Specialty Aluminas Refractory applications

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Samson Bryan
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1 Specialty Aluminas

2 0 Specialty Aluminas at a Glance World s largest supplier of Specialty Aluminas with 750,000 tonnes of alumina based products (hydrate, aluminas and fused) Headquartered in Gardanne (France) with regional office in Cleveland (US) Six production facilities in Europe and North America Global sales network Development centres in Europe and North America Leading positions in Ceramics (technical and standard), Refractory, Abrasives, Specialty Glass, Chemicals, Feedstock, Catalyst and Adsorbents More than,00 delivered sites spread in 60 countries over the five continents Specialty Aluminas Today s Specialities for a sustainable future Specialty Aluminas business from is the largest supplier of non-metallurgical grade alumina (NMGA) with an unrivalled capability of offering you a very broad range of alumina based products wherever you are located in the world. Our focus is on providing consistent products, reliable service, backed by a strong commercial organisation with the support of highly skilled application oriented technical teams. Thanks to our integrated approach from hydrates to aluminas, we provide a wide range of technical aluminas for your business. Our comprehensive product range extends to alumina hydrates, calcined aluminas, low soda aluminas, activated aluminas, tabular aluminas, and white and brown fused aluminas. In addition to these alumina based materials, there are a number of other related high performance products such as zirconia-aluminas, Abral, sintered alumina and sintered bauxite. These products find application in a plethora of markets, including advanced ceramics, refractories, abrasives, solid surfacing, fire retardants, adsorbents, specialty glasses, tiles and feedstocks for the manufacture of aluminium based chemicals particularly for catalysts and water treatment. We have recently reinforced our presence in the Ceramics, Abrasives, Specialty Glass and Refractory markets with dedicated sales and technical teams. These teams aim to answer all your needs for alumina supply. 0 Introduction 0 Business overview 0 Excellence through integration 04 Technical features 06 Product data BC Contact Locations

3 0 0 Business overview The Specialty Aluminas global organisation was created in 008 to focus on the manufacture, sales, marketing and development of NMGA within the Rio Tinto Group. This new business is combining the North American and European NMGA activities of s Bauxite & Alumina business unit. The Specialty Aluminas business operates six plants (four in Europe and two in North America) with a total annual capacity of over 750,000 tonnes of alumina based products. A brief history Specialty Aluminas combines a long and rich history of innovation in specialty hydrates and aluminas, based on previous PECHINEY and ALCAN activities. In operation since 89, the Gardanne plant was the first industrial alumina refinery plant. It continues to this day as an efficient and critical supplier of alumina hydrate and aluminas to Europe and the world. The business has been at the forefront of many areas of development and innovation in the specialty alumina industry and maintains a strong technical development team today. A clear focus on specialty aluminas Over the last 0 years, Gardanne s output has been progressively converted to specialty aluminas. In recent years, this drive has intensified, and today the entire focus of the Specialty Aluminas business is on these products. To achieve this objective, we have invested significant sums in recent years to: Increase grinding capacity in Gardanne and Beyrède (France) Improve our logistics management with new silos in Gardanne Invest in sustainable development (residue and water management, dust reduction). A commitment for Health, Safety and Environment Rio Tinto's philosophy, approach and standards in Health, Safety and the Environment are world class. The Specialty Aluminas business is committed to protecting the environment, preventing pollution and safeguarding the health, safety and welfare of those who work at or visit our sites in a manner that is respectful of local laws, customs and cultures. Development and innovation Our product development and application laboratories in Gardanne are equipped to undertake work in all key areas of activity including ceramics, refractories, abrasives and floorings. In order to improve our knowledge on applications, we work in close partnership with specialised external laboratories and technicallyleading customers. This application development team is supported by our extremely well equipped analytical laboratory and experienced analytical team in their work. For activated alumina, a dedicated product laboratory is established in our plant in Brockville. Excellence through integration Through our integrated production process we can deliver a technologically superior and diverse product range. From Bauxite to Specialty Aluminas Integrated process from ore to finished products Gardanne Bayer Process Hydrates Calcination Calcined Aluminas Our prime raw material is bauxite, which is converted to aluminium hydroxide and then alumina in our refineries (Gardanne in France and Vaudreuil in Canada). Aluminium hydroxide is supplied as feed to make activated alumina at our plant in Brockville (Canada). Calcined alumina is in turn supplied to our fusion and sintering plants to make fused and tabular alumina. Our ability to control all aspects of our production from the bauxite input through every stage of the process enables us to produce tailor made feeds, which are optimum for your application. The full control over all our prime feedstocks gives us almost an unparalleled ability to control the ideal particle size, purity and morphology of our products. Teutschenthal Sintering Tabular Aluminas La Bâthie Fusion White Fused Aluminas Thanks to this integrated model from hydrates to aluminas, we provide a wide range of technical aluminas for your business. We offer the following products from our six plants: Moist, dried and milled hydrate from Gardanne Moist, dried and super white hydrate from Vaudreuil Calcined, low soda and milled alumina from Gardanne Activated alumina from Brockville White fused alumina, bubble alumina, nitrides, and Abral from La Bâthie Brown fused alumina, and high performance grains (sintered bauxite, sintered alumina and zirconia-alumina) from Beyrède Tabular alumina from Teutschenthal. A global sales network The Specialty Aluminas business has a world wide sales force, supported by a market oriented organisation focussed on your business. This organisation is comprised of Marketing and Communication, Application Engineers and Logistic teams. Bauxite Beyrède Sintering Sintered Bauxite Fusion Brown Fused Aluminas Customers Vaudreuil Bayer Process Hydrates Dissolution/Precipitation Super White Hydrate Brockville Flashing/Pelletising Activated Aluminas

