THE REFRACTORIES INDUSTRY WORLDWIDE
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1 THE REFRACTORIES INDUSTRY WORLDWIDE (published March 2013) TABLE OF CONTENTS PAGE 1 EXECUTIVE SUMMARY Raw materials supply and demand Refractories supply Demand drivers by industry sector Industry structure Costs and prices Outlook and forecasts SCOPE INTRODUCTION RAW MATERIALS SUPPLY AND DEMAND Alumina and bauxite Calcined alumina Tabular alumina Fused alumina China Rest of the world Calcined bauxite China Guyana Brazil India Trade patterns Calcined bauxite trade China Guyana Europe USA Japan Summary Trade statistics Calcined alumina Fused alumina Refractory clays Production China Rest of the world Andalusite, kyanite and sillimanite Production Andalusite Kyanite... 72
2 Sillimanite Trade patterns Synthetic mullite Magnesia and dolomite Magnesia Resources and reserves Magnesite Seawater magnesia Surface and subterranean brines Dead burned magnesia Characteristics of dead burned magnesia Grades of dead burned magnesia Production Asia and Oceania China North Korea India Australia Japan South Korea Middle East Israel Iran Africa Europe Austria Ireland Norway The Netherlands France Spain Greece Russia Ukraine Serbia and Montenegro Slovakia Turkey North America USA Canada Latin America Brazil Mexico Trade patterns China Dolomite Production Producers Trade patterns Olivine Producers Spinel
3 4.8.1 Production Chrome and related materials Production Zircon Production Trade patterns Zirconia Baddeleyite Silicon carbide Production Producers Trade patterns Graphite Graphite in refractories Production Trade patterns Silica Binders for refractories Organic binders Inorganic binders Phosphate binders Calcium aluminate cements Other binders REFRACTORIES SUPPLY Europe Non-EU European countries North America Canada Asia Japan China India Other Asia Latin America Rest of world Russia Ukraine Turkey Middle East Africa Australia DEMAND DRIVERS BY INDUSTRY SECTOR Steel industry Consumption of refractories in steel production Trends in refractory usage in steel production Crude steel production trends Cement industry Lime industry
4 6.4 Glass industry Ceramics industry Non-ferrous metals industry Other end-user industry sectors REFRACTORIES INDUSTRY STRUCTURE Europe North America Asia Japan China India Latin America COSTS AND PRICES Raw materials The China factor Other costs Refractory materials prices COMPANY PROFILES Major refractory producers by 2011 sales > 200 million RHI AG Vesuvius plc Shinagawa Refractories Co Ltd Magnesita SA Krosaki Harima Corp Calderys SA Saint-Gobain SA Morgan Thermal Ceramics ANH Refractories Co Refratechnik Holding GmbH Posrec QingHua Refractories Magnezit Group Wugang Refractory Co Ltd Minteq International Inc Chosun Refractories Co Ltd Company profiles: other companies (166 companies) OUTLOOK AND FORECASTS Refractories outlook by country/region Steel markets Cement industry markets Pricing Growth predictions APPENDIX European Union countries: trade and production statistics for refractory products
5 TABLES Table 4.1: Total production of alumina for non-metallurgical applications, Table 4.2: Capacities of tabular alumina plants worldwide Table 4.3: Main producers of brown fused alumina in China Table 4.4: Chinese non-metallurgical bauxite production capacity by major companies, Table 4.5: Annual production of Guyanese bauxite, Table 4.6: Typical specifications for Guyanese bauxite Table 4.7: China: calcined bauxite, export quotas, Table 4.8: EU countries: imports of fused alumina, 2011 (Euros) (part 1) Table 4.9: EU countries: imports of fused alumina, 2011 (Euros) (part 2) Table 4.10: EU countries: imports of fused alumina, 2011 (tonnes) (part 1) Table 4.11: EU countries: imports of fused alumina, 2011 (tonnes) (part 2) Table 4.12: EU countries: exports of fused alumina, 2011 (Euros) (part 1) Table 4.13: EU countries: exports of fused alumina, 2011 (Euros) (part 2) Table 4.14: EU countries: exports of fused alumina, 2011 (tonnes) (part 1) Table 4.15: EU countries: exports of fused alumina, 2011 (tonnes) (part 2) Table 4.16: China: exports of fused alumina, Table 4.17: China: imports of fused alumina, Table 4.18: USA: exports of fused alumina, Table 4.19: USA: imports of fused alumina, Table 4.20: Canada: exports of fused alumina, Table 4.21: Canada: imports of fused alumina, Table 4.22: Brazil: exports of fused alumina, Table 4.23: Brazil: imports of fused alumina, Table 