FIRECLAY

Indian Minerals
Yearbook 2014
(Part- III: Mineral Reviews)

53rd Edition

FIRECLAY

(ADVANCE RELEASE)

GOVERNMENT OF INDIA
MINISTRY OF MINES
INDIAN BUREAU OF MINES

Indira Bhavan, Civil Lines,

NAGPUR – 440 001

PHONE/FAX NO. (0712) 2565471

PBX : (0712) 2562649, 2560544, 2560648
E-MAIL : [email protected]
Website: www.ibm.gov.in

December, 2015

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 FIRECLAY

20 Fireclay
PRODUCTION, STOCKS & PRICES
T he name fireclay is given to a group of refractory
clays which can withstand temperatures above
pyrometric cone equivalent (PCE) - 19. Refractoriness
The production of fireclay at 707 thousand tonnes
in 2013-14 decreased by 29% as compared to that in the
and plasticity are the two main properties needed in
previous year due to heavy rain, lack of demand and
fireclay for its suitability in the manufacture of refractory
closure of some mines for environment clearance.
bricks. A good fireclay should have a high fusion point
(>1,580o C) and good plasticity. Fireclay containing high There were 52 reporting mines in 2013-14 as
alumina and low iron oxide, lime, magnesia & alkalies is against 74 mines in the preceding year. Besides these
preferred by refractory manufacturers. The aluminous principal mines, the production of fireclay was also re-
(kaolinitic) variety of fireclay is more refractory because ported as an associated mineral by 17 mines, which
of its hardness and density and absence of iron, giving accounted for about 22% of the total production during
it a white-burning colour. The absence of alkalies gives the year 2013-14. Nine principal producers contributed
it a very high fusion temperature. 74% of the total production. Twenty four mines includ-
ing 8 associated mines each producing more than 5,000
RESOURCES tonnes annually accounted for about 88% of the total
India possesses substantial reserves of fireclay. production. Private sector mines reported 99% output
The best deposits occur in association with the coal of fireclay.
seams in the Lower Gondwana Coalfields of Andhra Rajasthan continued to occupy the first position
Pradesh, Jharkhand, West Bengal, Madhya Pradesh and among states with contribution of 44% followed by Tamil
Neyveli lignite fields in Tamil Nadu. Notable occurrences Nadu (23%),West Bengal (14%), Madhya Pradesh (7%),
of fireclay, not associated with coal measures, are Gujarat (6%), Andhra Pradesh (4%), Karnataka (2%) and
reported in Gujarat, Jabalpur region of Madhya Pradesh nominal production was reported from Maharashtra
and Belpahar-Sundergarh areas of Odisha. The reserves (Tables - 2 to 5).
of fireclay are substantial but reserves of high-grade The mine-head stocks of fireclay at the end of the
(non-plastic) fireclay containing more than 37% year 2013-14 were 305 thousand tonnes as compared
alumina are limited. to 429 thousand tonnes at the beginning of the year
Reserves and resources of fireclay as per UNFC (Table - 6).
system as on 1.4.2010 are estimated at 713.5 million The average daily employment of labour during
tonnes. Out of these, 30.1 million tonnes are grouped 2013-14 was 500 as against 777 in the preceding year.
under reserves category while the bulk, i.e., Domestic prices of fireclay are furnished in the General
683.4 million tonnes are classified under resources Review on 'Prices'.
category. Out of 30.1 million tonnes reserves, 14.4
million tonnes are proved reserves and 15.7 million MINING AND MARKETING
tonnes are probable reserves. Out of the total resources,
Odisha accounts for 24% followed by Madhya Pradesh Practically, all the fireclay mines are worked
(17%), Tamil Nadu (16%), Jharkhand & Rajasthan (9% manually. Most of the mines are small and worked by
each) and Gujarat (8%). Gradewise, refractory-plastic opencast method by forming benches in overburden
grade accounts for 36% followed by refractory- and fireclay. Most of the refractory manufacturing units
unspecified (16%) and refractory-non-plastic/semi- have their own captive mines.
plastic (15%). The remaining 33% are of others, The important marketing centres of fireclay are
unclassified and not-known grades (Table-1). Mahuamilan and Balumath in Jharkhand, Than in
Gujarat, Katni in Madhya Pradesh and Belpahar in
EXPLORATION & DEVELOPMENT Odisha. Water seepage beyond the depth of
6 m is the main problem commonly faced by most of the
No exploration was carried out during the year mine owners and as a result of which most of the mines
2013-14 by any Central/State govt. agencies. are kept closed during rainy season.
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 Table – 1 : Reserves/Resources of Fireclay as on 1.4.2010
(By Grades/States)
(In '000 tonnes)

