CHAPTER

CHAPTER -2
MAGNESITE
2.1. NATURE OF MAGNESITE

AN OVERVIEW

Metals

o c c u r i n nature, some times free ( i . e in

state),

uncombined
(i.e

but

mostly in the combined

state,

as compounds

with other elements). When a metal is

found

f r e e , it is s a i d to occur a s ' n a t i v e f . Metals found i n

copper, silver, g o l d , mercury and platinum.

native state are

others

a r e found

in the combined state1. Magnesite is found

in a

combined state.
4

The

Chemical

name

of

magnesite

is

magnesium

~ a r b o n a t e ( M g C 0 ~ )(.i . e )

Magnesite i s a c a r b o n a t e o f

maganesium.
(COz)

When pure,

it

contains 52.4 % carbon d i - o x i d e

, and

47.6% magnesium oxide (MgO)

But pure magnesite

is rarely found

in nature.

It

is usually associated with

small

percentage

of calcium, silicon, iron and aluminium,

10%. These elements are c a l l e d impuritiesZ

totals going u p t o @
Magesite

mineral can be compared with paddy.

Paddy

Raw magnesite
.LwCIw-.I

Rice
Food

Processed magnesite or calcined magnesite

Refractory bricks/ramming mass/ f e t tling mass/ gunning mix, etc.,

---I-I-

Paddy Similarly, limited. such.

has limited use, It can be used as

seed only.

the

uses

of

raw rnagnesite

are

very
be

much
as

From

paddy, we get rice. Rice cannot

used

It

is used to produce various food

items,

Similarly

when raw magnesite is processed, it gives calcined magnesite.

The calcined magnesite, as such, finds no much use.

It is

used to produce other usable products.

The consumed
to

rice is converted into food products which

can

be
used

as such. Similarly, the,clacined magnesite is

produce

refractory bricks, gunning mass,

ramming

mass,
utses.

fettling
Thus,

mass and many other products which find many paddy

there is a one bo one relationship between

and

magnesite.

For
magnesite, below.

clear

understanding

of

the

subject

of

a few terms

(used in this report) are explained

MINERALS

A mineral is a material dugout from earth a s such. It

is a compound (i.e) i t + i s a combination

of more

than one

mineral

must

have

the

following

characteristics. The form any specific

process of

material must be inorganic, not formed

animal

or

plant life, f a l l within

limits

of chemical composition and have a regular

internal

arrangement of atoms. 4

.Magnesite is a mineral as

it satisfies the above characteristics.

2.2.2:

ORE

Ore

is an aggregation of the minerals and gangue

from which one or more metals may be extracted at a profit 5

Magnesite is an ore as rnagesium metal can be

profitably

extracted from it.

2.2,3:

GANGUE Gangue minerals

are the

associated

non-metallic

materials

of

deposit.

They may,..beintroduced

minerals

or

the enclosing rock and are usually discarded

in the

treatment

of the

ore.

The gangue

in customary usage

includes

only

non-metallic minerals such as p y r i t e , which

is usually
materials,

discarded a s

worthless.

certain

gangue

however,

may

at times, be collected as byexample rock gangue may be

abrasive etc.,

products and utilised. For

utilised for road metal, quartz f o r

I n the

case of rnagnesite deposit, silicate, calcium, etc., are t h e

gangue materials.

2.2.4:

MINING
The

process

of taking out the ore from

the
out

earth
from

is called
mother

mining.

The magnesite

ore

is taken

earth by mining.

The first step in mining

is to

locate o r find the minerals. exploting.

This is called prospecting or

Next the best way of mining is p l a n n e d and used.

the m i n e r s must be cared

Finally, the safety and h e a l t h of

for

-.
METALLURGY

2.2.5:

The process crf extracting the metals from t h e i r o r e s

and refining t h e m is c a l l e d metallurgy .8

Note:

1. The process used

for the metallurgy of a ore from which the

metal depends

on

the n a t u r e

of t h e

metal
metal.
method

is being extracted and also on the properties of the

Thus it
for

is n o t p o s s i b l e t o

chalk out a universal

extraction of all the metals. Consideration the

Note:

extraction

magnesium metal from magnesite is beyond the scope of this

study.
2.2.6:

REFRACTORIES

These
temperature

are

substances

which

can

withstand

high

in the furnace without melting and does

n o t react
Chromite

with t h e
(FeO

material poured in it. $Alumina ( A 1 2 0 3 ) ,

(Mg COj) , T i t a n i a
(TiOZ) ,

Cr203), Magnesite (Si

C ) ,

Carborundum

Zirconia

(Zr02) are t h e important

refractory materials. 9

The

refractory

industry

consumes

90-95%

of

magnesite production Nagpur)

in India

( ~ n d i a nmineral

year books,

.
CALCINATION Calcination

2.2.7:

is t h e process of

heating

the ore

lightly.