4.24: Russia: exports of fused alumina, Table 4.25: Russia: imports of fused alumina, Table 4.26: Japan: exports of fused alumina, Table 4.27: Japan: imports of fused alumina, Table 4.28: Composition and properties of typical European refractory clays Table 4.29: Typical analyses of andalusite grades (run of mine) Table 4.30: Global production of andalusite and related minerals by country, Table 4.31: Global capacity of andalusite Table 4.32: South Africa: exports of andalusite, kyanite and sillimanite Table 4.33: France: exports of andalusite, kyanite and sillimanite, Table 4.34: Peru: exports of andalusite, kyanite and sillimanite, Table 4.45: USA: exports of andalusite, kyanite and sillimanite, Table 4.46: China: imports of andalusite, kyanite and sillimanite, Table 4.47: Japan: imports of andalusite, kyanite and sillimanite, Table 4.48: EU countries: imports of andalusite, kyanite and sillimanite, 2011 (Euros) (Part 1) Table 4.49: EU countries: imports of andalusite, kyanite and sillimanite, 2011 (Euros) (Part 2) Table 4.50: EU countries: imports of andalusite, kyanite and sillimanite, 2011 (tonnes) (Part 1) Table 4.51: EU countries: imports of andalusite, kyanite and sillimanite, 2011 (tonnes) (Part 2) Table 4.52: Composition of brines (%) Table 4.53: Production temperatures and properties of magnesia Table 4.54: Quality definitions of dead burned magnesia grades... 88
6 Table 4.55: World magnesite production, Table 4.56: World magnesia capacity, Table 4.57: China: magnesia production capacity, Table 4.58: RHI production capacities Table 4.59: China: exports of dead burned magnesia, Table 4.60: China: exports of electro-fused magnesia, Table 4.61: China: exports of other magnesium oxides, Table 4.62: Typical specifications for dead burned dolomite Table 4.63: Production of dolomite refractory bricks, Table 4.64: Typical mineral composition of olivine Table 4.65: Composition and physical properties of typical Norwegian olivine Table 4.66: Uses of commercial olivine in refractories Table 4.67: Composition and properties of several commercially available sintered spinel aggregates Table 4.68: Composition and properties of some commercially available fused spinel aggregates Table 4.69: World producers of spinel, including location and plant capacity Table 4.70: Main properties of fused and sintered spinel Table 4.71: Physical properties and chemical analyses of spinel cement kiln bricks Table 4.72: Worldwide production of chromite by country, Table 4.73: Production of zircon and baddeleyite by country, Table 4.74: EU countries: imports of zircon (Euros) (part 1) Table 4.75: EU countries: imports of zircon (Euros) (part 2) Table 4.76: EU countries: imports of zircon (100 kg) (part 1) Table 4.77: European Union countries: imports of zircon (100 kg) (part 2) Table 4.78: China: imports of zircon, Table 4.79: South Africa: exports of zircon, Table 4.80: Typical compositions of refractory grade baddeleyite and zircon Table 4.81: Europe: silicon carbide production capacity by producer, Table 4.82: America, Africa and Middle East: silicon carbide capacity by producer, Table 4.83: EU countries: silicon carbide imports, 2011 (Euros) (Part 1) Table 4.84: EU countries: silicon carbide imports, 2011 (Euros) (Part 2) Table 4.85: EU countries: silicon carbide imports, 2011 (tonnes) (Part 1) Table 4.86: EU countries: silicon carbide imports, 2011 (tonnes) (Part 2) Table 4.87: USA: silicon carbide exports, Table 4.88: USA: silicon carbide imports, Table 4.89: China: silicon carbide exports, Table 4.90: India: Silicon carbide: exports, Table 4.91: South Africa: silicon carbide exports, Table 4.92: Brazil: silicon carbide exports, Table 4.93: Russia: silicon carbide exports, Table 4.94: Japan: silicon carbide imports, Table 4.95: South Korea: silicon carbide imports, Table 4.96: Worldwide production of natural graphite by country and graphite type, 2004 to Table 4.97: EU countries: imports of natural graphite powder/flakes, 2011 (Euros) (Part 1) Table 4.98: EU countries: imports of natural graphite powder/flakes, 2011 (Euros) (Part 2) Table 4.99: EU countries: imports of natural graphite powder/flakes, 2011 (tonnes) (Part 1)
