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REFRACTORY MINERALS
© Industrial Minerals 2013 Production is latest known (mostly 2012) or estimated;
ACIDIC SPECIAL
in tonnes per annum; m. million Images: 1 M. O’Driscoll; 2 Grecian Magnesite SA;
3,4,9,12,13,14,16,17,18 RHI AG; 5 Tata Steel/Newscast; 6 © Lafarge Photo Library;
7 © AGC Glass Europe; 8 European Copper Institute; 11 JSC Borovichi Refractories;
15 Hoganas Refractories
MI
Zircon Chemicals 4%
Carborundum Universal Limited, P B No 1, K D Plot P O Geology: A typical contact metamorphic mineral found in clay rich Geology: Typical of high temperature metamorphism in schists and Geology: Uncommon mineral formed by the natural remelting of Tertiary Silicon Carbide Acidic resistance; in high-alumina shapes and bodies; also where disposal of
EFM: Australia Austria, Brazil, China, Russia, Mexico, N. Korea, Norway, S. Africa, Turkey.
NE
Non-ferrous metals 5%
sediments subjected to heat from an igneous intrusive mass and also gneisses. age clays. No commercial exploitation of mullite deposits. Bauxite Monolithics used Cr-refractories is a problem, eg. lime kilns, glass tank regenerator
Kochi 683109 INDIA, www.cumi-emd.com Graphite 20% Bauxite 28% Ceramics 5%
Applications: Bricks: low-iron (90-99% MgO), high iron (88-95% MgO), carbon-containing MgO, MgO-carbon (flake graphite 92-95%C used with pitch
in regional metamorphic rocks such as schist and gneiss. Also found in checkers. Some spinels are designed to be formed in-situ in refractory
Production: <30,000 Refractory grades: Synthetic mullite produced by calcination (sintered
+91 484 3023627 | salesemd@cumi.murugappa.com pegmatite vein assemblages.
Sources: China, India. grades) and fusion (fused grades) of selected, and blended aluminosilicate www.indmin. Cement and lime 7% and synthetic resins binders), MgO-chromite, MgO-spinel, spinel, MgO-zirconia, MgO-zircon, MgO-doloma. MgO bricks have high hot strength and great
resistance are used in high wear areas in steel and cement making. Lower grade DBM used in monolithics.
matrices from the reaction of free magnesia and alumina during use.
Production: 350-400,000 minerals, including kyanite, bauxite, calcined alumina, silica sand, and 1
PL
Kyanite excellent resistance to creep, thermal shock, and attack by low iron and Graphite 23% Basic Monolithics Formula/comp: FeCr2O4 with 32.09% FeO; 67.91% Cr2O3: typical: Formula/comp: (Mg,Fe)2SiO4: forsterite: 57.11% MgO; 42.89% SiO2 Formula/comp: Ca,Mg(CO3)2: 30.41% CaO; 21.86% MgO; in REfRactoRiEs
AN
Sources: Sintered: Brazil, China, Germany, India, Japan, UK, USA; Magnesite 12%
low lime slags. Used in the iron and steel, waste incineration, glass, and (Mg,Fe)(Cr,Al,Fe)2O4 fayalite: 70.51% FeO; 29.43% SiO2 47.73% CO2
T
Formula/comp: Al2SiO5: 62.98% Al2O3, 37.02% SiO2 furnace engineering. Andalusite substituting bauxite in certain uses. Fused: Brazil, China, Hungary, Germany, Japan, UK, USA. Source: PRE
OLIVINE
World refractories Geology: Found in ultrabasic rocks such as peridotite, dunite, or Geology: A major constituent of basic and ultrabasic igneous rocks, eg. Geology: Common sedimentary rock accumulated in thick layers.
Geology: In regionally metamorphosed clay-rich sedimentary rocks mullite bricks reach 75% Al2O3. Mullite from calcined bauxite and silica is
production 2 serpentine; large stratiform deposits account for 98% chromite reserves dunite comprising over 90% olivine, and serpentinite. Forsterite occurs in Also formed by the action of Mg-containing seawater on limestone –
(gneiss and schist) associated with garnet, staurolite, mica, quartz. Also as used in refractories for glass and steel.
41.5m. tonnes 2012 and output. Also occurs in smaller, irregular deposits in ophiolite dolomitic rocks subject to metamorphism. Most commercial operations dolomitisation. However, refractory grade dolomite is relatively rare. Raw
large elongated crystals in pegmatite and quartz veins and in some beach complexes. exploit olivines altered to serpentine. rock chemistry, crystallinity, and overall mineralogy
RE
sand deposits. 46.0m. tonnes 2017f
Monolithics 40% Refractory grades: 31-57% Cr2O3, 12-29% Al2O3, 12-20% MgO, Refractory grades: Most refractory olivines are forsteritic: 40-50% MgO; affects the degree of densifi cation that may be achieved so determining
FR
Production: 200,000 Bricks/Shapes 15-28% Fe2O3 and critically less than 6% SiO2 (as low as possible) and 35-45% SiO2; <6% Fe2O3 potential refractoriness of the end product.