Reserves Remaining resources

Total
Grade/State Proved Probable Total Feasibility Pre-feasibility Measured Indicated Inferred Reconnaissance Total resources
STD111 (A) STD211 STD331 STD332 STD333 STD334 (B) (A+B)
STD121 STD122 STD221 STD222

All India : Total 14,376 7,358 8,371 30,104 10,020 19,215 21,775 47,666 54,377 529,173 1,190 683,415 713,519
By Grades
Refractory-non-
plastic/semi-plastic 2,914 390 1,337 4,642 3,959 11,953 1,743 807 1,180 86,235 - 105,876 110,518
Refractory-plastic 2,801 1,165 1,253 5,220 719 3,656 2,934 4,241 4,527 238,860 232 255,168 260,388
Refractory-unspecified 7,240 3,990 4,945 16,175 4,743 3,208 5,244 1,115 2,658 79,233 - 96,201 112,377
Others 580 1,664 542 2,786 579 204 1,920 7,236 4,137 45,096 125 59,297 62,084
Unclassified 704 17 293 1,013 - - 5,097 59 30 5,679 - 10,865 11,878
Not-known 137 132 - 268 20 195 4,837 34,206 41,845 74,070 833 156,006 156,275

By States
Andhra Pradesh 548 647 381 1,576 50 735 1,314 56 908 18,444 132 21,638 23,214

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Assam - - - - - - - - - 3,161 - 3,161 3,161
FIRECLAY

Bihar - - - - - - - - - 44 - 44 44
Chhattisgarh - 23 12 35 - 27 - 7,180 3,400 10,336 - 20,942 20,978
Delhi - - - - - - - 6 13 45 - 64 64
Gujarat 276 29 132 437 1,175 635 923 638 962 53,526 - 57,859 58,295
Jharkhand 828 - 775 1,602 12 479 125 - 249 64,151 - 65,017 66,619
Karnataka 95 324 85 503 792 595 6,871 - 226 5,250 - 13,734 14,238
Kerala - - - - - - - 8,200 51 9,929 - 18,181 18,181
Madhya Pradesh 2,167 2,026 269 4,462 829 3,747 5,690 1,582 2,823 101,081 100 115,852 120,314
Maharashtra 244 - 388 632 - - - - - 6,850 - 6,850 7,482
Meghalaya - - - - - - - - - 10,999 - 10,999 10,999
Odisha 581 278 52 911 2,135 11,280 3,774 26,185 42,747 83,045 - 169,166 170,076
Rajasthan 8,543 659 5,000 14,202 195 1,071 583 2,256 2,580 45,536 - 52,221 66,423
Tamil Nadu 322 3,269 423 4,014 4,833 171 1611 1,561 - 102,069 - 110,244 114,258
Tripura - - - - - - - 1 - 369 - 370 370
Uttar Pradesh - - - - - - - - - 3,221 - 3,221 3,221
West Bengal 771 104 854 1,729 - 476 883 - 419 11,115 958 13,852 15,581
Figures rounded off.
 FIRECLAY

Table – 2 : Principal Producers of Fireclay, 2013-14 Table - 2 (Concld.)

Location of mine
Location of mine
Name & address of
Name & address of
producer State District
producer State District

Sampat Lal Daga, Rajasthan Bikaner Firoz Musabhai Kaladiya, Gujarat Surendranagar
Labuji Ka Katla, 1st Floor, C/o Musabhai Ismailbhai,
Bagree Mohalla, Kaladia, PO.Chotila,
Bikaner-334 001, Fulwadi, Thangadh Road,
Rajasthan. Surendranagar-363 530,
Gujarat.
A.Abdullah, Tamil Nadu Ariyalur
No.10/108, North Street,
T.Pottakollai.Z.Thathanur, Sunder Lal Daga, Rajasthan Bikaner
Udayarpalayam -621 804, Bagree Mohalla,
Distt. Ariyalur, Bikaner-334 001,
Tamil Nadu. Rajasthan.
Saurabh Chandana, Rajasthan Bikaner
Rathkhana Colony, Birbhum Kaolin & Allied West Bengal Birbhum
Bikaner - 334 001, Industries (P) Ltd,
Rajasthan. 19, Block -1, Pannajhill,
Barrackpur Road,
Prism Cements Ltd, Tamil Nadu Perambalur Barasat-700 125,
305, Laxmi Niwas Apartments, Distt. 24 Parganas North,
Ameerpet, West Bengal.
Hyderabad-500 016,
Andhra Pradesh
Smt.Arunachalam Saradha, Tamil Nadu Perambalur
45, Malvai Road,
Patelnagar Minerals & West Bengal Birbhum
Industries (P) Ltd, Dalmiapuram,
20-B,Abdul Hamid Street, Lalgudi-621 652,
(Formerly British India Street,) Distt. Tiruchirapalli,
Kolkata-700 069, Tamil Nadu.
West Bengal. (Contd.)