7 Table 4.100: EU countries: imports of natural graphite powder/flakes, 2011 (tonnes) (Part 2) Table 4.101: China: exports of graphite powder/flakes, Table 4.102: Canada: exports of graphite powder/flakes, Table 4.103: Mexico: exports of graphite powder/flakes, Table 4.104: Japan: imports of graphite powder/flakes, Table 4.105: USA: imports of graphite powder/flakes, Table 4.106: Turkey: imports of graphite powder/flakes, Table 4.107: South Korea: imports of graphite powder/flakes, Table 4.108: Reactivity of various calcium aluminate phases Table 4.109: Main calcium aluminate cement (CAC) grades and typical chemical compositions Table 4.110: Kerneos calcium aluminate cement plants Table 4.111: Comparison of colloidal alumina binders and colloidal silica for monolithics Table 5.1: Europe: production and sales of refractory products, Table 5.2: EU countries: production of refractory products, Table 5.3: EU countries: production of refractory products, Table 5.4: EU countries: balance of trade for refractory products (bricks and monolithics) Table 5.5: EU countries: apparent consumption of refractory products, Table 5.6: Norway: imports of refractory bricks, blocks and similar shaped products, Table 5.7: Norway: exports of refractory bricks, blocks and similar shaped products, Table 5.8: Norway: exports of refractory cement, concrete and mortar, Table 5.9: Switzerland: imports of refractory cement, concrete and mortar, Table 5.10: USA: production of refractory products, Table 5.11: USA: production of refractory products Table 5.12: USA: imports of refractory bricks, Table 5.13: USA: exports of refractory bricks, Table 5.14: USA: imports and exports of refractory monolithics, Table 5.15: USA: consumption of refractory products, Table 5.16: USA: imports of basic bricks, Table 5.17: USA: exports of basic bricks, Table 5.18: USA: imports of aluminosilicate/alumina bricks, Table 5.19: USA: exports of aluminosilicate/alumina bricks, Table 5.20: USA: imports of "other" refractory bricks, Table 5.21: USA: exports of "other" refractory bricks, Table 5.22: USA: imports of monolithic refractories, Table 5.23: USA: exports of monolithic refractories, Table 5.24: Canada: imports of refractory bricks, blocks and similar shaped products, Table 5.25: Canada: exports of refractory bricks, blocks and similar shaped products, Table 5.26: Japan: production of refractory products, Table 5.27: Japan: production of refractory products, Table 5.28: Japan: imports of basic refractory bricks, Table 5.29: Japan: exports of basic refractory bricks, Table 5.30: Japan: imports of aluminosilicate refractory bricks, Table 5.31: Japan: exports of aluminosilicate refractory bricks, Table 5.32: Japan: imports of other refractory bricks, Table 5.33: Japan: exports of other refractory bricks,
8 Table 5.34: Japan: imports of monolithic refractories, Table 5.35: Japan: exports of monolithic refractories, Table 5.36: Japan: apparent consumption of refractories, Table 5.37: China: production of refractory products, Table 5.38: China: imports of refractory products, Table 5.39: China: exports of refractory products, Table 5.40: China: apparent consumption of refractories, Table 5.41: India: imports of refractory bricks, blocks and similar shaped products, Table 5.42: India: exports of refractory bricks, blocks and similar shaped products, Table 5.43: India: imports of refractory cement, concrete and mortar, Table 5.44: India: exports of refractory cement, concrete and mortar, Table 5.45: Indonesia: imports of refractory bricks, blocks and similar shaped products, Table 5.46: Malaysia: imports of refractory bricks, blocks and similar shaped products, Table 5.47: Malaysia: exports of refractory bricks, blocks and similar shaped products, Table 5.48: South Korea: imports of refractory bricks, blocks and similar shaped products, Table 5.49: South Korea: exports of refractory bricks, blocks and similar shaped products, Table 5.50: South Korea: imports of other refractory products (crucibles, nozzles, retorts, tubes, rods, etc.), Table 5.51: Thailand: imports of refractory bricks, blocks and similar shaped products, Table 5.52: Thailand: exports of refractory bricks, blocks and similar shaped products, Table 5.53: Indonesia: imports of refractory cement, concrete and mortar, Table 5.54: Malaysia: imports of refractory cement, concrete and mortar, Table 5.55: Malaysia: exports of refractory cement, concrete and mortar, exports, Table 5.56: South Korea: imports of refractory cement, concrete and mortar, Table 5.57: South Korea: exports of refractory bricks, blocks and similar shaped products, Table 5.58: Thailand: imports of refractory cement, concrete and mortar, Table 