It does the following things.

i) It removes the volatile impurities like c a r b o n

di-oxide (C02), matter, moisture etc., from the ore.

ii)
iii)
Magnesite

It removes water from the hydrated oxide ore.

It removes C02 from a carbonate ore. 10 is heated

lightly

to

get

calcined

magnesite,
Mg C o g
Sintering

Calcination MgO + C 0 2 . ---------- > refers t o h e a t i n g of the o r e at a very

high temperature range of 1600

sintered at a
dead

2 0 0 0 ~ C.

Magnesite

is

temperature range of 1600

1800

C to get

burned magnesite.

(Sintering i s also called calcining

in usage)

INDUSTRIAL MINERAL

It
an

is

term of t h e trade only. A .mineral to

satisfy the following:

be

industrial mineral must

(i) the

nature of t h e substance m u s t be inorganic, available in

must
a

(ii) it must be

combined state,

(iii) one or more metals

(iv) some

be

extracted

from

it, profitably, and

other

products must

also be produced from it.

conditions, it
is

As magnesite
industxial

sqtisfies

a11 these

an

mineral.

Other

industrial minerals

are

alurnina(Al2O3.2H20)
(l?e304), hematite

carnallite (Fe203),

(KC1-Mg C12.6H20),

magnetite

siderite(Fe GO3) , etc.

2.3:

MAGNESITE FAMILY Though t h e raw magnesite has no much use as

such.

The

various

products produced from magnesite have various

uses.

Hence from

it is essential to know t h e various products

magnesite.

produced
be called

These products may collectively

"rnagnesite family". Chart 2.1 given on next Rage will give clear picture a b o u t the magnesite family.

2.3.1:

SEPARATION O F MAGNESITE FROM SOIL

Magnesite
drilling and

bearing

earth

is

first

loosened

by

blasting.

The run-of-mines

is separated into

raw

magnesite

(also called crude magnesite) and spoils by

the

method of

hand picking. Spoils are nothing but the soil

and rocks

which

are

obtained along with the

magnesite.

Spoils

are w a s t e and hence have no use.

2.3.2:

GRADING O F MAGNESITE

The magnesite ore is chipped and dressed by hand to

get rid

of the surface impurities associated with lt.

is then
graded

The
non-

raw magnesite

into

refractory

and

refractory grades by visual appearance and they are stacked

separately.

2.3.3:

MAGNESIUM METAL

Magnesium
magnesite
methods.

can
by

be

obtained

from by

the

calcined reduction

either

electrolysis

or

thermal

''

2.3.4:

REFRACTORY GRADE OF MAGNESITE

The

refractory grade magnesite is ased to

Magnesite

produce

DBM and CCM.

is calcined at a sufficiently high

1800
O

temperature ( 1600 from

called

hard

C ) to drive of the C02 and to

dense, periclase,

crystalline variety

of

magnesia,

which reacts neither with C 0 2 nor w a t e r

at

ordinary temperatures.

This

MgO

is

called

'Dead-

burned
700
O

magnesitef (DBM) 12
to
1000
OC

T h e raw magnesite fired at a more

produces

porous

and

reactive

material known

as

Caustic Calcined Magnesite (CCM). l 3 The

refractory grade magnesite is used only for these purposes.

The
DBM

is used to produce ramming mass, gunning

mass
and

mass,f ettling
chemicals produce

refectory

bricks.

Different
to

in different

proportions

are

added to DBM

these products.
They

These

products

are

called

monolithics.
chemicals added

are produced depending

DBM
by simple

upon
process

the
of

to

production

crushing. Refractory different chemicals mixture Caustic

bricks
are

manufactured

by

mixing

and

additives to DBM and passing the stages

of production

through different

process.

calcined magnesite,
and simply

also called lightly calcined called

calcined magnesite is

magnesite (LCM)

used as

such

in many industries for various purposes.