$04 05 Technical features Refractories are materials that can withstand high temperatures and chemically challenging environments.$

4 04 05 Technical features Refractories are materials that can withstand high temperatures and chemically challenging environments. Historically, the largest quantities of refractories have been made from alumino-silicate containing minerals but by adding pure alumina, this allows the refractory producer to manufacture products with improved chemical, mechanical and thermal resistance characteristics and much longer service lifetimes. In a typical refractory, aluminas have a key role as components of aggregates, matrix grains and additives. Aggregates bring refractoriness, high temperature strength with resistance to corrosion and erosion. The fine and ultrafine components of a refractory product, referred to as the matrix, are used to engineer specific properties in the finished product. Additives may be used in order to engineer specific properties or aid processing. Specialty Aluminas integrated approach enables us to control all aspects of our production from bauxite through to finished products. It also gives us the opportunity to offer a broad range of consistent, carefully controlled grades to provide our customers with the optimum material for a wide range of refractory applications. Function vs. alumina type Purpose Aggregates Matrix Additives Refractoriness High temperature strength with resistance to corrosion and erosion Specific properties for high density shaped and unshaped products White Fused Aluminas CAR (0 0 mm) CAR (0 0.mm) Brown Fused Aluminas SD (0 0 mm) SD (0 0.5 mm) Bubble Aluminas GL (0 5 mm) GL (0 0.5 mm) Tabular Aluminas Alutab (0 0 mm) Alutab ( mm) Zirconia Aluminas PBZ PBZ Calcined Aluminas AC4, AC44 Ground Calcined Aluminas AC4 or AC44 B4/B5/B6 GA4R Reactive Aluminas Mono-modal PFR, PFR5, PFR0 Reactive Aluminas Multi-modal PBR, PAR, PMR, PMR5, PMR0, PMR40, PFR40, XMD0, M4R Nitrides Processing aid Specific properties Sialon N50 Silicon Nitride N0/0 Wide range of applications: High alumina bricks Shaped materials High density materials Low cement, ultralow cement castables Insulating materials Wide range of placement materials: Selflow, pumpable, gunning castables Taphole clays Wide range of industries: Steel industry Foundry Glass industry Aluminium industry Incinerators Ceramic rollers. Aggregates Brown Fused Aluminas White Fused Aluminas Bubble Aluminas Zirconia Aluminas. Matrix Reactive and Calcined Aluminas. Additives Special products SEM picture of a high alumina low cement castables.

06 Product data Ground Calcined Aluminas 07 Calcined and Reactive Aluminas Our Calcined and Reactive aluminas are made from Bayer process hydrate feedstock manufactured in our Gardanne plant.

AC4/44 B4/B5/B6 GA4R Ground hard calcined aluminas are available with two different soda contents (AC4 and AC44) and with median particle size diameters varying from 4 to 6 μm.

Agglomerate (left) and single (right) crystal of calcined alumina. AC44 AC4 AC44 AC4 AC44 AC4 GA4R B4 B5 B6 Al O (%) 99.5 99.6 99.5 99.6 99.5 99.6 (by difference) Na O (%) 0.6 0.7 0.6 0.7 0.6 0.7 0.6 SiO (%) 0.

