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Converting Saprolite (a Low-Grade Unutilized Material) into Refractory Aggregates: A Viable Substitute for Calcined Clay in the Refractory Industry

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Abstract

JNARDDC has evaluated bauxite deposits of India from the geo-technological point of view. During the evaluation studies, it was observed that bauxite deposits are associated with saprolite resources. During bauxite mining, various low-grade materials such as saprolite, laterite and low-grade bauxite are generated. These materials typically have low-alumina, high-iron oxide and high-silica content. Owing to their inferior quality, these materials cannot be used for alumina production and hence remain unutilized at the mine site. For the present study, the saprolite samples were collected from the Western Ghats bauxite deposits in India. The sintering studies were conducted on saprolite granules using a variety of parameters. The sintered granules were characterized, and their properties determined. The test results showed that bulk density, apparent density, porosity and refractoriness (PCE 1645–1659 °C) of the aggregates were within the range of refractory specifications. The feasibility tests carried out at the refractory industry indicated that the developed aggregates are suitable as refractory material and can substitute for calcined clay. Currently, high-purity clay resources used in the refractory industry are limited and fast exhausting; therefore, the industry is likely to face an acute shortage of raw materials, which will become more critical in the future. Therefore the sintered granules (aggregates) developed from saprolite, which is a mining waste, provide a low-cost, eco-friendly solution for the fast-exhausting resources of the high-purity clays. The developed process may change the Indian bauxite mining scenario because saprolite may substitute as a potential raw material for the refractory industry.

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Abbreviations

AD:

Apparent density

BD:

Bulk density

JNARDDC:

Jawaharlal Nehru Aluminium Research Development and Design Centre

PCE:

Pyrometric cone equivalent

PLC:

Permanent linear change

SEM:

Scanning electron microscope

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Acknowledgements

The authors are grateful to Dr. Anupam Agnihotri, Director, JNARDDC for granting permission to publish this paper. Thanks are due to the staff of JNARDDC for carrying out the laboratory work.

Funding

The authors respectfully acknowledge the Science and Technology Wing, Ministry of Mines, Government of India for sponsoring and financial support of the research projects.

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Authors and Affiliations

  1. Jawaharlal Nehru Aluminium Research Development and Design Centre (JNARDDC), Amravati Road, Wadi, Nagpur, Maharashtra, 440 023, India

    P. G. Bhukte, G. T. Daware, S. P. Masurkar, M. J. Chaddha & A. Agnihotri

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  1. P. G. Bhukte
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  2. G. T. Daware
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  3. S. P. Masurkar
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  4. M. J. Chaddha
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  5. A. Agnihotri
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Correspondence to P. G. Bhukte.

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Bhukte, P.G., Daware, G.T., Masurkar, S.P. et al. Converting Saprolite (a Low-Grade Unutilized Material) into Refractory Aggregates: A Viable Substitute for Calcined Clay in the Refractory Industry. Mining, Metallurgy & Exploration 38, 1589–1595 (2021). https://doi.org/10.1007/s42461-021-00407-w

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