2.3.5:

NON-REFRACTORY GRADE OF MAGNESITE

The
and used

non-refractory
by

grade magnesite is When

pulvarised
the

some industries as such.

non-

refractory grade magnesite is calcined at a temperature range

of 700'

~OOOOC,

it

also

gets

converted

into

caustic

calcined magnesite. But this product will be of lower quality than the one obtained from calcining

refractory grade

magnesite; hence the use of this calcined magnesite will also differ.

2.3.6:

IMPROVING THE QUALITY OF LOW-GRADE MAGNESITE The quality o f low-grade

or

magnesite c a n be

improved
The
called

by physical
magnesite thus High

chemical beneficiation methods. converted

into high quality,

is

Q u a l i t y Sinter Magnesia (HQSM). This HQSM can be used

-a

to

manufacture high quality refractory bricks.

Thus

the

magnesite metal,

family
calcined

consists

of

raw
DBM,

magnesite, magnesium

magnesite,

ramming

mass,

gunning mass,

fettling mass,

refractory

bricks, HQSM, etc., Note:

(i)

The use of the various magnesite products

are explained latter in this c h a p t e r .

(ii)
into refractory and

The process

of separation of magnesite

non-refractory grade and the production

process
have been

of

the various products of the magnesite family

explained in detail in the c h a p t e r o n 'Mining and

Production'.

2.4:

PROPERTIES OF MAGNESITE

The

raw

magnesite

has

both

physical

and

chemical properties. An account of these properties are given below:

2.4.1:

PHYSICAL PROPERTIES
The
following

are

the

physical

properties

of

magnesite.

(i)
to

COLOUR: The colour ranges from chalk white

and

grayish

white

pinkish

white

and

sometimes

takes

greenish or brown colour.

(ii) HARDNESS: Varies from 3.5 to 5 in the Moh's

s c a l e . 14

(iii) SPECIFIC GRAVITY:

ranges

The

specific

gravity

from 3.0

to

3.12

15.

It is comparatively a

light

mineral. 16

(iv) 'LUSTRE: The lustre of magnesite ranges from

earthly dull in
the case of amorphous variety to vitreous in

crystalline variety. l7

(v)

STREAK

: White. l8

(vi) CLEAVAGE : Perfect. l9 (vii) FRACTURE: ~ o n c h o i d a l

(viii) STATE : Solid state

.
HABITS: Trigonal,

(ix)

CRYSTAL

SYSTEM

AND

rhombohedra; massive, fibrous, granular, compact. 21

( x ) QUALITY : I t i s h e t e r o g e n e o u s in quality.22

2.4.2:

CHEMICAL PROPERTIES The

chemical properties of raw magnesite are very

much limited but t h e calcined magnesite has many chemical

properties.

Hence here we

give the

important
the

chemical

p r o p e r t i e s of
magnesite in

r a w magnesite and t h a t of

calcined

t h e appropriate place.
( i)

CHEMICAL

COMPOSITION:

The

chemical and

composition of magnesite varies

from place
give

to place

hence

it

is not

possible

to

general

chemical
grade

composition of magnesite.
rnagnesite
treated
for
23

However,

the usual

of
the

calcination will

contain

following composition,

A1203

CaO

(ii) MELGING POINT: Around

2800'

C.

24

(iii) HEAT CONDUCTIVITY: Very low.

2.5:

FORMATION, OCCURRENCE

AND STRUCTURE

Magnesite

is

formed in different ways.

It

occurs

in different

varieties

and

the structure

of

magnesite

also varies from variety to variety.

2.5.1:

FORMATION OF MAGNESITE

Magnesite

is found in nature u s u a l l y as secondary i) alteration of ultramafic rocks Salem, and

deposit formed due t o

(mostly serpentine)

as is found in Chalk hills,

Dodkanya in Karnataka; ii) replacement deposit in carbonate rock as found in Almora(U.P)

in dolomite rock; iii) bedded

deposits as found in Manchuria and South

a vein
based
are

Nevada; and i v ) as
four varieties of

Thus

there

are

magnesite
deposits

on

the process of formation. commercial mainly bedded in (i)

found

to

( i i i ) types

of

deposits. In India,

or

vein filling deposits have

not been located. 2 6

2.5.2:

