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Refractories to 2016


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Refractories to 2016

  1. 1. Refractories to 2016Report Details:Published:December 2012No. of Pages: 242Price: Single User License – US$4900This study analyzes the US refractory industry. It presents historical demand data for the years2001, 2006 and 2011, and forecasts for 2016 and 2021 by refractory form (e.g., bricks andshapes, monolithics), material (e.g., nonclay, clay) and market (e.g., metals industries, nonmetallicmineral processing, engineering contractors).The study also considers market environmentfactors, details industry structure, evaluates company market share and profiles industry players.US demand to rise 3.7% annually through 2016US demand for refractories is projected to grow 3.7 percent per year to $2.6 billion in 2016. Outputof 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 stronggrowth through 2016, prompting a resurgence in the production of a number of goods such ascement and glass. The market for refractories as measured in tons will increase 1.4 percent perannum to 2.3 million tons in 2016, still short of 2006 levels.Iron, steel manufacturing to benefit refractory demandIn 2011, sales of refractories to iron and steel manufacturers made up 45 percent of totalrefractory sales. After the steep decline in steel output during the recent recession, steelmanufacturing 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 ofrefractories; however, trends in refractory technology toward long lasting, durable refractories thatresist corrosion, spalling, and mechanical stresses will limit gains in demand going forward bylengthening replacement intervals. Nevertheless, high-performance refractories can commandpremium prices, aiding value gains in the market. Most materials manufacturing industries havereduced their per-production-unit consumption of refractories by using these new products andutilizing improved industrial processes.Monolithic, specialized forms to lead sales gainsMarket gains for refractories will be led by sales of monolithic refractories, specialized shapes, andother types of refractories through 2016. The performance of monolithic refractories has improvedgreatly over time, making them more versatile, durable, and easier to use, raising sales of thesetypes. Technological advancements have also made products such as specialty shapes muchmore cost effective and efficient, spurring demand for those forms as well. With regard tomaterials, the shift toward optimized product selection will continue. Refractory consumers areincreasingly choosing high-grade refractories with an elevated price, tuned to perform well under
  2. 2. specific operating conditions. As a result, sales of materials such as zirconia, zircon, and siliconcarbide will increase quickly. Shipments of nonclay products are expected to outperformshipments of clay refractories through 2016.Nonmetallic minerals to be fastest growing marketThe 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 recenteconomic downturn. Shipments from these industries will rise quickly as the US economycontinues to grow, fueling associated refractory demand. Further gains will come fromnonmanufacturing markets for refractories, such as waste-to-energy plants, traditional powerplants, and the construction and renovation of restaurants with in-house bakeries and stoneovens. These refractory markets are much smaller than those for metals or nonmetallic mineralsprocessing.COMPANY PROFILESCompany Profiles for competitors in the US industry including ANH Refractories, Cookson, Imerys,Magnasita, Minerals Technologies, RHI, and Saint-GobainAdditional InformationThis study analyzes US markets for and manufacturers’ shipments of refractory products.Historical data (2001, 2006, and 2011) and forecasts for the years 2016 and 2021 are provided incurrent US dollars for refractory product supply and demand by form (bricks and shapes,monolithics, and other) and by material (clay and nonclay). For detailed product classifications,historical data and forecasts for shipments in both current dollars and short tons are presented.Historical and forecast demand by end user/application (iron and steel, and nonferrous metalsproducers; ceramics, glass, and minerals processing companies, etc.) are also provided. Inaddition, major manufacturers of refractory products and refractory raw materials are identified andprofiled, and the key industry competitive variables are discussed. The entire report is framedwithin the refractory industry’s economic, technological, and market environments.It should be noted that this report