Table – 3 : Production of Fireclay, 2011-12 to 2013-14(P)

(By States)
(Qty in tonnes; Value in ``’000)

2011-12 2012-13 2013-14(P)

State
Quantity Value Quantity Value Quantity Value

India 983155 158016 999925 182739 706639 159859

Andhra Pradesh 55578 10103 49478 10512 31686 7178
Chhattisgarh 3423 856 2570 643 - -
Gujarat 120266 9338 86316 6602 39555 2842
Jharkhand 85819 14895 111594 17151 - -
Karnataka 5184 1428 16307 10000 13966 7808
Madhya Pradesh 66823 7894 71226 12671 45852 9746
Maharashtra 9512 1284 7547 1132 4670 701
Rajasthan 447615 88291 410331 87771 313927 88028
Tamil Nadu 106512 15953 145468 19768 161479 25278
West Bengal 82423 7974 99088 16489 95504 18278

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 FIRECLAY

Table – 4 : Production of Fireclay, 2012-13 and 2013-14 (P)

(By Sectors/States/Districts)
(Qty in tonnes; Value in ` `’000)

2012-13 2013-14 (P)

State/District
No. of mines Quantity Value No. of mines Quantity Value

India 74(24) 999925 182739 52(17) 706639 159859

Public Sector 1(1) 6793 3297 1(1) 5917 3545
Private Sector 73(23) 993132 179442 51(16) 700722 156314

Andhra Pradesh 15(2) 49478 10512 10(1) 31686 7178

East Godavari 12(2) 42098 8244 7(1) 27746 5615
West Godavari 3 7380 2268 3 3940 1563

Chhattisgarh 1 2570 643 - - -

Korba 1 2570 643 - - -

Gujarat 9(1) 86316 6602 6 39555 2842

Kachchh 2(1) 660 73 2 650 111
Rajkot 1 45867 3256 - - -
Surendranagar 6 39789 3273 4 38905 2731

Jharkhand 7 111594 17151 - - -

Dhanbad 1 295 47 - - -
Latehar 5 83699 13792 - - -
Palamu 1 27600 3312 - - -

Karnataka 1(1) 16307 10000 1(1) 13966 7808

Hassan (1) 4307 2800 (1) 3936 3149
Tumkur 1 12000 7200 1 10030 4659

Madhya Pradesh 8(6) 71226 12671 9(5) 45852 9746

Jabalpur 1(1) 12791 1787 1(1) 3413 390
Katni 4(2) 37746 5160 5(3) 27758 4243
Satna (2) 12090 4836 (1) 7564 4401
Sidhi (1) 93 37 - - -
Umaria 3 8506 851 3 7117 712

Maharashtra 1 7547 1132 1 4670 701

Amravati 1 7547 1132 1 4670 701

Rajasthan 10(2) 410331 87771 11(2) 313927 88028

Bikaner 10(2) 410331 87771 11(2) 313927 88028

Tamil Nadu 16(3) 145468 19768 8(2) 161479 25278

Ariyalur 4 90185 9510 1 74900 9887
Cuddalore 3 25817 4016 3 4661 851
Perambalur 8(1) 28941 6174 4 63805 12125
Tiruchirapalli 1(2) 525 68 (2) 18113 2415

West Bengal 6(9) 99088 16489 6(6) 95504 18278

Bankura 4(2) 32757 4962 4(1) 12541 3326
Birbhum 2(7) 66331 11527 2(5) 82963 14952

Figures in parentheses indicate associated mines of ball clay, bauxite, clay (others), laterite and kaolin.

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 FIRECLAY

Table – 5 : Production of Fireclay, 2012-13 and 2013-14 (P)

(By Frequency Groups)
(Qty in tonnes)

No. of Production for the Percentage in total Cumulative

mines group production percentage
Production group

2012-13 2013-14 (P) 2012-13 2013-14 (P) 2012-13 2013-14 (P) 2 0 1 2 - 1 3 2013-14 (P)

All Groups 74(24) 52(17) 999925 706639 100.00 100.00 - -

Up to 1000 21(8) 15(1) 7493 3995 0.75 0.57 0.75 0.57

1001 to 5000 24(9) 21(8) 95845 77846 9.59 11.02 10.34 11.59
5001 to 10000 8(3) 5(4) 78141 59037 7.81 8.35 18.15 19.94

10001 & Above 21(4) 11(4) 818446 565761 81.85 80.06 100.00 100.00

Figures in parentheses indicate the number of associated mines with ball clay, bauxite, clay (others), kaolin and
laterite.