OCCURRENCE OF MAGNESITE
Magnesite has three modes of occurrences as d e s c r i b e d limestone

below:

dolomite

(Ex.Washington, Austria, Manchuria,

Czechoslovakia,

and

Quebec) ; (ii) veins

(Ex.California, Greece, India, Russia,

Yugoslavia and Nevada) ; (iii) sedimentary beds (Ex.Nevada) .2 7 The' replacement deposits

yield

the

crystalline

variety and (rarely

have resulted from progressive r e p l a c e m e n t

complete)

of

lime

stone

or

dolomite

by

Mg

C03

through hydrothermal solutions, This forms bedded deposits, lenslike or irregular generally contain in shape and of

l a r g e size. They

some ferrous iron. 28

The veins contain t h e hard amorphous variety

and

occupy

fractures

of crushed zones in serpentine or

ultrabasic

rocks.

They

result

from

the

breakdown

of

serpentine by

hydrothermal solutions, accompanied by the

forms opal or chalcedony. 29

release of silica, which

The sedimentary 'depositsare probably formed

by evaporation
and

but

they are so interbedded with

dolomite

other rocks to make their extracting unprofitable. 30

STRUCTURE OF MAGNESITE

2.5.3:

There

are

three

kinds
(ii)

of

magnesite,
'

namely,
(iii)

(i)

cryptocrystalline

crystalline,

and

amorphous.31.

This classification is on the basis of t h e

structure af magnesite.
Magnesite

is

formed

by the

alteration

of

dolomitic limestone with the intrusive are the

by magnesium-bearing solution associated rocks. The crystalline varieties

products of such alterations.
of

magnesite
crypto

The

crystalline varieties are the products of alteration

of serpentine and of similar

magnesium bearing rocks.

Magnesite of this

type

is found extensively in an area

where there are serpentine rocks and or in the sheer-zones

it occurs in fissures

thoroughly mixed' up with serpentine,

chalced ony.32 Magnesite resulting

along with some opal and

f r o m the alteration of nature. 3 3

serpentinous rock is amorphous in

2.6:

EFFECTS OF IMPURITIES

The

magnesite is associated with various' objectionable

of

constituents, called impurities, like silica in the form talc, iron

below.

lime in the form of calcite, lime-stone

as

dolomite

and

~ederite.~* The effects of

impurities are

given

2.6.1

SILICA AND LIME

Silica and lime form fluid silicate with relatively low melting bricks point and greatly reduce the strength of
they

magnesite
silica
as

in which

are present.

When

much

is

present,

dicalcium

silicate (2Ca0

SiOZ)

forms and

this
whole

disintegrates

on cooling, it tends to break down

the

mass. Magnesium calcium silicate containing 20% of magnesium,

30%

of lime and 50% of silica has a melting point of

1 3 5 0 ~ ~

only.3 5

High silica in magnesite causes ring or wdll (rotary) resulting in chocking.

formation inside the kiln Keeping silica

under control is the major problem for the

magnesite industry. 3 6

At present, selective

the silica in

magnesite manual

is

controlled

by

mining,

efficient

dressing, crushing and screening.

The

silica

present

usually

forms

much

less

refractory product with any lime or iron oxide present. However, a small proportion of lime is considered favorable

as

without

it, magnesium
is

ferrite

is not readily

formed.

When
with

dicalcium ferrite

formed. It produces an entectics

magnesia which melts at 1 3 8 0 ~ ~ that the whole mass so

below 1 4 0 0 ~ ~When a mixture of .

can sinter at or slightly

magnesia

and

iron oxide is heated

to

1 5 0 0 ~ ~ - 1 5 5 0 an , ~~

entectic melting at that temperature the silicates which

is

formed.

his and

are molten at this temperature farm a assisting,

viscous fluid which instead of

hinders

the

formation
2.6.2:

of

crystals

of periclase. 37

I R O N OXIDE

The

presence

of

iron

oxide

is

not

regarded

commercially as an impurity because rnagnesite which is almost

free from iron oxide is very difficult t o sinter. If this is

present in the
flux

range of 2 to 4 % ,
thus

it a c t s * a s a convenient
sintered product.
If

and

can

produce

well

present in

large percentage, it is undesirable because it refractoriness of the product. 38

reduces t h e

2.7:

SPECIAL FEATURES OF MAGNESITE

In this section,. s o m e of
magnesite are given.
2.7.1:

the s p e c i a l

features

of

PURITY
The

purity of magnesite is decided on the

basis

of

its silica content. If the silica content is more, t h e

magnesite

is not pure. On the otherhand, if it is less, then

is said to be pure

the meterial

(ie, of high grade)

The

Chalk Hills

rnagnesite (Salem dt., TN) is said to be of

high

grade compared to Alrnora (U.P ) magnesite. 3 9

2.7.2:

PURIFICATION

When

the raw magnesite is heated, the carbondioxide

in it goes out; but the silica does not decompose. Silica can
be reduced only by physical or chemical benefication

of the

raw magnesite. When silica cantent is reduced, the purity of

the magnesite is improved/increased.

