Metals production: Why refractories are essential

Metallic elements are typically found in nature within stable oxides or sulfides. High temperatures are traditionally required to efficiently separate them as molten metal from slag, which avoids impurity entrapment and makes large-scale production economically viable.

However, these extreme conditions create a harsh environment for the processing equipment. Molten metals and slags are highly corrosive and lead to erosion, while thermal cycling can cause severe mechanical stress. These challenges are where refractory materials come in: They can be engineered to provide heat resistance, chemical stability, and structural integrity, forming the protective lining of furnaces, kilns, electrolytic cells, and other equipment. Without refractories, the high-temperature processes that make modern metal production possible would simply not exist.

While iron and steel production dominates refractory consumption (60% or more), nonferrous metals also account for a significant share of consumption at approximately 30–40% of the total refractories market.^a

Approximately 75–85% of nonferrous metals have melting points greater than 500°C. They include most transition metals (e.g., nickel, chromium, titanium), refractory metals (e.g., tungsten, molybdenum, tantalum), and lanthanides and actinides (rare earths and nuclear metals). However, even nonferrous metals with relatively low melting points, such as tin (~230°C), lead (~328°C), and zinc (~420°C), will use refractories for thermal insulation, corrosion resistance, wear resistance, and purity control. Therefore, refractories find application during processing of virtually all nonferrous metals.

References

^a“Refractories market size, share, and growth forecast, 2025–2032,” Persistence Market Research. Published October 2025.

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