Table – 6 : Mine-head Stocks of Fireclay, 2013-14(P)

(By States)
(In tonnes)

State At the beginning of the year At the end of the year

India 428683 304745

Andhra Pradesh 2436 1826

Chhattisgarh 26957 24256

Gujarat 7522 5940

Jharkhand 80878 78771

Karnataka 11745 10153

Madhya Pradesh 37992 21165

Maharashtra 35 35

Odisha 1011 4

Rajasthan 186002 112269

Tamil Nadu 18032 22466

West Bengal 56073 27860

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 FIRECLAY

USES AND SPECIFICATIONS Table – 7 : Specifications of Plastic and

Fireclays are used in the manufacture of Non-plastic Fireclays
bricks, blocks, retorts, crucibles, mortars,
Constituent
masses, pottery, floor tiles, etc. Low-grade
Grade Al 2 O 3 Fe 2 O 3 PCE
material is used for manufacturing heavy
(orton)
sanitaryware, such as, pipes and bath tubs.
i) Non-plastic/Semi-plastic Fireclay
Firebricks are used where heat generation is
involved. Firebricks are used extensively in Grade-I 35-40% 1.0% max 33 min
furnaces, kilns and ovens. Firebricks are required
Grade-II 32-35% 1.0-1.5% max 32 min
chiefly by metallurgical industries.
Grade-III 30-32% 1.5-2.0% max 30 min
The fireclays are graded into: i) low duty
ii) intermediate duty iii) high duty and iv) super
duty, depending upon their capacity to withstand ii) Plastic Fireclay

high temperature before melting. The low duty Grade-I 30-32% 1.0-1.5% 30 min
fireclay can withstand temperatures between
Grade-II 28-30% 2.0-3.0% 28 min
1,515 and 1,615 oC (PCE 19-28); intermediate duty
fireclay up to 1,650oC (PCE 30), high duty fireclay Grade-III 22-28% 1.0-2.0% 26 min
o
up to 1,700 C (PCE 32) and super duty beyond
Grade-IV 18-20% 1.5-2.0% 18-21 min
1,775oC (PCE 35).

BIS has not standardised any specifications

for fireclay. However, the erstwhile Director Crude fireclay and other clays including

General of Technical Development Sub-committee kaolin (china clay) are also used in a few
on Refractory Raw Materials had recommended cement manufacturing plants to increase the
specifications as given in Table-7. alumina content in the raw meal and its

The Expert Group on Classification of plasticity.

Minerals with regard to their Possible Optimum
Industrial Use had recommended the following CONSUMPTION
end-use classification of fireclay for Refractory The total consumption of fireclay increased
Industry: from 493,600 tonnes in 2012-13 to 536,400 tonnes
in 2013-14. Cement Industry was a major
Constituent consumer of crude fireclay accounting for about
Ty p e Al 2 O 3 Fe 2 O 3 PCE 55% consumption in 2013-14, followed by
(orton)
refractory (34%), ceramic (8%) and iron & steel
Non-plastic/ 30% (min) 2% (max) 30 (min) (2%) industries. The remaining 1% was consumed
semi-plastic in other industries, i.e. pesticide, alloy steel,
Plastic 18% (min) 3% (max) 18 (min)
graphite products, foundry, sugar, etc. (Table - 8).

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 FIRECLAY

Table – 8 : Consumption* of Fireclay, Table – 9 : Exports of Fireclay

2011-12 to 2013-14 (By Countries)
(By Industries)
(In tonnes) 2012-13 2013-14
Country
Industry 2011-12 2012-13(R) 2013-14(P) Qty Value Qty Value
(t) (` ` ’000) (t) (`’000)
All Industries 516400 493600 536400
Alloy steel 500(9) 500(9) 500(9) All Countries 36148 58678 2100 16879
Cement 275800(4) 252800(4) 293500(4) Ethiopia 216 820 120 4702

Ceramic 43700(13) 44200(13) 44200(13) Nepal 216 2432 309 2776

Foundry 200(23) 200(23) 200(23) Bangladesh 3884 7637 426 1060

Graphite products 1100(18) 1200(18) 1300(18) Norway 80 428 140 982

Iron & steel 10500(6) 10500(6) 10500(6) Rwanda - - 157 962

Pesticides 2900(2) 2900(2) 2900(2) Kenya 159 817 91 928

Refractory 181500(42) 181100(44) 183100(44) Mauritious 6 38 55 810

UAE 84 178 60 780
Sugar 100(27) 100(27) 100(27)
Sri Lanka 66 400 181 631
Others (abrasive, 100 (21) 100(21) 100(21)
glass, paper, textile, Senegal 13 32 205 500
and vanaspati)
Other countries 31424 45896 356 2748

Figures rounded off.