2.7.3:

VARYING TEMPERATURES

The varies

temperature

range to produce

CCM the

and
input

DBM

according

to

the quality

of

raw

magnesite. the raw output

2.7.4:

The temperature r e q u i r e d is determined by testing

magnesite

in

the

chemical l a b o r a t o r y to give the

at

a desired level of purity.

HEATING

EFFECTS OF MAGNESITE
When

ON

CHEMICAL

PROPERTIES

OF

raw

magnesite

is heated
When

around

8 0 0 ~ it ~

becomes

f r e e from carbondioxide. heated

the magnesite
tr

is

further
stronger.

to

1 6 0 0 ~t h e ~ m e t e r i a l ~

becomes

more

In

calcination,

t h e r e is a slight possibility of properties whereas

the presence

of

some chemical

in

sintering t h e meterial

(DBM) becomes i n e r t .

2 - 7 . 5 : NO EFFECT ON FURTHER HEATING

Once t h e magnesite

is heated

and

cooled

down,

it

becomes inactive

and
So of

hence it will not get any

effect

on

further heating.
temperature range

calcined magnesite,
700

obtained at

1 0 0 0 ~ a n n o t be used a s t h e c~

input

in

t h e manufacture of DBM, which

is obtained at a

temperature
2 ..7.7:

range 1400

OF

1600~~.
DOUBLING

THE PROPERTY CALCINATION

Magnesite

OF
Mg,

SILICA

(Si02)
SiOz,

IN

i s a compound of

CaO,

FeO,

A1203, C02 e t c . Of these elements, C 0 2 is a g a s s i o u s element

whereas the
others are solids. When magnesite i s h e a t e d , the

silica content

(the

impurity which determines the quality This

of can

the magnesite)

gets doubled in proportion t o MgO.

be understood from the following:

Let

t h e Si02 c o n t e n t

i n the r a w magnesite

be

6%

( i . e ) 100 grams of magnesite contains 6 grams of S i O Z .

Let

l o s s on i g n i t i o n ( L O 1 ) be grams

5 0 % ~(usually

it is
grams on
8

49-52%).

When

raw magnesite

heated,

and
i g n i t i o n and

other impure gases w i l l escape due t o lass hence after heating the weight
will

of the c a l c i n e d

magnesite

be around 50 grams o n l y . A s silica i s a solid, it

will
silica

not decompose upon h e a t i n g . Hence the same 6 grams of

will
(i,e)

remain with t h e calcined magnesite, even after

heating
6

in

the quantum of 50 grams of calcined

magnesite,
the

grams

of silica w i l l b e p r e s e n t . I n otherwords,

silica

content

in the calcined magnesite expressed as a

percentage

will be 12. This means t h a t t h e portion of silica in calcined

magnesite has doubled compared t o that of r a w r n a g n e s i t e .

In

DBM

also, the presence

of silica shall be the

same (doubled) as i n the case of calcined magvesite, because,

when h e a t i n g i s increased t o 1600c, n o t h i n g goes out except

that the meterial becomes s t r o n g e r .
This

i s further confirmed from the following:

l1While
SiOZ

manufacturing
content

t h e high

g r a d e basic

refrectories,
The

should be resonably low in DBM.

IS1

has

prescribed that the S i O ,

c o n t e n t i n DBM and m a g n e s i t e

bricks

should not exceed 5.5%. In order t o achieve this requirement,

the raw magneslte should not contain more than 2.5% S i 0 , l 1
40

2.8:

USES OF MAGNESITE PRODUCTS

The
below:
2.8.1:

uses

of

various

rnagnesite

products

are

given

R A W MAGNESITE T h e r a w r n a g n e s i t e -has t h e following applications.