AC
PRODUCTS
Sources: Australia, Brazil, China, India, Ukraine, USA. 60% 0.80% CaO. Refractory grades: Dead burned (and fused) dolomite: raw dolomite
TO
Production: 6.5m.
calcined at 1,800-2,000°C in rotary or shaft kilns,
RY
Investing in
Production: 160-200,000 (refractory grade) Sources: Austria, Australia, Brazil, China, Italy, Japan, Mexico, Norway,
56-62% MgO, 36-40%, CaO, <2% SiO2, BD 3.30-3.50 g/cm3
Sources: Brazil, India, Iran, Oman, Pakistan, Philippines, S. Africa, Turkey. S. Korea, Spain, Taiwan, Turkey, USA.
HIGH ALUMINA 3 4 Production: 1m. (refractory grade)
Applications: Chromite increases thermal shock and corrosion resistance Applications: Various mixes for spraying, ramming and gunning
Bauxite Group Sources: Belgium, Brazil, Canada, China, Macedonia, Germany, Italy,
the future of
to slags. Chromite bricks <30% MgO, >30% Cr2O3; picrochromite applications; tundish spray linings; EBT tap hole filler; bonded bricks in
products >75% Cr2O3. Used in steel (vacuum degasser), ferroalloys (CLU storage heaters. Poland, Russia, Spain, Turkey, UK, USA.
Bauxite Aluminas
MA
converter), non-ferrous metals (Cu, Ni, Pt), foundries (EAF); declined use Applications: Variety of monolithics and bricks. Ceramic or chemically
R
Formula/comp: A rock primarily comprising a mix of the three aluminium hydroxides; boehmite, diaspore and Synthetic alumina in cement and glass. bonded bricks with 40-70% (rarely 90%) MgO, and
www.indmin.com
KE
refractory
gibbsite in varying proportions along with impurities such as oxides of iron and titanium, silica, and clay minerals. World production: Produced via Bayer processing of bauxite – digestion, precipitation (to aluminium trihydrate, a range of other products with carbon, magnesia, zirconia, iron oxides,
T
Boehmite: AlO(OH): 84.98% Al2O3, 15.02% H2O ATH), rotary kiln calcination; >99.5% Al2O3; standard, 0.3-0.7% Na2O, intermediate, 0.1-0.3% Na2O, low soda, Editor: Mike O’Driscoll, Global Head of Research, modriscoll@indmin.com fused minerals for a multitude of uses in metallurgy,
Steel Cement Glass Copper
Hardness/S.G: Mohs 3.0/3.0 0.03-0.1% Na2O, high purity, <0.01 Na2O. Advertising: Ismene Clarke, Advertising Manager, iclarke@indmin.com cement, and lime manufacture.
10-12 kg/t 0.6-1.0 kg/t 4.0 kg/t 2.0 kg/t
Benjamin Ash, Advertising Sales, bash@indmin.com
minerals
Diaspore: HAlO2: 84.98% Al2O3, 15.02% H2O Calcined alumina: 2.6m. 5 6 7 8
Sources: Australia, Brazil, China, France, Germany, Hungary, India, Japan, Netherlands, USA. Specific refractory consumption in kg per tonne commodity produced
Hardness/S.G: Mohs 6.5-7.0/3.3-3.5
Gibbsite: Al(OH)3: 65.35% Al2O3, 34.65% H2O Tabular alumina: milling and pelletising calcined alumina, sintered in shaft kiln at 1,815-1,925°C; almost 100%
Al2O3; large, flat, hexagonal tablet-shaped crystals.
Hardness/SG: Mohs 2.5-3.5/2.4
Geology: Bauxite, found in younger Tertiary and Mesozoic rocks, is the tropical weathering product of rocks
Brown fused alumina (BFA) LIGHTWEIGHT HEAT INSULATING
containing aluminium. The degree of bauxitisation, separation of original constituents, and form of the deposit is Refractory: Abrasive grade bauxite calcined at 1,100°C, then fusing (Higgins/tilt furnace) calcined alumina with coke and iron
dependent on a variety of factors. at >2,000°C; >96% Al2O3; regular 2.7%TiO2, semi-friable, 1.4% TiO2; Mohs 9/SG 3.95 Diatomite Perlite Vermiculite
Refractory grades: Raw bauxite: min.55% Al2O3, max. 2% Fe2O3; 1.5-5.5 SiO2; max. 2.5 TiO2 World production: 1.9-2m. Formula/comp: A siliceous rock comprising the skeletons of minute aquatic plants called diatoms. Contains up to Formula/comp: A silica-rich volcanic rock containing entrapped water. Formula/comp: Mg3(AlSi3O10)(OH)2.nH2O
Calcined bauxite: calcined at 1,650°C by shaft/rotary/round kiln; min. 85% Al2O3, <2% Fe2O3, <4% TiO2, <7- Sources: Austria, Brazil, China, Czech Republic, France, Germany Hungary, India, Italy, Japan, Russia, Poland, 75% SiO2. Geology: Formed by the extrusion and rapid cooling of silica-rich viscous lava to form steep-sided volcanic domes with Hardness/SG: Mohs 2-3/2.4-2.7
10% SiO2; BD 3-3.25 g/cm3 Slovenia, Ukraine, USA, Venezuela. Geology: Predominantly young beds of Tertiary age sedimentary rocks of variable thickness accumulated with varying subsequent hydration by meteoric water. Geology: Shallow deposits formed by weathering or hydrothermal alteration of phlogopite and biotite and other ferric
Production: Raw bauxite for non-met. use: 13m.; Calcined refractory bauxite: 2.3m. White fused alumina (WFA) proportions of shales, clays or limestones with the purest deposits being almost exclusively the shells of diatoms. Refractory grades: 65-80% SiO2,12-16% Al2O3 minerals in complex ultrabasic and carbonatite deposits.