5 06 Product data Ground Calcined Aluminas 07 Calcined and Reactive Aluminas Our Calcined and Reactive aluminas are made from Bayer process hydrate feedstock manufactured in our Gardanne plant. The flexibility of our Bayer process and rotary kilns allows us to offer a large portfolio covering different alpha alumina contents and unground, milled, and superground products. AC4/44 B4/B5/B6 GA4R Ground hard calcined aluminas are available with two different soda contents (AC4 and AC44) and with median particle size diameters varying from 4 to 6 μm. GA4R is a hard calcined aluminium oxide Al O with a medium soda content, ground to a consistent and tightly controlled particle size distribution. Air selection ensures a top-cut of 98% < 45 µm. Agglomerate (left) and single (right) crystal of calcined alumina. AC44 AC4 AC44 AC4 AC44 AC4 GA4R B4 B5 B6 Al O (%) (by difference) Na O (%) SiO (%) Fe O (%) Calcined Aluminas AC4/AC44 Hard calcined aluminas contain more than 96% of α-alumina providing very high temperature stability. Calcined aluminas with two different soda contents are offered: AC4 and AC44. B4 B5 B6 GA4R D50 (µm) < µm (%) 6 5 < µm (%) < 45 µm (%) 0.5 BET (m²/g) 0.8 Agglomerate of calcined alumina. AC44 AC4 Al O (%) Na O total (%) SiO (%) Fe O (%) AC44 AC4 D50 (µm) < 6 µm (%) 5 Typical particle size distribution.

08 Reactive Aluminas: Superground Low Soda Aluminas 09 PFR/PFR5/PFR0 These superground aluminas have a very well controlled particle size distribution in the 0.5 to µm range.

Three different grades of mono-modal reactive aluminas are available to design your own castables based on different percentages of each component.

6 08 Reactive Aluminas: Superground Low Soda Aluminas 09 PFR/PFR5/PFR0 These superground aluminas have a very well controlled particle size distribution in the 0.5 to µm range. They are mainly used in low cement castable (LCC) and ultra low cement castable (ULCC) formulations to give fine particle size distribution control of customers formulations. Three different grades of mono-modal reactive aluminas are available to design your own castables based on different percentages of each component. Mono-modal reactive alumina can be used in association with ground calcined and very fine aggregates to give a continuous and very broad particle size distribution (PSD). PBR/PAR/ PMR40/PFR40 We offer a full range of multi-modal reactive aluminas that are designed to give your formulation low water demand, high density and a controlled PSD. They are designed to make high performance ULCC or LCC products with good placement properties as well as high temperature performance. PBR PAR PMR40 PFR40 Na O total (%) SiO (%) Fe O (%) PMR/PMR5/ PMR0/M4R/ XMD0 We continuously develop new reactive aluminas to give the best performance in castable formulations. Additionally, we have developed reactive alumina for self flow castables as well as less dilatant aluminas dedicated to gunning and pumpable refractories. PMR PMR5 PMR0 M4R XMD0 Na O total (%) SiO (%) Fe O (%) PFR PFR5 PFR0 Na O total (%) SiO (%) Fe O (%) PBR PAR PMR40 PFR40 D50 (µm).5.9. D90 (µm) BET (m²/g) PMR PMR5 PMR0 M4R XMD0 D50 (µm)..7. D90 (µm) BET (m²/g) PFR PFR5 PFR0 D50 (µm) 0.5. D90 (µm) BET (m²/g) 6.4. Typical particle size distribution. Typical particle size distribution.

$These products are useful in silicon carbide based refractories for its corrosion resistance. They are also used in taphole clay formulations because of its non-wetting properties.$ $Specialty Aluminas has four production sites in Europe and has the ability to manufacture different aggregates to cover a broad range of alumina based refractory formulations.$ Sintered or fused aggregates can be used to make shaped or unshaped material displaying a wide range of thermo-mechanical properties as well as excellent chemical resistance.

Sintered or fused aggregates can be used to make shaped or unshaped material displaying a wide range of thermo-mechanical properties as well as excellent chemical resistance.

$Bubble aluminas are resistant to high temperatures and provide thermal insulating characteristics to give very light shaped refractories or monolithics.$ This gives materials enhanced corrosion and thermal shock resistance. CAR SEM picture of white fused alumina grain.

This gives materials enhanced corrosion and thermal shock resistance. CAR SEM picture of white fused alumina grain.

$We offer a wide range of sizes from 0 mm down to very fine products that can enable you to achieve the best particle packing in your refractory product. Al O Na O SiO Fe O CAR (all sizes) (%) 99.7 0.$