focuses primarily on the dollar values for refractory shipmentsand demand, while also presenting tonnage data. The primary reason for this is that, due to thedifferent performance properties (often referred to as “refractoriness”) and densities of the variousrefractory materials, one ton of a given refractory material or product does not necessarily providethe same performance as one ton of another. Consequently, tonnage and dollar comparisonsbetween different refractory materials should be made within the context of the refractorinessprovided by each material. Also, sales of raw materials are excluded from this study, althoughsuppliers of raw materials are mentioned.As used in this study, the term “shipment” includes all production from US manufacturing sites thatis then shipped to both US and foreign markets. The terms “demand” and “sales” are usedinterchangeably and defined as all shipments from US plants, plus imports, minus exports. Tabulardetails may not add to totals due to independent rounding, and some ratios are based onunrounded numbers. Throughout the study, demand for power and hand tools is related to variousindicators for comparative purposes and to facilitate further analysis. Macroeconomic anddemographic indicators in this study were obtained from The Freedonia Group ConsensusForecasts dated April 2012. Because of the Bureau of Economic Analysis’ use of chain-weighted
  3. 3. price indices, inflation-adjusted Gross Domestic Product components (2005 dollars) do notnecessarily add to the total.A wide variety of primary and secondary sources were used in the compilation of this report.Historical data were based on US Bureau of the Census figures, including the Current IndustrialReport, Economic Census, and Annual Survey of Manufactures; data from the US GeologicalSurvey’s Mineral Commodity Summaries and Mineral Industry Surveys; and various foreign tradeand pricing series statistics. These figures were refined and adjusted based on consultation withindustry and other private sources and contacts. Corporate sales figures and refractory relatedsales represent estimates based on annual reports, SEC Form 10-K filings, security analystreports, corporate product literature, and interviews with competitors and with responsible officersin the companies themselves. Macroeconomic and demographic indicators used in this study havebeen obtained from The Freedonia Group Incorporated Consensus Forecasts dated August 2012.A variety of trade publications were also used in the preparation of this report. These includedAmerican Metal Market, Ceramic Bulletin, Ceramic Industry, Forge, Industrial Minerals, IndustrialHeating, and Refractories Applications & News.Get your copy of this report @ points covered in Table of Contents of this report includeTABLE OF CONTENTSINTRODUCTION viiiI. EXECUTIVE SUMMARY 1II. MARKET ENVIRONMENT 4General 4Macroeconomic Trends 5Capital Spending/Fixed Investment Trends 8Manufacturing Sector Outlook 11Durable Goods 13Nondurable Goods 14Refractory Technology 15Basic Refractory Properties 17Refractory Shapes & Forms 20Refractory Materials 21Other Technological Developments 22Pricing Trends 23Historical Market Trends 26International Environment 29World Supply & Demand 30Trends in US Foreign Trade 34Imports 35Exports 38
  4. 4. III. FORMS 41General 41Refractory Supply & Demand by Value 42Refractory Supply & Demand by Volume 45Refractory Bricks & Shapes 48Standard Bricks 50Preformed Shapes 53Monolithic Refractories 56Castables 59Gunning Mixes 61Plastic & Ramming Mixes 63Bonding & Other Mortars 65Other Refractory Forms 67IV. MATERIALS 70General 70Refractory Supply & Demand by Value 71Refractory Supply & Demand by Volume 73Nonclay Refractory Products 76Magnesite & Chrome 80Zircon & Zirconia 83Extra-High-Alumina 86Silicon Carbide 88Graphite & Carbon 90Ceramic Fibers 92Silica 95Mullite 97Dolomite & Other Nonclay Refractories 99Clay Refractory Products 102High-Alumina 106Fireclay 108Insulating 110V. MARKETS 113General 113Metals Industries 116Outlook 118Iron & Steel 119Nonferrous Metals 121Metal Casting & Fabrication 122Refractory Market 123Iron & Steel 124Nonferrous Metals 129Metal Casting & Fabrication 132
