US Refractories Market

  • December 2012
  • -
  • Freedonia
  • -
  • 242 pages

US demand to rise 3.7% annually through 2016

US demand for refractories is projected to grow 3.7 percent per year to $2.6 billion in 2016. Output of steel in the US is expected to reverse its decline, driving up demand for refractory products. Gains will also result as nonresidential fixed investment spending returns to strong growth through 2016, prompting a resurgence in the production of a number of goods such as cement and glass. The market for refractories as measured in tons will increase 1.4 percent per annum to 2.3 million tons in 2016, still short of 2006 levels.

Iron, steel manufacturing to benefit refractory demand

In 2011, sales of refractories to iron and steel manufacturers made up 45 percent of total refractory sales. After the steep decline in steel output during the recent recession, steel manufacturing in the US -- along with the associated refractory demand -- is expected to rebound. The expected resurgence in US manufacturing output through 2016 will aid in driving sales of refractories; however, trends in refractory technology toward long lasting, durable refractories that resist corrosion, spalling, and mechanical stresses will limit gains in demand going forward by lengthening replacement intervals. Nevertheless, high-performance refractories can command premium prices, aiding value gains in the market. Most materials manufacturing industries have reduced their per-production-unit consumption of refractories by using these new products and utilizing improved industrial processes.

Monolithic, specialized forms to lead sales gains

Market gains for refractories will be led by sales of monolithic refractories, specialized shapes, and other types of refractories through 2016. The performance of monolithic refractories has improved greatly over time, making them more versatile, durable, and easier to use, raising sales of these types. Technological advancements have also made products such as specialty shapes much more cost effective and efficient, spurring demand for those forms as well. With regard to materials, the shift toward optimized product selection will continue. Refractory consumers are increasingly choosing high-grade refractories with an elevated price, tuned to perform well under specific operating conditions. As a result, sales of materials such as zirconia, zircon, and silicon carbide will increase quickly. Shipments of nonclay products are expected to outperform shipments of clay refractories through 2016.

Nonmetallic minerals to be fastest growing market

The fastest gains of any market will be posted in the nonmetallic minerals market through 2016. This market includes glass, ceramics, and cement producers, all of which were hurt by the recent economic downturn. Shipments from these industries will rise quickly as the US economy continues to grow, fueling associated refractory demand. Further gains will come from nonmanufacturing markets for refractories, such as waste-to-energy plants, traditional power plants, and the construction and renovation of restaurants with in-house bakeries and stone ovens. These refractory markets are much smaller than those for metals or nonmetallic minerals processing.

Study coverage

This upcoming industry study, Refractories, presents historical demand data for 2001, 2006 and 2011, plus forecasts for 2016 and 2021 by refractory form (e.g., bricks and shapes, monolithics), material (e.g., nonclay, clay) and market (e.g., metals industries, engineering contractors, nonmetallic mineral processing). The study also considers key market environment factors, evaluates company market share and profiles industry competitors such as ANH Refractories, Cookson, Magnasita, Minerals Technologies, RHI, and Saint- Gobain.

Table Of Contents


TABLE OF CONTENTS

INTRODUCTION viii

I. EXECUTIVE SUMMARY 1

II. MARKET ENVIRONMENT 4

General 4
Macroeconomic Trends 5
Capital Spending/Fixed Investment Trends 8
Manufacturing Sector Outlook 11
Durable Goods 13
Nondurable Goods 14
Refractory Technology 15
Basic Refractory Properties 17
Refractory Shapes and Forms 20
Refractory Materials 21
Other Technological Developments 22
Pricing Trends 23
Historical Market Trends 26
International Environment 29
World Supply and Demand 30
Trends in US Foreign Trade 34
Imports 35
Exports 38

III. FORMS 41

General 41
Refractory Supply and Demand by Value 42
Refractory Supply and Demand by Volume 45
Refractory Bricks and Shapes 48
Standard Bricks 50
Preformed Shapes 53
Monolithic Refractories 56
Castables 59
Gunning Mixes 61
Plastic and Ramming Mixes 63
Bonding and Other Mortars 65
Other Refractory Forms 67

IV. MATERIALS 70

General 70
Refractory Supply and Demand by Value 71
Refractory Supply and Demand by Volume 73
Nonclay Refractory Products 76
Magnesite and Chrome 80
Zircon and Zirconia 83
Extra-High-Alumina 86
Silicon Carbide 88
Graphite and Carbon 90
Ceramic Fibers 92
Silica 95
Mullite 97
Dolomite and Other Nonclay Refractories 99
Clay Refractory Products 102
High-Alumina 106
Fireclay 108
Insulating 110

V. MARKETS 113

General 113
Metals Industries 116
Outlook 118
Iron and Steel 119
Nonferrous Metals 121
Metal Casting and Fabrication 122
Refractory Market 123
Iron and Steel 124
Nonferrous Metals 129
Metal Casting and Fabrication 132
Nonmetallic Mineral Processing Industries 134
Outlook 135
Refractory Market 136
Ceramics 137
Glass 139
Cement, Lime, and Other Mineral Processing 142
Engineering Contractors 145
Nonmanufacturing Refractory Market 147
Petroleum and Chemicals 149
Other Manufacturing Industries 152