Sources: Raw bauxite for non-met. use: Australia, Brazil, Greece, Guyana, Italy, Russia, Turkey; Calcined Refractory: Higher purity than BFA; fusion of Bayer alumina (99.5% Al2O3) in an electric arc furnace at over 2,000°C; 99.5- Refractory grades: >75% SiO2. Production: 1.7m. Refractory grade: 45% SiO2, 31% MgO, 13% Al2O3, 7% Fe2O3
refractory bauxite: China, Guyana, India, Russia. 99.9% Al2O3; regular, 0.4% Na2O, medium, 0.05% Na2O, low, 0.018% Na2O; Mohs >9/SG 3.97. Production: 2m. Sources: Armenia, China, Greece, Italy, Japan, Turkey, Hungary, Mexico, Russia, USA. Production: 550-600,000
Applications: Typically bauxite bricks range from 55-95% Al2O3, used in ladles, electric arc furnace roofs, and World production: 450-500,000 Sources: Argentina, Australia, Chile, China, Czech Republic, Denmark, France, Japan, Mexico, Peru, Russia, Spain, Applications: Comminuted perlite heated to about 1,000°C expands forming white spheroidal hollow material which fi nds Sources: Australia, Brazil, China, Russia, S. Africa, Uganda, USA, Zimbabwe.
rotary cement kilns. Phosphate-bonded bauxite bricks have been used in aluminium melting furnaces. Sources: Australia, Bahrain, Brazil, China, France, Hungary, India, Japan, Russia, S. Korea, USA, Venezuela. Turkey, USA. refractory applications below 1,100°C in variety of shapes and castables. Above this temperature perlite refractories used Applications: At 900-1,000°C vermiculite expands to around 10 times original volume with reduction in bulk density.
Applications: Alumina grades impart high mechanical and chemical corrosion resistance and are used in a wide Applications: Blended with about 30% of plastic clay into refractory shapes. as back-up insulating linings for the primary refractory material. A sintering temperature of 1,260°C and melting point of 1,315°C allows exfoliated vermiculite to be used as an insulating
range high alumina monolithics and shapes, calcium aluminate cements. refractory in a variety of metallurgical tasks.
Key refractory applications showing primary chemical compositions of typical refractory products used, average volume required, average life expectancy of refractories.
Olivine Products
NUOVA CIVES srl LKAB Minerals (formerly Minelco) is an international industrial minerals
Località Crose - 10080 Vidracco - ITALY group with a leading position in a number of product applications. We
develop sustainable mineral solutions in partnership with our customers,
Tel +39 0125 789078 - Fax +39 0125 789511 supplying natural minerals engineered for functionality and usability. LKAB
e-mail: info@nuovacives.com Electric arc furnace Blast furnace Steel ladle BOF Converter AOD Converter Torpedo car Cement rotary kiln NF metals anode furnace Glass melting furnace Municipal waste incinerator Minerals is part of the Swedish company LKAB, one of the world’s leading
producers of highly upgraded iron ore products. www.lkabminerals.com
www.nuovacives.com MgO-C, MgO-Cr, Al2O3, Al2O3-SiC-C Al2O3, C, SiC, Al2O3-SiC, MgO- Al2O3 MgO, MgO-C, MgO-Cr, Al2O3, MgO-Al2O3, Al2O3-MgO-C MgO-C, MgO CaO-MgO, MgO-Cr Al2O3-SiO2, Al2O3-SiC-C MgO-Cr, MgO-Al2O3, Al2O3-SiO2, Al2O3, CaO-MgO MgO-Cr, MgO, Al2O3-C, Al2O3-Cr, Al2O3 Al2O3-ZrO2-SiO2, SiO2, Al2O3-SiO2 SiC, Al2O3, ZrO2, Al2O3-Cr
9 120 tonnes; 1 month 10 900 tonnes; 15 years 11 70 tonnes; 1 month 12 800 tonnes; 6 month 13 100 tonnes; 1 week 14 200 tonnes; 2 years 15 250 tonnes; 10 months 16 150 tonnes; 3 month 17 500-8,500 tonnes; 10 years 18 200-1,000 tonnes; 2-10 years
PASEK Minerales
& PASEK Dunit@
Value in Use