Lightweight alumina refractory aggregate. Final report

Technical Report · Tue Jul 16 04:00:00 EDT 1996

DOI:https://doi.org/10.2172/409840· OSTI ID:409840

Swansiger, T G; Pearson, A

Objective was to develop a lightweight, high alumina refractory aggregate for use in various high performance insulating (low thermal conductivity) refractory applications (e.g., in the aluminium, glass, cement, and iron and steel industries). A new aggregate process was developed through bench and pilot-scale experiments involving extrusion of a blend of calcined and activated alumina powders and organic extrusion aids and binders. The aggregate, with a bulk density approaching 2.5 g/cc, exhibited reduced thermal conductivity and adequate fired strength compared to dense tabular aggregate. Refractory manufacturers were moderately enthusiastic over the results. Alcoa prepared an economic analysis for producing lightweight aggregate, based on a retrofit of this process into existing Alcoa production facilities. However, a new, competing lightweight aggregate material was developed by another company; this material (Plasmal{trademark})had a significantly more favorable cost base than the Alcoa/DOE material, due to cheap raw materials and fewer processing steps. In late 1995, Alcoa became a distributor of Plasmal. Alcoa estimated that {ge}75% of the market originally envisioned for the Alcoa/DOE aggregate would be taken by Plasmal. Hence, it was decided to terminate the contract without the full- scale demonstration.

• Research Organization: Aluminum Co. of America, Alcoa Center, PA (United States). Alcoa Technical Center
• Sponsoring Organization: USDOE Assistant Secretary for Energy Efficiency and Renewable Energy, Washington, DC (United States)
• DOE Contract Number: FC07-89ID12903
• OSTI ID: 409840
• Report Number(s): DOE/ID/12903--5; ON: DE97000107
• Country of Publication: United States
• Language: English

Related Subjects

29 ENERGY PLANNING, POLICY, AND ECONOMY
36 MATERIALS SCIENCE
ALUMINIUM OXIDES
ECONOMIC ANALYSIS
FEASIBILITY STUDIES
GRANULAR MATERIALS
MARKET
PRODUCTION
PROGRESS REPORT
REFRACTORIES
SINTERED MATERIALS
THERMAL INSULATION