(i) On addition of sulphuric acid, it forms magnesium

sulphate,
commonly known as epsum saltf

Epsom salt i s

used i n t h e manufacture of

artificial silk, tanning and in

pharmaceuticals.
about

Each kilogram of rayon produced

consumes

5 kgs of epsom salt. 42

(ii)
the

Pure

magnesite

free from iron is used

in

glass i n d u s t r y to control the viscosity and improve the

workability of t h e glass.43

(iii) R a w
industry

magnesite
the

is

used in the

electrode

t o protect

molten metal from aerial exidation

44

by

way

of forming slag and layer of C02.

(iv) Raw magnesite is used as a constituent of

vitreous
industry. 4 5
(v) to
The paper and pulp industry uses magnesite

enamal

frit

and

ceramic

glaze

frit

in

ceramic

produce magnesium bi-sulphate -

which acts as cooking

is used

liquor. 46

(vi)

High grade raw magnesite

in the

pharmaceutical industry.
(vii) Raw

magnesite

is used

as

a very

good

filler

agent

in many p r o d u c t s .
chips of
of low grade magnesite are

(viii) Small
used

in

the manufacture

mosaic

tiles

to

give

attraction

to

the floor.47 ,

2.8.3 : CAUSTIC CALCINED MAGNESITE (CCM)

CCM

is

useful

for

the

following
CEMENT
:

purposes:

(i) MANUFACTURE O F SORE

discovered by Sorel
material. 49

Sorel

cement,

in

1867,

requires magnesia as a raw

a strong

W h e n pulverised CCM is treated with

solution
magnesium

of

magnesium

chloride,

sore1

cement, cement

called

oxychloride,

is obtained.

This

expands

very slightly after setting. It appears to be warm in

as

in touch

cold weather; it is also noiseless

and

therefore used

flooring material in hospitals, hotels,

ships

and

docks, It is flexible, durable, non-shrinking and dustless.5 0

This

cement

is

used as wood

preserver,

particularly manufacture

for of

railway grinding

sleepers. stone

It

is also used in

the

and abrasive wheels, Emery powder

is

mixed

carefully
abrasives.

with sore1 cement for manufacturing durable

(ii) FERTILIZER
fertilizer. It

CCM

with

90% MgO

is used in

increases crop

production. Usually magnesia

alone is not added to

the soil, but it is introduced in the

as

soil along with constituent

of

superphosphate,

chemically balanced

complex fertilizer 51
: CCM is very

(iii) PAPER

useful in manufacturing

paper pulp from wood and bamboo. It is capable of p r o d u c i n g

high quality p a p e r ,

For
magnesia

the

manufacture of cigarette papers,

is considered as an excellent ingradient for

harmless smoking.

(iv) GLASS

By virtue of its chemical purity,

of colourless and

it is suitable for the manufacture

scientific glassware.

It

improves the chemical resistance

of the finished product. It is also used as opacifier.

( v ) RUBBER
powerful accelerator in increases resilence

It is used

extensively
of

as

the manufacture

rubber. It

and

tensil strength. It acts as a

rubber manufacture. It is

curing agent in the process of

also used for the manufacture of synthetic rubber. It is very much perferred for hard rubber moulding. (vi) CHEMICALS : It is used in the manufacture of

magnesium based chemicals.

(vii) AEROPLANE
: Because

of

lightness and

strength of the magnesium alloy, it is

being increasingly

used in the manufacture

(viii) R I C E

of

aeroplane parts. 5 2
: Magnesia

MILLS

cement

is used in

rice mills

in

conjunction with

emery powder for hulling

and polishing the rice. 5 3

(ix) PHARMACEUTICALS
number of

: Magnesia

is . used in a

medical

preparations such as magnesia pondezosa

(heavy) magnesia levis(1ight)

and milk of magnesia. 54

:

( x ) COSMETICS
preparation of cosmetics.-

It

is

alss

used

in

the

(xi) STEAM PLANTS

incorporated with producing a asbestos in

: Lightly calcined magnesia is

boiler

lagging compositions,
which greatly

permanent

and efficient covering

improves the thermal it is applied.55

efficiency of any steam plant to which

(xii) PLASTICS:
produced by
a

High

purity

(99% MgO) magnesia

chemical d i r e c t

acidification process is

used in

elastomer

plastics and thermo plastics to impart

flame retardent properties. 5 6 (xiii) ANIMAL FEED: Caustic calcined magnesia is used in the preparation

of animal feed.
: Magnesia powder

(xiv)

A S A POLISHING MATERIAL

is used as a polishing material in preparing metallurigical

and ore-mineral
test pieces

examined

under

the relfecting

microscope.

