Object: ООО Russkiy Basalt Plant (Borodino Group of Companies)
Type of Order: Organization of Heat-Insulating Material Production in the Form of Basalt Wool from the Nonmetallic Metals Mixture
Country: Kimry, Tver’ Region, Russian Federation
Beginning of the Construction: 2007
End of the Construction: 2009

Brief Description of the Project
The production volume of mineral fibers from molten rocks including heat-insulating products made of basalt raw material is increasing all over the world. Materials based on basalt, diabase, gabro have replaced such heat-insulating materials as asbestos and glass wool, as due to their dangerous influence on health, they have been out of production and disused.
Basalt wool is a unique environmentally safe material that meets the whole range of standards requirements and possesses high heat-/sound- and electrical insulating properties.
The project envisages construction and erection works, acquisition and installation of advanced equipment of Italian company Ro.ma S.r.l (design capacity of the line - 35 000 t/h). Modern technologies enable to process basalts cost-effective and in bulk: to melt, mold, transform into dispersion form (powders, threads). As a finished product there is high-quality basalt fiber of different density and two-layer heat insulating plates of mineral wool with the layers of various densities to be used as heat-insulating layer in roof structures and for walls insulation of one layer.
Main Production Stages
- raw material preparation
- raw material melting and silicate melt production
- melt processing into fiber
- mineral-wool carpet formation
- mineral-wool fiber cutting
- marking and packaging.

Characteristics of Buildings and Facilities of the Industrial Site:
- Production facility of mineral-wool mats from basalt rocks is a one-floor building, 72 х 180 х 10,2 (Н), with attached 4-level equipment rack 27х47х24m (Н). The line for mineral-wool mats production and storage premises are located in the building. Preparation and processing of basalt raw material is located in the attached equipment rack. The carcass is combined, prefabricated reinforced concrete columns, metal trusses. Walls and siding are of sandwich-panels. Equipment racks is single metal structure. Foundations are of solid reinforced concrete.
- Storage of inert materials — flat reinforced concrete areas with reinforced concrete partitions Н=2 m. Total area is 4000 m2.
- Loading point — metal hoppers on single metal stanchions;
- Gallery — engineering structure for transportation of inert materials. Carcass — separate metal structures with siding of shaped sheets.
- Live storage of inert materials – one-floor engineering structure for measuring units installation. Carcass — metal with sandwich panels siding.
- Check point and artesian well with pump station – one-floor brick buildings with flat soft roofing along reinforced concrete flooring. Foundations are solid reinforced concrete.
- Gas boiler house is designed for heating and hot water supply of the complex as well as process steam supply. Capacity is 11,5 Gcal/h.
- Gas distribution substation is built for gas pressure reduction and its maintenance on the set level. Capacity is 1500 m3 /h.
- Transformer substation consists of the room for high-voltage switchgear 10 kV from the cells and two transformers of foreign production 10/0,4 kV with the power of 2000 kVA each, with solidly-grounded neutral and a room for low-voltage switchgear 0,4 kV from the cells of foreign production.
- Artesian well is designed for water supply to the plant. Capacity is 20 m3/h (1 working + 1 stand-by). Working time - 15 h. Above the artesian well there is presupposed a pavilion with the plan dimension of 3,1 х 3,5 m.
- Potable water storage tank with pump station and sewage treatment facilities.
- Emergency water storage tank with pump station – 2-compartment with the total volume of 1200 m3, dimensions - 20х20, interconnected with pump station 6,5 х12 m. Total area is 478 m2.
- Sewage treatment facilities for storm runoff with reservoirs and pump stations.
- Sewage pumping station with the capacity of 2 m3/h in package-modular version, depth - 5 m, reservoir diameter - 1,5 m.