Lightweight alumina refractory aggregate. Phase 2, Pilot scale development

Kilogram quantities of refractory aggregate were prepared from both a paste and a pelletized form of extruder feed material in both bench and pilot-scale equipment. The 99{sup +} % alumina aggregate exhibited a bulk density approaching 2.5 g/cm{sup 3} and a fired strength slightly lower than fused alumina. Based on initial evaluation by two refractory manufacturers in brick or castable applications, the new aggregate offered adequate strength with thermal conductivity reductions up to 34%, depending on the temperature and application of the new aggregate in these initial trials. The new aggregate was simply substituted for Tabular{trademark} in the refractory formulation. Thus, there is room for improvement through formulation optimization with the lightweight aggregate. The new aggregate offers a unique combination of density, strength, and thermal properties not available in current aggregate. To this point in time, technical development has led to a pelletized formulation with borderline physical form leaving the Eirich mixer. The formulation requires further development to provide more latitude for the production of pelletized material without forming paste, while still reducing the bulk density slightly to reach the 2.5 g/cm{sup 3} target. The preferred, pelletized process flowsheet was outlined and a preliminary economic feasibility study performed based on a process retrofit into Alcoa`s Arkansas tabular production facilities. Based on an assumed market demand of 20,000 mt/year and an assumed selling price of $0.65/lb (25% more than the current selling price of Tabular{trademark}, on a volume basis), economics were favorable. Decision on whether to proceed into Phase 3 (full- scale demonstration) will be based on a formal market survey in 1994 October