2.8.4. DEAD BURNED*MAGNESITE (DBM)

The principal use of rnagnesite is in the manufacture

of refractory
When DBM

material which is used for furnace

lining.

is mixed w i t h c h r o m i t e i n different proportions,

(depending upon the

chrome-mag bricks and mag-chrome bricks

ratio of magnesite and chrome) are manufactured.

DBM
basic slags

is desired chiefly as a basic refractory in metallurgical furnaces, for kiln and for

for use

with corrosive materials.

industrial processes,

It is most an

suited

for use

in

where

acidic

reaction

is

undesirable. 57

It

is an ideal mineral

for manufacture of

super duty basic

refractory bricks.

Magnesia

bricks are used

for b o t t o m s
steel

and

sides of

furnaces

employed

in

iron

and

industries;

the

construction of bottom and side walls of electric furnaces;

the

construction of refining furnaces for gold, silver, and the construction

platinum;

of

melting

furnaes

for

lead,

antimony and
high

copper; all other construction furnaces where

temperatures and high resistance to metalic o x i d e s and

slags are required; and covering fire clay bricks. 58

2.8.5:

FUSED MAGNESIA

Fused

magnesia

is manufactured

by

fusing

pure

calcined magnesia

in

a high temperature electric

2550

furnace

within
product

a temperature range of looks like point to

of

3 0 0 0 ~ ~ The .

fused

the normal mineral periclase, which has

2 8 0 0 ~ ~ . The

fusion

product

is

highly

resistant

chemical changes

which

take place

in

metallurgical furnace at

high temperatures. It is used in

t h e s h a p e of m o u l d e d

vessels

and

also

as

compressed

material during the melting operation

and

of non-ferrous metals
and

alloys

such

as

lead,

copper,

zinc

tin.

Fused and

magnesia

bricks can withstand very high

temperature

hence used extensively in alloy steel

manufacture and non-

ferrous metal refining f u r n a c e s .

It is commonly

used

for

immersion
annealing

heaters,
chamber

resistance elements, laboratory-wave 59

melting

pots,

and

Due t o t h e non-availability

of h i g h

temperature

electric furnaces

in India, fused magnesia

is not produced

and hence imported for our metallurgical industries. 60

2.8.6:
RFiMMING MASS

As already stated, ramming mass i s produced

from DBM

by mixing some chemicals and then crushing the mixture.

It

will be of coarse variety after crushing. I t i s used a s the intermittant binder between two bricks in

the construction of
of
the

the k i l n w i t h the magnesite bricks. After the construction of the kiln,

the walls

a thin coating is given on the inside surface

of

the kilns with ramming mass t o

make

surface uniform. FETTLING MASS

Fettling

mass

is

finer

in variety than

ramming

mass.When the furnace is put into operation, due to wear and

tear, patches may occur on the inner surface of the w a l l s . To set-right these patches, the kiln o p e r a t i o n
cannot
be

stopped b e c a u s e ,

it will result in loss of production and

high
paste

cost in f u e l consumption. Fettling mass is made into

form by

adding water

and

then

it is thrown on the
with
shavels, The

patches

through the outlet

of

the kiln

chemicals mixed with the DBM

the sticking property

to produce fettling mass have

and hence

when thrown on t h e patches,

it immediately
almost uniform.

sticks

on the walls and makes the surface

2.8.8:

GUNNING MASS
When

the

patches

on

the

i - n s i d e walls

of

the

kiln

could not used,

be set r i g h t with f e t t l i n g mass, g u n n i n g mass

is

Gunning mass is finer i n variety. It c a n b e m i x e d w i t h

w a t e r easily.
A special equipment called air-gun

is used t o

spray t h i s
hung f r o m

mixture on t h e patches. The e q u i p m e n t i s made

the

to
to

t o p of t h e kiln and t h e m i x e r is allowed

the

f l o w through
the

equipment when operated. T h e

be

position
of

of

equipment

may

adjusted

with t h e

help

crane.

