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European Refractory MarketsDr Jürgen Puhl Managing Director Alumina Products Marketing/R&DDr. Jürgen Puhl – Managing Director Alumina Products - Marketing/R&D
IA. • Dr. Jürgen Puhl • 13.03.2012
Contents
Current and future steel demand and impact on theCurrent and future steel demand and impact on therefractory market
Challenges - New markets for refractories andareas of demand
Comparison of different types of refractorymaterials and their markets
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Refractories – Indispensable for Basic IndustriesRefractory products High-temperature production
processes
Steel production
Bricks Mixes LiningsRefractory products are used in all high-temperature industrial processes (>1,200°C) since they protect the production units/furnaces against thermal(and also mechanical and chemical) stress
Cement / lime production
g
Base materials are for instance magnesite and dolomite (melting point of fused magnesia >2,800°C)
Glass production
Magnesite Dolomite
Nonferrous metals production
21
Definition refractories: ISO 836 / DIN 51060: refractoriness >1,500 °C
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Refractory Industry in Europe Facts and Figures 2010 (Source PRE 2011)
About 24,000 employeesApprox. 5 million tonnes of refractories produced (PRE: 4.17)Trend: Overcapacity in production€3.77 billion turnover€3.77 billion turnover
35-45% Production for export (2009)15-20% Consumption from imports (mainly from China) (2009)
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Crude Steel Production – EU27250,000
n in
150,000
200,000
oduc
tion
mt
100,000
150,000
Stee
l Pro
000.
m
50,000
Cru
de S
Source: World Steel Assoziation
02000 2002 2004 2006 2008 2010 2012 f)
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f) MEPS – World Steel Outlook Quarter 4/2011
EU Steel Market
Source: Q1-2012 Report from EUROFER`s Economic Committee
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Refractory Market Steel – Western Europe
80.0100.0120.0
100 About 60% of refractories are
d i th t l i d t
20.040.060.0
ex 2
008
= 1 used in the steel industry
(source PRE 2011: members only; based on total 3.7 million tonnes).
0.02008 2009 2010 2011 2012 2013
Inde Source: RHI AG
World refractory demand (.000s tonnes)
Region 2004 2009 2014 2004-2009(% annual growth)
2009-2014(% annual growth)
North America 3,305 2,445 3,150 -5.8 5.2
W t E 3 550 2 725 3 240 5 2 3 5
Clear correlationbetween refractories
Western Europe 3,550 2,725 3,240 -5.2 3.5
Asia Pacific 13,350 21,340 27,850 9.8 5.5
Other Regions 5,460 4,990 6,460 -1.8 5.3
TOTAL 25 665 31 500 40 700 4 2 5 3
market and steelproduction
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TOTAL 25,665 31,500 40,700 4.2 5.3Source: The Fredonia Group Inc., M. Deneen, 2011)
Total Production of Refractories in Europe
100 06 000
Total production/Trend: Unshaped (members)
4.3124 021 4.206
4.5984.854
4.6184.171
80.0
90.0
100.0
5.000
6.000
Trend Total Production (members)
Total production
4.0213.520
4.171
50.0
60.0
70.0
3.000
4.000
and
tonn
es
(members)
% of unshaped production
32.0 33.037.8 39.8 42.1 42.5 42.8 43.8
20.0
30.0
40.0
1 000
2.000Thou
sa
Trend production unshaped (members)
% of unshaped production
Source: PRE 2011
0.0
10.0
0.000
1.000
2003 2004 2005 2006 2007 2008 2009 2010
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Overview of Refractories Production in Europe
3000
Overview of product categories 2010
21343
2500
3000
Total: 2.342 million tonnes
Total: 1.829 million tonnes
1343
78
26175 3090
1500
2000
0 to
nnes
Unclassified
Pre-cast
Other products
Insulating products
Total: 1.829 million tonnes
346
1343
922
500
1000
1000 Insulating products
Basic products
High Alumina
Fireclay
361 273
346312
0
500
Shaped Products Unshaped Products Source: PRE 2011
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Shaped Products Unshaped Products Source: PRE 2011
Mean Specific Refractory Consumption - Europe
50
60
umpt
ion
World total
G
Furnace/Plant Mean Specific Consumption 1)
Product Share Shaped Unshaped
kg refractories/tonne
approx. % approx. %
20
30
40
efra
ctor
yco
nson
ne s
teel
Germany
USA
/tonne
Pig
Iron
Blast Furnace (with tapholes) 0,7 15 85
Hot Blast Stove 0,3 95 5Transport Vessels 0,5 70 30Oxygen Converter 1 2 75 25
0
10
20
vera
gesp
ec.
rkg
/t
Japan
Stee
l
Oxygen Converter 1,2 75 25Electric Arc Furnace 5,1 30 70AOD-Converter 6,2 92 8Steel Treatment Ladles 3,3 90 10RH and DH Units 1,3 50 50Continuous Casting (with 1,2 10 90
1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010Av
Year
Average specific refractory consumption in Europe:
tundish)
1) Specific Consumption is depending on furnaces used for particular production line.
10-12 kg/tonne steel4-5 kg/tonne glass0.6-0.8 kg/tonne cement clinker (VDZ 2011: 0.65kg/tonne clinker in Germany)
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g ( g y)5-10 kg/tonne nonferrous metal
Challenges - New Markets and Area of DemandRestricted growth in Europe compared to the emerging marketsChina/India/Brazil with a trend for lower refractory consumption per tonne/product in BRIC countries. Extension of sales into emerging markets.