VI. INDUSTRY STRUCTURE 154

General 154
Industry Composition and Restructuring 155
Market Share 159
Leading Refractory Suppliers 160
Significant Raw Material Suppliers 164
Product Development and Manufacturing 166
Marketing and Distribution 170
Mergers and Acquisitions 172
Company Profiles 175
Alcoa Incorporated 176
Allied Mineral Products Incorporated 177
Almatis GmbH 179
Alteo Holding 182
AluChem Incorporated 183
American Precast Refractories, see Allied Mineral
Products
ANH Refractories Company 184
Asbury Carbons Incorporated 189
BNZ Materials Incorporated 190
Calderys, see Imerys
C-E Minerals, see Imerys
CerCo LLC 192
Cookson Group plc 194
Corning Incorporated 197
Harbison-Walker Refractories, see ANH Refractories
Imerys SA 199
Kerneos, see Materis Holding Luxembourg
Lhoist SA 205
Luossavaara-Kiirunavaara AB 206
Magneco/Metrel Incorporated 207
Magnesita Refratários SA 209
Materis Holding Luxembourg SA 211
McDanel Advanced Ceramic Technologies LLC 212
Minelco, see Luossavaara-Kiirunavaara
Minerals Technologies Incorporated 213
Minteq International, see Minerals Technology
Morgan Crucible Company plc 216
North American Refractories, see ANH Refractories
Plibrico Company LLC 220
Resco Products Incorporated 222
RHI AG 224
Rio Tinto Group 226
Saint-Gobain 228
Thermal Ceramics, see Morgan Crucible
Timcal, see Imerys
Treibacher Schleifmittel North America, see Imerys
TYK Corporation 232
Unifrax I LLC 233
Veitsch-Radex America, see RHI
Vesuvius Group/NV, see Cookson Group
Other Companies Mentioned in the Study 236

LIST OF TABLES


SECTION I -- EXECUTIVE SUMMARY

Summary Table 3

SECTION II -- MARKET ENVIRONMENT

1 Macroeconomic Indicators 8
2 Nonresidential Fixed Investment 11
3 Manufacturers’ Shipments 13
4 Selected US Manufacturer Refractory Pricing 25
5 Refractory Market, 2001-2011 28
6 US Foreign Trade in Refractories 35
7 US Refractory Imports by Source 37
8 US Refractory Exports by Destination 40

SECTION III -- FORMS

1 Refractory Supply and Demand by Form in Value Terms 44
2 Refractory Supply and Demand by Form in Volume Terms 47
3 Refractory Brick and Shape Supply and Demand 50
4 Standard Brick Refractory Shipments 53
5 Preformed Shape Refractory Shipments 56
6 Monolithic Refractory Supply and Demand 59
7 Castable Refractory Shipments 61
8 Gunning Mix Refractory Shipments 63
9 Plastic and Ramming Mix Refractory Shipments 65
10 Bonding and Other Mortar Refractory Shipments 67
11 Other Refractory Form Supply and Demand 69

SECTION IV -- MATERIALS

1 Refractory Supply and Demand by Material in Value Terms 72
2 Refractory Supply and Demand by Material in Volume Terms 75
3 Nonclay Refractory Supply and Demand 78
4 Magnesite and Chrome Refractory Shipments 83
5 Zircon and Zirconia Refractory Shipments 86
6 Extra-High-Alumina Refractory Shipments 88
7 Silicon Carbide Refractory Shipments 90
8 Graphite and Carbon Refractory Shipments 92
9 Ceramic Fiber Refractory Shipments 95
10 Silica Refractory Shipments 97
11 Mullite Refractory Shipments 99
12 Dolomite and Other Nonclay Refractory Shipments 102
13 Clay Refractory Supply and Demand 104
14 High-Alumina Clay Refractory Products 107
15 Fireclay Refractory Shipments 110
16 Insulating Clay Refractory Products 112

SECTION V -- MARKETS

1 Refractory Demand by Market 115
2 Metals Industry Indicators 119
3 Metals Industry Refractory Market 124
4 Iron and Steel Production Refractory Market 125
5 Nonferrous Metal Production Refractory Market 132
6 Metal Casting and Fabrication Refractory Market 134
7 Nonmetallic Mineral Product Shipments 136
8 Nonmetallic Mineral Product Refractory Market 137
9 Ceramics Refractory Market 139
10 Glass Refractory Market 142
11 Cement, Lime, and Other Mineral Processing Refractory Market 145
12 Engineering Contractor Refractory Market 147
13 Nonmanufacturing Refractory Market 149
14 Petroleum and Chemical Refractory Market 151
15 Other Manufacturing Industries Refractory Market 153

SECTION VI -- INDUSTRY STRUCTURE

1 Revenue Data: Selected Refractory and Raw Materials
Manufacturers, 2011 158
2 Capital Spending Patterns: Selected Refractory Manufacturers 169
3 Selected Acquisitions and Divestitures 174

LIST OF CHARTS

SECTION II -- MARKET ENVIRONMENT

1 Melting Points of Industrial Materials and Refractories 18
2 Selected US Manufacturer Refractory Pricing, 2001-2021 26
3 Refractory Market, 2001-2011 29
4 World Refractory Demand by Region, 2011 33
5 US Refractory Imports by Source, 2011 38
6 US Refractory Exports by Destination, 2011 40

SECTION III -- FORMS

1 Refractory Demand by Form in Value Terms, 2001-2021 45
2 Refractory Demand by Form in Volume Terms, 2001-2021 48

SECTION IV -- MATERIALS

1 Refractory Demand by Material in Value Terms, 2001-2021 73
2 Refractory Demand by Material in Volume Terms, 2001-2021 76
3 Nonclay Refractory Shipments by Material, 2011:
Value and Volume 79
4 Clay Refractory Shipments by Material, 2011:
Value and Volume 105

SECTION V -- MARKETS

1 Refractory Demand by Market, 2011 116

SECTION VI -- INDUSTRY STRUCTURE
1 US Refractory Market Share by Company, 2011 160

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