7 Specialties: Nitrides 0 Aggregates Fused Aggregates: Bubble Aluminas We offer a range of high technical products prepared by nitridization of silicon and aluminium. These products are useful in silicon carbide based refractories for its corrosion resistance. They are also used in taphole clay formulations because of its non-wetting properties. Left: Molten steel on white fused alumina. Right: Molten steel on nitride. Specialty Aluminas has four production sites in Europe and has the ability to manufacture different aggregates to cover a broad range of alumina based refractory formulations. Sintered or fused aggregates can be used to make shaped or unshaped material displaying a wide range of thermo-mechanical properties as well as excellent chemical resistance. Fused Aggregates: White Fused Aluminas (WFA) GL/GLHP SEM picture of bubble aluminas. Bubble aluminas are resistant to high temperatures and provide thermal insulating characteristics to give very light shaped refractories or monolithics. Al O Na O SiO Fe O CaO+MgO Standard GL (%) High Purity GLHP (%) Silicon Nitrides N0/0 Nitrosil 0 and 0 are mainly used in alumina and silicon carbide based refractories. This gives materials enhanced corrosion and thermal shock resistance. CAR SEM picture of white fused alumina grain. White fused aluminas are produced from our Bayer process alumina feedstock to gives a very pure and consistent product. WFA is useful for applications that require pure materials that can perform at elevated temperature and is chemically inert under aggressive conditions. We offer a wide range of sizes from 0 mm down to very fine products that can enable you to achieve the best particle packing in your refractory product. Al O Na O SiO Fe O CAR (all sizes) (%) Standard GL Melting point ( C) 050 Thermal conductivity (kcal/h/m²/m/ C) 0.7 Fused Aggregates: Zirconia Aluminas PBZ PBZ is used for its extreme toughness and low thermal expansion. This grain provides very high mechanical resistance and improves the service life of control systems. This aggregate is a good alternative to zirconia-mullite in refractory as well as in ceramic rollers applications. N O Si Fe N0 (%) 4 6 N0 (%) Particle size distribution +50 µm +06 µm +6 µm + µm - µm N0/0 (%) 0 % 0 5% 0 0% 5 45% 55 95% Fused Aggregates: Brown Fused Aluminas (BFA) SD BFA is an electrofused aggregate produced from calcined bauxite. It s a very dense, non porous aggregate that could be used up to 650 C in all type of castables for application including iron and slag runners and blast furnaces. BFA is available in a wide range of grit size (see the table on page ). Al O ZrO TiO Fe O CaO+MgO SiO PBZ (%) Sintered Aggregates: Tabular Aluminas Sialon N50 Nitrosial 50 is mainly used as a binder in the manufacture of silicon carbide monolithic refractories. Brown fused alumina fine grains. Al O TiO SiO Fe O CaO MgO SD (all sizes) (%) Fine fraction (%) ALUTAB Our Tabular alumina is made by sintering our Bayer alumina feedstock in order to give a large crystalline, pure and consistent material. Al O Na O SiO Fe O CaO Iron Fe Alutab (all sizes) (%) < 0.0 N O Si Al N50 (%) Tabular alumina grains. Particle size distribution +50 µm +6 µm + µm - µm N50 (%) 0 % 0 0% 5 45% 55 95% Bulk specific gravity Apparent porosity Alutab (all sizes) >.5 g/cm³ ~ 5%

8 Grit size availability for our range of aggregates Tabular White Fused Brown Fused Bubble Zirconia Mesh Aluminas Aluminas Aluminas Aluminas Aluminas Closed size 5 0 mm /4./ inch 0 5 mm / inch 5 0 mm /4 / inch 6 mm mm mm 6 /4 inch 5 mm /4 inch 8 mesh mm mm 4 /4 inch mm 6 4 mm 8 4 0,5 mm 8 8 0,5 mm 4 8 0, mm Tabular balls 9mm Fines fractions 0, 0,6 mm 0, 0,5 mm , 0,5 mm ,045 mm -5 Open size 0 0 mm -/ inch 0 5 mm -/4 inch 0 mm -6 0 mm -8 0 mm ,5 mm , mm , mm , mm -40 Other grit sizes are available on request

9 Visit our website Locations Americas. Vaudreuil (Canada). Brockville (Canada). Cleveland (USA) 4. Montreal (Canada) 5. Rio de Janeiro (Brazil) 6. Mexico City (Mexico) Europe and MEA. Gardanne (France). Beyrède (France). La Bâthie (France) 4. Teutschenthal (Germany) 5. Koblenz (Germany) 6. London (UK) 7. Milan (Italy) 8. Lisbon (Portugal) 9. Istanbul (Turkey) 0. Cairo (Egypt). Dubai (United Arab Emirates). Johannesburg (South Africa) Asia Pacific. Shanghai (China). Tokyo (Japan). Singapore (Singapore) 4. Brisbane (Australia) 5. Seoul (South Korea) 6. Taipei (Taiwan) 7. Bangkok (Thailand) Key Headquarters Development centre Production facility Sales representation Designed and produced by SampsonMay Copyright Rio Tinto plc April 00

HIGH PERFORMANCE REFRACTORIES.

HIGH PERFORMANCE REFRACTORIES. 2018 Specialty Aluminas FOR HIGH PERFORMANCE REFRACTORIES www.alteo-alumina.com Aluminas for refractories Alumina is one of the most common oxides used in refractory applications. ln a typical refractory,