From raw materials to processes: Why are fireproof core materials directly supplied from brucite mines more cost-effective?
With the rapid growth of demand for fireproof materials in industries such as construction, transportation, and electricity, brucite-based fireproof core materials have gradually become the mainstream choice in the market due to their excellent flame retardant properties and environmental protection characteristics. However, in the context of fierce competition among similar products, how to achieve cost optimization has become the key to success for enterprises. In recent years, brucite fireproof core materials in the "direct supply from mines" model have rapidly occupied the market share with their significant cost-effectiveness advantages.
1. Raw material end: "zero middleman" cost chain from mines to factories
1. Natural advantages of brucite resources
The flame retardant principle of brucite (mainly magnesium hydroxide, Mg(OH)₂) is that it releases crystal water when it is thermally decomposed (decomposition temperature is about 340°C), absorbs a large amount of heat and dilutes the oxygen concentration, and the generated magnesium oxide covers the surface of the material to form an insulation layer. This natural mineral property makes it an ideal choice for fireproof materials, and the purity of the raw materials directly affects the performance stability of the final product.
Under the traditional procurement model, fireproof core material manufacturers usually obtain brucite ore through multi-level distributors. In this chain, the cost increases by an average of 15%-20% for each additional intermediate link. The mine direct supply model directly mines from the ore deposit to the processing plant, eliminating the intermediary costs of agents, traders, etc. Taking a medium-sized enterprise with an annual procurement volume of 50,000 tons as an example, the cost of raw material procurement alone can save more than 8 million yuan.
2. Pre-positioning of quality control
Mine direct supply companies can achieve standardized management of raw materials by building or holding mines. For example, a large brucite mining company in Liaoning has established an integrated "mining-sorting-calcination" base to stabilize the magnesium oxide content of the ore at ≥62% and the impurity iron content at ≤0.8%. This quality consistency controlled from the source reduces the energy consumption and scrap rate of subsequent process adjustments, and reduces the overall production cost by 12%.
2. Process innovation: Efficiency breakthrough brought by supporting processing in mines
1. Short-process production system
In the traditional mode, ore needs to go through a lengthy process of "mining → long-distance transportation → intermediate storage → secondary transfer → factory processing". Mining direct supply enterprises build special processing parks around the mining area to enable the mined ore to directly enter the crushing, grinding, modification and other processes. The transportation radius is shortened to within 50 kilometers, the logistics cost is reduced by 40%, and the raw material loss caused by multiple loading and unloading is reduced (the average loss rate is reduced from 3% to 0.5%).
2. Customized modification technology
The particle size distribution and surface activity of brucite ore directly affect its dispersibility and flame retardant efficiency in the polymer matrix. Mining direct supply enterprises can carry out targeted treatment at the ore processing stage according to the needs of downstream customers. For example, the "wet ultrafine grinding + silane coupling agent coating" process developed by a certain company controls the D50 particle size of brucite powder to 2.8-3.2μm, and the activation index is ≥98%. Compared with the traditional dry process, the oxygen index (LOI) of the fireproof core material is increased by 5 points, and the modification cost is reduced by 18%.
3. Supply chain collaboration: the key path to cost reduction in the whole chain
1. Dynamic optimization of inventory costs
Through the digital linkage between mines and processing plants, enterprises can establish a real-time inventory monitoring system. When it is detected that the raw material inventory is lower than the safety threshold, the mine mining equipment production increase instruction is automatically triggered. This JIT (just-in-time) supply mode reduces the average inventory turnover days from 45 days to 12 days, reduces capital occupation by 70%, and avoids the raw material price risk caused by market fluctuations.
2. Intensive layout of the transportation network
Mine direct supply enterprises usually build a multimodal transport system of "trunk railway + short-haul road". For example, a company in Shaanxi built a dedicated railway line to transport ore from the mine to the processing base, and then radiated to the surrounding 300-kilometer customer base through the highway network. This layout reduces the ton-kilometer transportation cost to 0.28 yuan, saving 33% compared with traditional road transportation, and reducing carbon emissions by 40%.
IV. Empirical analysis: Quantitative comparison of cost advantages
Take the production of 1 ton of PP modified material with flame retardant grade of UL94 V-0 as an example, compare the cost structure of the two models:
| Cost item | Traditional procurement model (yuan) | Mine direct supply model (yuan) | Reduction rate |
| ---- | ---- | ---- | ---- |
| Raw material procurement | 3200 | 2650 | 17.2% |
| Modification treatment | 850 | 720 | 15.3% |
| Logistics warehousing | 480 | 210 | 56.3% |
| Quality control | 180 | 90 | 50% |
| Total cost | 4710 | 3670 | 22.1% |
Data source: 2023 China Inorganic Flame Retardant Industry Cost Analysis Report
V. Industry trend: Extended value of mine direct supply model
1. Green premium advantage: The direct supply model reduces carbon footprint by shortening the supply chain, complies with EU CBAM carbon tariff and other regulatory requirements, and improves product export competitiveness. A Zhejiang company has achieved a premium of 8%-12% in the European market with carbon footprint certification.
2. Accelerated technology iteration: In-depth cooperation between mining companies and scientific research institutions promotes the improvement of flame retardant efficiency. For example, the latest "nano-brucite/graphene composite system" reduces the thickness of the fireproof core material by 30% while increasing the fire resistance limit to 120 minutes.