5.59: Thailand: exports of refractory cement, concrete and mortar, Table 5.60: Latin America: production of refractory products, Table 5.61: Brazil: imports of refractory bricks, blocks and similar shaped products, Table 5.62: Brazil: exports of refractory bricks, blocks and similar shaped products, Table 5.63: Brazil: imports of refractory cement, concrete and mortar, Table 5.64: Brazil: exports of refractory cement, concrete and mortar, Table 5.65: Mexico: imports or refractory bricks, blocks and similar shaped products, Table 5.66: Mexico: exports of refractory bricks, blocks and similar shaped products, Table 5.67: Mexico: imports of refractory cement, concrete and mortar, Table 5.68: Mexico: exports of refractory cement, concrete and mortar, Table 5.69: Chile: imports of refractory bricks, blocks and similar shaped products,
9 Table 5.70: Columbia: imports of refractory bricks, blocks and similar shaped products, imports, Table 5.71: Columbia: exports of refractory bricks, blocks and similar shaped products, exports, Table 5.72: Argentina: Imports of refractory bricks, blocks and similar shaped products, Table 5.73: Argentina: imports of refractory cement, concrete and mortar, Table 5.74: Russia: imports of refractory bricks, blocks and similar shaped products, Table 5.75: Russia: exports of refractory bricks, blocks and similar shaped products, Table 5.76: Russia: imports of refractory cement, concrete and mortar, Table 5.77: Ukraine: imports of refractory bricks, blocks and similar shaped products, Table 5.78: Ukraine: exports of refractory bricks, blocks and similar shaped products, Table 5.79: Ukraine: imports of refractory cement, concrete and mortar, Table 5.80: Ukraine: imports of other refractory products (crucibles, nozzles, retorts, tubes, rods, etc.), Table 5.81: Turkey: imports of refractory bricks, blocks and similar shaped products, Table 5.82: Turkey: exports of refractory bricks, blocks and similar shaped products, Table 5.83: Turkey: imports of refractory cement, concrete and mortar, Table 5.84: Turkey: exports of refractory cement, concrete and mortar, Table 5.85: South Africa: imports of refractory bricks, blocks and similar shaped products, Table 5.86: South Africa: exports of refractory bricks, blocks and similar shaped products, Table 5.87: Australia: imports of refractory bricks, blocks and similar shaped products, Table 5.88: Australia: imports of refractory cement, concrete and mortar, Table 6.1: Specific consumption of refractories by iron/steel vessel (kg of refractories per tonne of iron/steel) Table 6.2: Consumption of refractories (kg) per tonne of steel (integrated plant vs. mini-mill) Table 6.3: Historical world steel growth rates, Table 6.4: Crude steel production, , by country, with forecasts to Table 6.5: Crude steel production, , by region, with forecasts to Table 6.6: Ceramic tile industry worldwide; top companies by sales of millions of square metres of tiles, Table 6.7: World primary aluminium production, Table 8.1: Estimated average cost of refractories in steel making Table 10.1: World refractories production, Table 10.2: Estimated production of refractory products by region/country, Table 11.1: EU countries: refractory cement, concrete and mortar, imports, 2011 (Euros) (Part 1) Table 11.2: EU countries: refractory cement, concrete and mortar, imports, 2011 (Euros) (Part 2)
10 Table 11.3: EU countries: refractory cement, concrete and mortar, imports, 2011 (tonnes) (Part 1) Table 11.4: EU countries: refractory cement, concrete and mortar, imports, 2011 (tonnes) (Part 2) Table 11.5: EU countries: refractory cement, concrete and mortar, exports, 2011 (Euros) (Part 1) Table 11.6: EU countries: refractory cement, concrete and mortar, exports, 2011 (Euros) (part 2) Table 11.7: EU countries: refractory cement, concrete and mortar, exports, 2011 (tonnes) (part 1) Table 11.8: EU countries: refractory cement, concrete and mortar, exports, 2011 (tonnes) (part 2) Table 11.9: EU countries: refractory bricks, blocks and similar shaped products, imports, 2011 (Euros) (part 1) Table 11.10: EU countries: refractory bricks, blocks and similar shaped products, imports, 2011 (Euros) (part 2) Table 11.11: EU countries: refractory bricks, blocks and similar shaped products, imports, 2011 (tonnes) (part 1) Table 11.12: EU countries: refractory bricks, blocks and similar shaped products, imports, 2011 (tonnes) (part 2) Table 11.13: EU countries: