Egyptian refractory raw materials

Abstract

The Egyptian refractory raw materials available for application in the production of acidic and basic refractories are reviewed. Quartz and quartzite as well as fireclay and kaolin deposits suitable for the production of shaped and unshaped acidic products; namely, silica and aluminosilicate refractories exist at some localities in Aswan, Sinai and Eastern Desert. More than 60 thousand ton of high grade shaped and unshaped semi–silica, fireclay and aluminous fireclay refractories are locally produced from these raw materials for lining some Egyptian and Arabian industrial furnaces. Meanwhile , shaped and unshaped silica refractories are annually imported for lining coke ovens as well as ductile-iron induction furnaces. On the other hand,more than 70 thousand ton of shaped and unshaped basic refractories, i.e. MgO- based products are annually imported for lining and repairing of steel and cement furnaces due to the shortage of pure magnesite deposits in Egypt. However, some basic raw materials; namely, limestone, dolomite, dolomitic-magnesite and serpentinite rocks were assessed for the production of high quality lime, dolomite, MgO-dolomite, forsterite and cordierite refractories. It is concluded that Egyptian quartz and quartzite raw materials can be utilized in the production of shaped and unshaped silica refractories for lining coke ovens and ductile–iron induction furnaces, respectively.Also, the semi-silica and fireclay bricks currently produced from the available kaolinitic clays can be economically applied for lining steel ladles and tundishes, beside the aluminous fire clay bricks. On the other side, dense and hydration resistant shaped and unshaped lime, dolomite and MgO-dolomite refractories for lining and repairing of steel and cement furnaces can be produced from their available raw materials. In addition, shaped cordierite bodies can be produced as furniture for tunnel kilns used in firing white ware ceramics and forsterite bricks for lining the lower courses of the glass tank heat exchangers from varieties of serpentinite rocks.