Aluminium Industry

Your Bringing the best out of aluminium.

The aluminium industry, both primary and secondary, is globally one of the anchor points of Mathios Refractories S.A. We have been growing together with our customers, for more that 45 years, developing a deep understanding of the industry.

We are responsible for innovative solutions such as the unique application of the rotary calcinations kiln. We exclusively use Mathios Low Cement Castables, solving the immense problem of shell deformation for our customers. Our materials are of the highest quality, specially designed fit in any of the parts of the plants. At the same time, we are keen on improving energy efficiency, reduced downtime, shorter repair cycles and enhanced productivity. We are able to provide bricks, monolithic, precast sections as well as special parts for plants like the ones listed below: Content Goes Here

Anode Baking Furnace

Roof Side Walls
Bottom Lining Insulating Lining

Anode baking furnaces require refractory bricks which combine special shapes and extremely strict technical specifications.
MATHIOS REFRACTORIES  has created special formulations in order to offer refractory bricks with high hot moduli of rupture, low gas permeability, high resistance to disintegration in carbon monoxide (CO) atmosphere and great alkali resistance, as expected by primary aluminium plants around the world.
Products from the following lines are recommended by our experts:

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay, mullite and andalusite, are used as side walls and bottom linings
  • MAT: Alumina (Al2O3) regular castables (dense), with formulations based on chamotte, are used as top blocks
  • MAT MW: Alumina (Al2O3) insulating castables, with formulations based on light weight chamotte, for use as insulation linings.

Static Furnace Calcination of Alumina

Refractory Lining Insulating Lining

Calcination is the last step in pure aluminium oxide (alumina) production, where water is removed from the aluminium hydroxide. Alumina is then cooled in a series of cyclones, while its energy is simultaneously recovered so as to be used again to preheat the aluminum trihydroxide entering the system. The whole installation is subjected to abrasive loads from the two-phase stream, with the cyclones being especially affected, due to the centrifugation process. Thermal shock is also present.

The refractory materials offered by MATHIOS REFRACTORIES are tested and proven by the aluminium industry around the world. Products from the following lines are recommended by our experts:

  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on andalusite and bauxite, are used as refractory linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on bauxite, are used as refractory linings
  • MAT NANO: Alumina (Al2O3) no cement castables, with formulations based on bauxite, are used as refractory linings
  • MAT LG: Alumina (Al2O3) low cement gunning materials (LCG), with formulations based on mullite, are used as refractory linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on expanded clay and vermiculite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on expanded clay and vermiculite, for use as insulation lining

Rotary Kiln Calcination of Alumina

Inlet Zone Calcination Zone Cooling Zone

Calcination is the last step in the Bayer process in which bauxite is refined in order to produce alumina (Al2O3), in a rotary kiln.
The refractory materials offered by MATHIOS REFRACTORIES are vastly tested and proven by the industry.
Products from the following lines are recommended by our experts:

  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on chamotte, mullite, andalusite, bauxite and silicon carbide for use at the inlet, calcination and cooling zones
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on bauxite for use at the inlet, calcination and cooling zones

Tilting Melting Furnace

Bath Zone Roof & Side Walls Burner Lining
Roof & Door Insulation Insulating Lining

Melting furnaces serve the purpose of supplying casting machines with molten aluminium on a steady and continuous tempo.
When molten aluminium comes in touch with refractories at the bath zone, it can lead to them being fast and heavily corroded. For this reason MATHIOS REFRACTORIES has created a unique barium oxide (BaO) containing product line, with special anti-wetting abilities.These products bear the characteristic AL on their name.
Products from the following lines are recommended by our experts:

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on mullite and bauxite, are used at the bath zone, roof and side walls
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on mullite, andalusite and bauxite, are used at the bath zone, roof & side walls and as burner linings.
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on mullite, andalusite and bauxite, are used at the bath zone, roof, side walls and as burner linings.
  • MAT NANO: Alumina (Al2O3) no cement castables, with formulations based on mullite, bauxite and sintered alumina, are used at the bath zone, roof, and side walls.
  • MAT: Alumina (Al2O3) regular castables (dense), with formulations based on mullite and tabular alumina, are used at the roof and side walls
  • MAT LG: Alumina (Al2O3) low cement gunning materials (LCG), with formulations based on chamotte, mullite, bauxite and corundum, are used at the roof and side walls
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on mullite, are used at the roof and side walls
  • MAT: Alumina (Al2O3)  insulating castables, with formulations based on vermiculite and perlite, for use as roof and door insulation
  • MAT MW (G): Alumina (Al2O3) insulating castables & gunning materials, with formulations based on light weight chamotte, for use as roof, door and general insulation.

Ladle for Molten Aluminium Transportation

Refractory Lining Cover
Insulating Lining Insulation

Ladles are used to transport the molten aluminium within the plant. Their refractory lining must be resistant to thermal shock and erosion, while simultaneously keeping heat losses at a minimum.
The refractory materials offered by MATHIOS REFRACTORIES are vastly tested and proven by the industry.
Products from the following lines are recommended by our experts:

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay and bauxite, are used as hot face linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on chamotte, bauxite and silicon carbide  are used as hot face linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on bauxite, are used as cover linings
  • MAT PLUS MC: Alumina (Al2O3) medium cement castables (MCC), with formulations based on chamotte, bauxite and silicon carbide are used as cover linings
  • MAT: Alumina (Al2O3) regular castables (dense), with formulations based on chamotte, are used as cover linings
  • MAT MW (G): Alumina (Al2O3) insulating castables & gunning materials, with formulations based on light weight chamotte, are used as insulation linings. Those with special anti-wetting abilities, bear the characteristic AL on their name