Increasing raw material costs and decreased amounts of highest qualityraw materials.
Uniform raw material policy in EU –decrease the dependency on imported raw materials. Production
Development of synthetic fused and sintered rawmaterials to improve the properties of standard products.
of fusedsyntheticrawmaterial
21
materials to improve the properties of standard products.
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Raw Material Prices for Refractory Industry
390
Index development of commodity prices for the refractory-industry
290
340
390
240
290
= 10
0
Source: VDFFI
140
190
Inde
x 20
00
90
andalusite bauxite white fused alumina
brown fused
alumina
silicon carbide
fused magnesia
sintered magnesia
zircon tabular alumina
cement average
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2000 2001 2002 2003 2004 2005 2006 1q2007 2q2007 3q2007 4q2007 1q2008 2q20083q2008 4q2008 1q2009 2q2009 3q2009 4q2009 1q2010 2q2010 3q2010 4q2010 1q2011 2q2011 3q2011 4q2011
Recycling
rawt i l
Recycling – secondary rawmaterials – problems in quality and
material
80%processing of secondary rawmaterials.
internal recyclingnon refr appl
RefractoriesApplication
Refr.Recycl.
non-refr. appl.20% 35% 18% 27%
pp
product orby product w
aste Flow chart of refractories in application
Source: UNITECR Proceedings 2003
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by-product w
Refractories for Steel Industry – Comprehensive Products, Services and Solutions Offered
Tailored products and solutions
Standardized/High-Volume Products Complex Solutions and Services
pfor customers in the steel industry
Systems and solutions for complete refractory management
B i k d h d d t f b i
(full line service)
Bricks and unshaped products e.g. for basic oxygen furnaces, electric arc furnaces and steel casting ladles
Regarded as a consumable product due to the comparably short replacement cycles (20 minutes to 2 months)
Engineering &Design
Services &Logistics
Machinery & Equipment
Full Line Service
Refractories
(20 minutes to 2 months)
Customer demand is correlated to steel output due to the consumable nature of refractory products in the
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steel industry
Customized refractory Products and Solutions - Examples
All-inclusive refractory solutions based th ifi i t f iC /
Keyindustries
Applicationexamples
Replacementcycle
Customized solutions
on the specific requirements of various customers’ industrial production processes including:
Complete lining concepts
Cement/ Lime
Kilns Annually
Refractory engineering with state-of-the-art CAD systems
Detailed project documentation including installation instructions
Glass Glass furnace Up to 10 years
including installation instructions
Developments of specific, individual refractory solutions in cooperation with research centres
NonferrousMetals
Copper converter
Energy-
1 – 10 years
Complete installation and lining supervision by experienced engineers
EnergyEnvironment-Chemicals
Secondary reformer
T i ll l l t l d hi h t i ti d t d t id d t t l i d t
5 – 10 years
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Typically longer replacement cycles and higher customization compared to products provided to steel industry Wide areas of application, project driven demand cycles and perceived as an investment
Challenges - Areas of Demand
Tailor-made solutions for customers with ademand for the highest quality productsdemand for the highest quality products.
Increased use of unshaped products (global ratio: shaped/unshaped = 56:44 1) ). Developments concerning: fast heating up and drying; properties close to bricks.
Tundish lining – fast heating up
Precasts to realize large and complicatedshapes.
1) M. Deneen, Business Economics, Oct. 2010
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Challenges - Areas of DemandImplementation of computerized simulation techniqueslike fluid dynamics or numerical simulation for productdevelopment, product design and lining optimization.
New binder systems for bricks and castables.
Velocity contour of SEN
MgO-C brick – Carbon binding structureCement plant – inlet chamber –
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MgO C brick Carbon binding structureCement plant inlet chambercastable field trial
Challenges - Areas of Demand
Improvement of lining techniques (different zones), improved repair techniques.
New refractory materials for lining because of new
EAF gunning operation
New refractory materials for lining because of newprocess conditions. For instance use of secondary fuels(cement industry) or use of secondary raw materialsbecause of a lack of primary raw materials(for instance primary copper and lead production).
Damage of cement
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Damage of cementclinker cooler
Challenges - Areas of DemandEnvironmental restrictions. REACH (for instance environmentally friendly C-binder). CO2- and NOx-emissions. Recognizing emission sources. Problem: inevitable CO2-emissions from magnesite and dolomite.
Providing intelligent refractory solutions: to reduce energy consumption and CO2-emissions and optimize metal output and quality. D l t f lt ti d ti t dDevelopment of alternative production processes to decrease energyconsumption during refractory production.
Extended R&D activities to ensure technological progress.
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Refractory Materials and Their Main Markets
Steel Cement Glass Non-ferrous OthersEEC
Basic, shapedfired 1)
C-bonded
+ + + + + + + + + + + (+)
Basic unshaped 2) + + + (+) (+)
Non-basic, shapedfired 1)
C b d d
+ + ++ + + + + + + + +
C-bonded
Non-basic unshaped 2) + + + + (+) + + +
Non-basic shaped +fused cast +
1) Including chemically bonded bricks2) Mortars and plastics not considered
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Mortars and plastics not considered
How much Refractory Material Was Needed toMake This Car?
The car weighs about 1.3 tonnes
Approximately 10 kg of refractory bricks and mixes wererequired to manufacture the steel, glass, aluminium, copperand plastic (upholstery, cables, safety belts) products.
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