collaboration with the Mining Institute, which was founded in Tbilisi in 1957 and which is involved in exploration for useful minerals, including basalt. The current leader, Guram Abashidze, appears to be developing the project in an effective way, with support from Mineral-7.
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Marketing and sales |
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Two Georgian purchasers have indicated that they are ready to purchase products as soon as production is underway. Mineral-7 has been advising on marketing. The Commercialisation team has been visiting potential customers with the Project Leader .
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Jobs |
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8 new jobs (including 6 jobs for SIPT staff) had been created by the end of Q 1, 2011-2012.
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Cost |
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Total cost of the project is £ 240,800.
The DECC's contribution is £ 165,800. DECC contribution includes: Procurement of equipment and materials (production line for basalt fibre, Foam generator); Installation of the equipment, launching, commissioning, staff training; Shipping and custom fees (Lvov-Tbilisi); Hood, Air supply channel for burning, Liner, Gas equipment, Pyrometer, Cables, Rubber pipes, Cranes, rack, Water piping, Ladder, Compressor; Labour costs.
The SIPT contribution in kind has been estimated at £ 75,000: it includes premises and
infrastructure (£ 12,000), laboratory equipment (£ 43,000) and intellectual property
accumulated over a long period of research funded by SIPT and through grants which it has won
(£ 20,000).
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Beneficiary |
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Sukhumi Institute of Physics and Technology, Tbilisi
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