Iron silicate fines (Fayalite)

Iron silicate fines, also called fayalite, is a by-product produced by Aurubis Bulgaria, with universal application in variety of areas in construction. Received by complicated metallurgical process it has stable physical and chemical characteristics.

Properties of iron silicate fines make it compatible with various materials like limestone, clay, clinker, cement, sand, gravel, chemicals, etc. Its’ application transfer building materials to those with lower environmental impact and reduced utilization of natural resources.

Material is certified as by-product by the Ministry of Environment and Water in October 2021. No additional environmental permits are required by the building material producers.

Iron silicate fines is applied for the main areas of construction in reinforce concrete buildings and facilities: starting from the structural elements, through brick walls till finishing works like plasters and coatings for buildings and facilities.

Iron-silicate fines is a universal source of raw materials applied in variety of applications, making final products with better performance.

Basic characteristics:
Particle shape	angular
Appearance	Anthracite
Bulk density	1800 kg/m^3
Specific density	3700 kg/m^3
Moisture content	Two types: 12 % & 1%
Loss of ignition	0,01%
Friction angel	At moisture 12 % – 70% lower than 1 % – 45%

Composition:
Element	Typical range
Fe elem.	46% (as Fe2O3>60 %)
SiO2	27%
Al2O3	3.20%
CaO	1.80%
MgO	0.70%
Zn	1.50%
Cu	0.42%
S	0.36%

Applications:

Cement clinker with iron-silicate fines (ISF)

Cement clinker with iron silicate fines (ISF)

Portland cement clinker production consumes large amounts of natural resources, mostly limestone and clay, but also sand and iron additives. Nowadays, the cement industry is facing the challenge of protecting the environment by decreasing CO2 emissions which reflect to reduced consumption of natural raw materials.

Various industrial solid wastes have been utilized as alternative raw materials in Portland cement clinker production. Iron silicate fines (ISF) are such alternative material, which can be used as a substitute of the commonly used iron ores. According to the mineral composition of the main raw materials (clay and limestone), ISF could be used as iron and silica corrective material or as a source of iron.

There are several benefits of ISF valorisation in the cement industry:

Ready-to-use source of iron;
No need for additional crushing and grinding;
Suitable for both dry and wet clinker production lines;
Good mixing properties;
Promote lower calcination temperature;
Eliminate the need for mineralizers.

The chemical composition of the material includes the minerals fayalite, magnetite, pyroxene and quartz, basically in the form of ferrous and silica dioxide, which give the name of the material – iron silicate.

Element	Typical value	Range
Fe	46,0% (Fe2O3>60 %)	(44,0÷48,0)%
SiO2	27,0%	(26,0÷28,0)%
Al2O3	3.20%	(2,7÷3,7)%
CaO	1.80%	(1,3÷2,5)%
MgO	0.70%	(0,6÷1,1)%
Zn	1.50%	(0,9÷2,8)%
Cu	0.42%	(0,36÷0,48)%
S	0.36%	(0,25÷0,55)%

ISF contractors are: Heidelberg Cement, Lafarge Holcim, Titan, American Cement, etc.

Detailed reference on material specification, material safety data sheet, logistics and shipping options, can be obtained in our PDF brochures here.