Effect of Basalt Melt-out Nozzle Length on Fiber Forming
LIU Chunyue1, ZHANG Qifan2, ZHANG Jianwei1,*, ZHANG Lei2,3, LIU Jiaqi1,3, WANG Qipeng2
1 School of Environmental and Geographic Sciences, Institute of Basalt Fiber Ecological Applications, Qingdao University, Qingdao 266071, Shandong, China 2 Zhongke Shiyuan New Material Technology (Qingdao) Co., Ltd., Qingdao 266237, Shandong, China 3 Institute of Geology and Geophysics, Chinese Academy of Sciences, Beijing 102213, China
Abstract: The successful formation of basalt fibers and the stability of the fiber drawing process are directly governed by the length parameter of the spinneret nozzle. The influence of spinneret nozzle length on basalt fiber formation was systematically investigated through the design of a quintuple-orifice crucible with precisely controlled nozzle dimensions of 2 mm, 3 mm, 4 mm, 5 mm, and 6 mm. Under standardized experimental conditions with consistent basalt melt composition and thermal environment, optimal fiber formation was achieved at 1 450 ℃, wherein the 3 mm nozzle exhibited superior process stability. While continuous filaments were obtainable with 2 mm and 4 mm nozzles, notable process fluctuations were observed. The 5 mm and 6 mm configurations demonstrated compromised fiber-forming capability under equivalent process parameters. The quantitative correlation between spinneret nozzle geometries and fiber formation efficiency was systematically validated through COMSOL Multiphysics simulations conducted at 1 450 ℃ melt temperature. Computational results demonstrated precise consistency with experimental observations regarding filament continuity and process stability across varying nozzle lengths. The inverse correlation between nozzle length and melt flow velocity was quantitatively established, wherein optimal fluidity characteristics were attained at the 3 mm configuration, whereas excessive velocity gradients induced by the 2 mm nozzle were identified as detrimental to fiber drawing stability. Concurrently, longitudinal thermal gra-dients within the melt were demonstrated to be inversely governed by nozzle length, with the 3 mm variant exhibiting minimal temperature variation along the flow path, thus enabling continuous fiber formation. By contrast, terminal temperature differentials ranging from 14.7 ℃ to 29.6 ℃ were recorded in 4—6 mm nozzles due to intensified convective heat dissipation, resulting in compromised fiber-forming continuity. A positive correlation between spinneret nozzle length and melt viscosity was established through characterization, with the 3 mm configuration exhibiting an optimal terminal viscosity differential of 3.2 Pa·s that ensured stable fiber formation. Progressive destabilization of the fiberization process was observed as the nozzle length increased, attributable to amplified viscosity gradient magnitudes within the melt flow field. An inverse correlation between basaltic melt viscosity and temperature was established. Optimal fiber formation efficiency was demonstrated under standardized conditions of 1 379.9 ℃ melt temperature, 1.08×10-3 m/s flow velocity, and 48.5 Pa·s viscosity at the spinneret orifice, achieving superior process stability with the 3 mm nozzle configuration. The established methodology was validated as providing a critical optimization framework for spinneret nozzle length parameters and industrial fiber production process adjustments in basaltic melt fiberization systems.
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2026, Vol. 40 