Figures in parentheses denote the number of units in organised
sector. Table – 10 : Exports of Refractory Bricks
(* includes actual reported consumption and/or estimates made (By Countries)
wherever required).
2012-13 2013-14
FOREIGN TRADE Country
Exports Qty Value Qty Value
(t) (``’000) (t) (`’000)
The exports of fireclay decreased drastically to
2,100 tonnes in 2013-14 from 36,148 tonnes in 2012-13.
All Countries 330660 6330676 213394 6212776
Exports were mainly to Bangladesh (20%), Senegal
(10%), Nepal (15%), Sri Lanka (9%), Rwanda and
Italy 846 83824 3088 359553
Norway (7% each). Exports of refractory bricks
considerably decreased to 213 thousand tonnes in USA 831 92006 2996 349541
2013-14 from 331 thousand tonnes in 2012-13. Exports
Turkey 12834 568824 31073 296599
were mainly to Turkey (15%), Saudi Arabia (5%), UK
and UAE (4% each), Indonesia, Iran & Bangladesh (2% UK 11510 290068 7501 246796

each). (Tables - 9 & 10). Saudi Arabia 12559 264613 10388 222817

Imports Indonesia 10477 361817 4537 202318

Imports of fireclay in 2013-14 decreased drastically Iran 8005 302985 4287 192797
to 146 tonnes from 1,610 tonnes in the previous year.
Imports were mainly from China (75%), Turkey (12%) UAE 9788 198901 9392 192577
and U K (9%). Imports of refractory bricks decreased
Russia 1593 101234 2280 180504
drastically to 272 thousand tonnes in 2013-14 from 384
thousand tonnes in the previous year. The share of Bangladesh 3079 111589 4054 157740
imports from China was 83% which was followed by
Germany (6%), Austria (4%) (Tables - 11 & 12). Other countries 259138 3954815 133798 3811534

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 FIRECLAY

Table – 11 : Imports of Fireclay FUTURE OUTLOOK

(By Countries)
Fireclay is one of the most important minerals
2012-13 2013-14
Country used in the Refractory Industry. Almost the
Qty Value Qty Value
(t) (``’000) (t) (`’000) entire production in the country is consumed in

All Countries 1610 22423 146 4473

the manufacture of refractories and about 80% of
these refractories are used by the Iron & Steel
China 1576 21750 110 3370
Industry. India has huge reserves of fireclay and
UK - - 13 611
therefore the possibility of encountering problems
Turkey 18 280 17 311
in respect of supplies to the Refractory Industry
Denmark - - 2 91
in the near future. There is, however, a scarcity in
USA 15 310 4 69
the availability of high-grade fireclay analysing
Australia - - ++ 21 37% and above Al 2 O 3 with Fe 2 O 3 and fluxing
Other countries 1 83 - - impurities less than 2% for supply to the
Refractories. To fulfil the increasing demand of
the Refractory Industry, it is imperative that
Table – 12 : Imports of Refractory Bricks
(By Countries) deposits of high-grade fireclay be explored and
delineated.
2012-13 2013-14
Country The export prospect of fireclay is relatively
Qty Value Qty Value
(t) (``’000) (t) (`’000) less as it is considered as low-value high bulk
All Countries 384234 15855045 272306 15304944 mineral. However, fireclay bricks as a commodity
China 329015 12108721 224782 11377919 could have high export potential and therefore
Germany 24229 1819853 17092 1592072
must be encouraged.
Austria 10805 768052 10142 850732
France 1886 170564 4866 418078 The apparent domestic demand of fireclay
Japan 608 71892 2852 162071 which was estimated at 480 thousand tonnes by
Italy 1380 137316 1732 160298 2012-13 and at 739 thousand tonnes by 2016-17
Turkey 2376 139287 2067 140805
at 9% valid with decreased estimated consumption
Chinese Taipei/ 351 20740 987 98059
i.e. 480 thousand tonnes growth rate as per the
Taiwan
Spain 1009 78504 864 79950 Sub-Group Report on 12 th Plan, Planning
Belgium 110 7449 771 72023 Commission of India does project a rather
Other countries 12465 532667 6151 352937 competitive trade future for fireclay.

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