Powerful b i n a c u l a r

i s - u s e d t o l o c a t e t h e patches

and then

the

equipment

is p l a c e d in t h e p r o p e r position so that when

sprayed, t h e
right.
that

m i x t u r e w i l l s t i c k on the p a t c h

and

make

it

Thus gunning

mix is used to s e t right all patches

occur Note:

on t h e surface of t h e i n n e r s i d e of the kiln.

(i) Ramming mass,

fettling

mass

and

gunning

mass

a r e g e n e r a l l y called 'monolithics'.

( i i ) They m a y

also

be

called

ramming

mix,

fettling mix and gunning mix, respectively.

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Madan

R.D., Modern Inorganic Chemistry, S.Chand Company., (P) Ltd., New Delhi; 1987, P.753.

and

Sinha

R.K, A Treatise on Industrial Minerals

of

India,

~ l l i e dpublishers ( P ) Ltd, Bombay, 1969, P.383.

Venkatesh.V., Status note on the Magnesite deposits and occurrences of Tamil Nadu, Handbook on Magnesite, TANMAG, Salem, 1985, P.1.

Britanica ~ u n i o r Encyclopedia Venkatesh, V. Op. Cit, P. 1.

Madan R.D. Op. Cit, P.753.

10/M, P.206.

Britanica Junior Encyclopedia, Op, Cit, P.210.

Madan R.D. Op. Cit, P.756.
ibid, P.977.
i b i d , P.758.

ibid, P.918. Kuriacose, J.C., and Rajaram J, Chemistry in Engneering and Technology, Volume 2, T a t a - M c G r o w Hill Publishing Company Ltd., New Delhi, 1984, P.609. Gopal,V., Magnesite Industry in Tamil Nadu, Magnesite, Tanmag, Salem 1985. P. 90. Handbook

on

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IBH

Whitten DGA, and Brooks JRV, A Pengion Dictionary of Geology, Penguin Books, Great Britain, 1974, Appendix.
ibid, Appendix

20.
21.

ibid, Appendix
ibid, Appendix

22. 23.

Hariharan,M., Some observations of a field geologist. Handbook on Magnesite, Tanmag, Salem, 1985, P.54. Sinha R - K . ,
Op. Cit, P ,
386.

24. 25.
26. 27.

Hariharan, M. O p . Sinha R.K.,

ibid, P .

it, P.

53.

Op. Cit, P.

383.

383.

Bateman, Alan M., ~conomic Mineral Publishing House, Bombay, 1962, P. 724.
ibid, P. 724.

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28.

29.
30.

ibid, P. 724. Jenson M.L*, Deposits, John

P.516.
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and Bateman A.M., Economic Wiley and sons, New Yark, 3rd

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31.

S.,

Op. Cit, P. 340.

32.

ibid, P.344. Sinha R.K.,

Op.

33.

Cit, P.353.

34.

Monograph on Magnesite, Op. Cit, P.6

ibid, P . 6 .
Tayb,
M.A.K.,

Handbook on

Magnesite,

Tanmag,

Salem,

1985, Preface.

Monograph an ~ a g n e s i t e ,Op. Cit, P.7. ibid, P.7,

An

Account of Salem Magnesite Deposits, Company Ltd., Salem 1981, P. 3.

Burn

Standard

A11

A c c o u n t af Salem magnesite, O p .
Op. Cit, P ,
385.

Cit, P.

2.

Sinha R.K.,

Monograph on Magnesite, O p .
ibid, ibid, ibid,

Cit, P . 5 .

P.4,
P.4.

P.4. Op. C i t ,

sinha R . K . ,
Dep,
ibid,
S.,

P. 387.

Op. Cit, P. 344-345.

P.342.

J e n s o n M.L.,
Dep,
S.,

a n d Bateman A . M . ,

Op.

Cit,

P.

516.

Op. Cit, P. 341.

Cit,

An Account of Salem Magnesite, O p .

ibid, ibid,

P.4.

P.4.

P.4.

ibid, P.3.
Gerry
Clarke,'

i n s o f t markets

Magnesia around t h e w o r l d - ( H a r d t i m e s again ) ',Industrial M i n e r a l s , Monthly,

London, A p r i l 1 9 9 2 , P.53.
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Cit,

P.5.

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Dep,

Khanna

S.,

Op. Cit, P. 342.

sinha R.K.,

Op. Cit, P. 386.

An Account Of Salem magnesite, Op. Cit, P.5.