refractory bricks, blocks and similar shaped products, exports, 2011 (Euros) (part 1) Table 11.14: EU countries: refractory bricks, blocks and similar shaped products, exports, 2011 (Euros) (part 2) Table 11.15: EU countries: refractory bricks, blocks and similar shaped products, exports, 2011 (tonnes) (part 1) Table 11.16: EU countries: refractory bricks, blocks and similar shaped products, exports, Table 11.17: EU countries: other refractory shaped products (crucibles, nozzles, retorts, tubes, rods, etc.), imports, Table 11.18: EU countries: other refractory shaped products (crucibles, nozzles, retorts, tubes, rods, etc.), imports, Table 11.19: EU countries: other refractory shaped products (crucibles, nozzles, retorts, tubes, rods, etc.), imports, Table 11.20: EU countries: other refractory shaped products (crucibles, nozzles, retorts, tubes, rods, etc.), imports, Table 11.21: EU countries: other refractory shaped products (crucibles, nozzles, retorts, tubes, rods, etc.), exports, Table 11.22: EU countries: other refractory shaped products (crucibles, nozzles, retorts, tubes, rods, etc.), exports, Table 11.23: EU countries: other refractory shaped products (crucibles, nozzles, retorts, tubes, rods, etc.), exports, Table 11.24: EU countries: other refractory shaped products (crucibles, nozzles, retorts, tubes, rods, etc.), exports, Table 11.25: EU countries: production of refractory products, 2011 (tonnes) (part 1) Table 11.26: EU countries: production of refractory products, 2011 (tonnes) (part 2) Table 11.27: EU countries: production of refractory products, 2011 (thousands of Euros) (part 1) Table 11.28: EU countries: production of refractory products, 2011 (thousands of Euros) (part 2)
11 FIGURES Figure 4.1: Chemical grade alumina worldwide, quarterly production, Figure 4.2: Calcined alumina demand, all applications, 2011 (percentage breakdown of total tonnage by region) Figure 4.3: Calcined alumina demand, refractories and other applications, 2011 (percentage breakdown of total tonnage by region) Figure 4.4: Brown fused alumina capacity (percentage breakdown of total tonnage by region), Figure 4.5: Guyana: exports of calcined bauxite, Figure 4.6: Guyana: average price of dried and calcined bauxite, Figure 4.7: EU countries: imports of non-metallurgical bauxite from Guyana, Figure 4.8: EU countries: average value of imports of non-metallurgical bauxite from Guyana, Figure 4.9: EU countries: imports of non-metallurgical bauxite from China, Figure 4.10: EU countries: average value of imports of non-metallurgical bauxite from China, Figure 4.11: EU countries: combined imports of non-metallurgical bauxite from China and Guyana, Figure 4.12: USA: imports of refractory grade bauxite from Guyana, Figure 4.13: USA: imports of refractory grade bauxite from China, Figure 4.14: Japan: imports of non-metallurgical bauxite from China, Figure 4.15: Japan: Imports of non-metallurgical bauxite from Guyana, Figure 4.16: Japan: combined imports of calcined bauxite from China and Guyana, Figure 4.17: South Africa: exports of andalusite, Figure 4.18: Reserves of magnesite Figure 4.19: Global magnesite production by country, Figure 4.20: Exports of magnesia by country, Figure 4.21: Exports of magnesia by country, Figure 4.22: Average price of magnesia, Figure 4.23: Global output of non-metallurgical chrome ore/concentrate, Figure 4.24: Major producers of zircon, Figure 4.25: Price trends for large flake graphite (94-97% C, +80 mesh), Figure 6.1: Worldwide consumption of refractories by end user industry, Figure 6.2: Europe: refractories consumption by industry sector, Figure 6.3: Average refractory consumption (kg) per tonne of steel, Figure 6.4: Life expectancy of iron and steel vessels Figure 6.5: World cement production by region, Figure 6.6: World cement production by region and main countries, Figure 6.7: EU glass production by type, Figure 7.1: Leading refractory producers by sales, Figure 7.2: Leading refractory producers by sales, Figure 7.3: Leading refractory producers by sales, Figure 7.4: Leading Chinese refractory producers by sales, Figure 7.5: Market share of refractories in India, by major company, Figure 8.1: Index development of raw material prices for the refractory industry,
12 Figure 8.2: USA: long term natural gas prices, Figure 8.3: Crude oil spot price (Brent crude), Figure 8.4: Euro area labour costs,
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