As a global leader in providing solutions for industries operating in high-temperature environments, Calderys is committed to continuously enhancing its processes to offer the best possible solutions to its customers. In the field of cement-bonded refractory castables, furnace dry-out has long been a critical challenge due to its lengthy duration, which can halt operations for several days after the installation of refractory lining.
Calderys directly addresses this challenge with the expansion of its CALDE® FD (Fast Dry) product range. This new solution is designed to integrate seamlessly within Calderys’ existing offerings, providing customers with increased reliability, reduced downtime, optimized processes, and improved CO2 reductions. The expanded CALDE® FD range aligns with Calderys’ Environmental, Social, and Governance (ESG) objectives, supporting customers in their energy transition efforts.
Bruno Touzo, Global Vice President, Innovation & Technology, says: “Comparative alternatives to CALDE® FD tend to require additional components, or are less robust when handling, or harder to adjust to climate conditions. Our product maintains all the advantages of regular cement-bonded castables, so customers don’t need to adjust their processes to integrate them. Besides, this new solution significantly reduces downtime, which is key for our customers, whatever their markets.”
Fast Dry Technology Addresses Key Challenges for Boilers, Incinerators, and Aluminum Producers
Calderys' Fast Dry technology effectively resolves the concrete challenges faced by boiler and incinerator operators, as well as aluminum producers.
For Calderys' customers in boiler and incinerator operations, typically utility plants that generate power or provide water supply to municipal grids, and waste management facilities, managing non-operational periods in their furnaces is essential. During these times, operators often need to rely on backup power from external suppliers or use generators fueled by diesel or natural gas.
Such alternatives can be costly and environmentally detrimental due to their impact on both operating expenses and carbon emissions. CALDE® FD addresses this problem by providing an advanced technology that minimizes the need for additional external solutions. While cement-bonded castables are naturally sensitive to rapid changes, CALDE® FD’s durability significantly reduces downtime, enabling customers to quickly restore full operational capacity.
CALDE® FD Technology Reduces Furnace Dry-Out Time and Saves Energy
Longer dry-out times typically result in higher energy consumption. With CALDE® FD, a new refractory technology from Calderys, furnace operators can save up to 72 hours in reaching 1,200°C, even with a lining thickness greater than 100mm. This innovation significantly reduces energy use during furnace operations.
For aluminum production, Calderys has long offered the specialized ALKON® range, a dedicated refractory line formulated for aluminum contact. Now, Fast Dry technology is seamlessly integrated into the ALKON® product family, further enhancing its performance.
Previously, fast-drying solutions were limited in application and could not be used across all areas of a furnace. As a result, the overall furnace dry-out time was determined by the slower-drying sections. The new ALKON® FD range overcomes this limitation, as it is suitable for installation throughout the entire furnace. This enables Calderys to provide a complete service with faster heat-up times using a single product family, eliminating the need for multiple product ranges to cover a full furnace.
“We are excited to showcase that ALKON® FD delivers only benefits, marking a significant step forward in our offerings for aluminum customers: faster dry-out speeds without compromising refractory performance,” says Bruno Touzo. “ALKON® FD represents a complete furnace solution, allowing for quicker handovers, less disruption, and improved productivity.”
About Calderys Calderys is a global leader in providing solutions for industries operating in high-temperature environments, with 2023 revenue of approximately €1.6 billion and adjusted EBITDA exceeding €220 million. The company specializes in thermal protection for industrial equipment, offering a wide range of refractory products and advanced solutions to optimize steel casting, metallurgical fluxes, and molding processes. With a presence in over 30 countries, including a strong foothold in the Americas through its HWI (HarbisonWalker International) brand, Calderys delivers tailored services through a network of experts. With over 150 years of experience, Calderys supports customers in their energy transition goals. Headquartered in Paris, France, the company employs 5,800 people across 50 plants on five continents.