  5. 5. Nonmetallic Mineral Processing Industries 134Outlook 135Refractory Market 136Ceramics 137Glass 139Cement, Lime, & Other Mineral Processing 142Engineering Contractors 145Nonmanufacturing Refractory Market 147Petroleum & Chemicals 149Other Manufacturing Industries 152VI. INDUSTRY STRUCTURE 154General 154Industry Composition & Restructuring 155Market Share 159Leading Refractory Suppliers 160Significant Raw Material Suppliers 164Product Development & Manufacturing 166Marketing & Distribution 170Mergers & Acquisitions 172Company Profiles 175Alcoa Incorporated 176Allied Mineral Products Incorporated 177Almatis GmbH 179Alteo Holding 182AluChem Incorporated 183American Precast Refractories, see Allied MineralProductsANH Refractories Company 184Asbury Carbons Incorporated 189BNZ Materials Incorporated 190Calderys, see ImerysC-E Minerals, see ImerysCerCo LLC 192Cookson Group plc 194Corning Incorporated 197Harbison-Walker Refractories, see ANH RefractoriesImerys SA 199Kerneos, see Materis Holding LuxembourgLhoist SA 205Luossavaara-Kiirunavaara AB 206Magneco/Metrel Incorporated 207Magnesita Refratários SA 209
  6. 6. Materis Holding Luxembourg SA 211McDanel Advanced Ceramic Technologies LLC 212Minelco, see Luossavaara-KiirunavaaraMinerals Technologies Incorporated 213Minteq International, see Minerals TechnologyMorgan Crucible Company plc 216North American Refractories, see ANH RefractoriesPlibrico Company LLC 220Resco Products Incorporated 222RHI AG 224Rio Tinto Group 226Saint-Gobain 228Thermal Ceramics, see Morgan CrucibleTimcal, see ImerysTreibacher Schleifmittel North America, see ImerysTYK Corporation 232Unifrax I LLC 233Veitsch-Radex America, see RHIVesuvius Group/NV, see Cookson GroupOther Companies Mentioned in the Study 236LIST OF TABLESSECTION I -- EXECUTIVE SUMMARYSummary Table 3SECTION II -- MARKET ENVIRONMENT1 Macroeconomic Indicators 82 Nonresidential Fixed Investment 113 Manufacturers’ Shipments 134 Selected US Manufacturer Refractory Pricing 255 Refractory Market, 2001-2011 286 US Foreign Trade in Refractories 357 US Refractory Imports by Source 378 US Refractory Exports by Destination 40SECTION III -- FORMS1 Refractory Supply & Demand by Form in Value Terms 442 Refractory Supply & Demand by Form in Volume Terms 473 Refractory Brick & Shape Supply & Demand 504 Standard Brick Refractory Shipments 535 Preformed Shape Refractory Shipments 566 Monolithic Refractory Supply & Demand 597 Castable Refractory Shipments 618 Gunning Mix Refractory Shipments 639 Plastic & Ramming Mix Refractory Shipments 65
  7. 7. 10 Bonding & Other Mortar Refractory Shipments 6711 Other Refractory Form Supply & Demand 69SECTION IV -- MATERIALS1 Refractory Supply & Demand by Material in Value Terms 722 Refractory Supply & Demand by Material in Volume Terms 753 Nonclay Refractory Supply & Demand 784 Magnesite & Chrome Refractory Shipments 835 Zircon & Zirconia Refractory Shipments 866 Extra-High-Alumina Refractory Shipments 887 Silicon Carbide Refractory Shipments 908 Graphite & Carbon Refractory Shipments 929 Ceramic Fiber Refractory Shipments 9510 Silica Refractory Shipments 9711 Mullite Refractory Shipments 9912 Dolomite & Other Nonclay Refractory Shipments 10213 Clay Refractory Supply & Demand 10414 High-Alumina Clay Refractory Products 10715 Fireclay Refractory Shipments 11016 Insulating Clay Refractory Products 112SECTION V -- MARKETS1 Refractory Demand by Market 1152 Metals Industry Indicators 1193 Metals Industry Refractory Market 1244 Iron & Steel Production Refractory Market 1255 Nonferrous Metal Production Refractory Market 1326 Metal Casting & Fabrication Refractory Market 1347 Nonmetallic Mineral Product Shipments 1368 Nonmetallic Mineral Product Refractory Market 1379 Ceramics Refractory Market 13910 Glass Refractory Market 14211 Cement, Lime, & Other Mineral Processing Refractory Market 14512 Engineering Contractor Refractory Market 14713 Nonmanufacturing Refractory Market 14914 Petroleum & Chemical Refractory Market 15115 Other Manufacturing Industries Refractory Market 153SECTION VI -- INDUSTRY STRUCTURE1 Revenue Data: Selected Refractory & Raw MaterialsManufacturers, 2011 1582 Capital Spending Patterns: Selected Refractory Manufacturers 1693 Selected Acquisitions & Divestitures 174LIST OF CHARTS
  8. 8. SECTION II -- MARKET ENVIRONMENT1 Melting Points of Industrial Materials & Refractories 182 Selected US Manufacturer Refractory Pricing, 2001-2021 263 Refractory Market, 2001-2011 294 World Refractory Demand by Region, 2011 335 US Refractory Imports by Source, 2011 386 US Refractory Exports by Destination, 2011 40SECTION III -- FORMS1 Refractory Demand by Form in Value Terms, 2001-2021 452 Refractory Demand by Form in Volume Terms, 2001-2021 48SECTION IV -- MATERIALS1 Refractory Demand by Material in Value Terms, 2001-2021 732 Refractory Demand by Material in Volume Terms, 2001-2021 763 Nonclay Refractory Shipments by Material, 2011:Value & Volume 794 Clay Refractory Shipments by Material, 2011:Value & Volume 105SECTION V -- MARKETS1 Refractory Demand by Market, 2011 116SECTION VI -- INDUSTRY STRUCTURE1 US Refractory Market Share by Company, 2011 160Contact: for more information.