Calderys launches an expanded range of Fast Dry refractory solutions for improved drying in industrial furnaces

As the world’s leading provider of solutions for industries operating in high-temperature environments, Calderys is committed to continuously improving its processes to offer its customers the best possible solutions. In the field of cement-bonded refractory castables, the drying out of furnaces has long been a critical challenge, as it can take several days after the installation of the refractory lining before operations can be halted.

Calderys is tackling this challenge head-on with the expansion of its CALDE® FD (Fast Dry) product range. This new solution is designed to integrate seamlessly with Calderys’ existing range, offering customers greater reliability, reduced downtime, optimised processes and improved CO₂ reduction. The expanded CALDE® FD range is aligned with Calderys’ environmental, social and governance (ESG) goals and supports customers in their efforts towards the energy transition.

Bruno Touzo, Global Vice President, Innovation & Technology, comments: “Comparable alternatives to CALDE® FD typically require additional components, are less robust in use or more difficult to adapt to climatic conditions. Our product offers all the advantages of a conventional cement-bonded cast, meaning customers do not need to adapt their processes to integrate it. Furthermore, this new solution significantly reduces downtime, which is crucial for our customers across all markets.”Fast Dry Technology Addresses Key Challenges for Boilers, Incinerators and Aluminium Producers

Calderys’ Fast Dry technology is an effective solution to the specific challenges faced by operators of boilers and incinerators, as well as aluminium producers.

For Calderys’ customers who operate boilers and incinerators – typically utility companies that generate electricity or supply water to municipal networks, as well as waste management facilities – managing furnace downtime is of crucial importance. During these periods, operators often have to rely on emergency power from external suppliers or use diesel or natural gas-powered generators.

Such alternatives can be costly and harmful to the environment, as they affect both operating costs and carbon emissions. CALDE® FD addresses this issue by offering advanced technology that minimises the need for additional external solutions. Whilst cement-bound casting compounds are, by their very nature, sensitive to rapid changes, the durability of CALDE® FD significantly reduces downtime and enables customers to quickly return to full operating capacity.

CALDE® FD technology shortens the furnace drying time and saves energy

Longer firing times generally lead to higher energy consumption. With CALDE® FD, a new refractory technology from Calderys, furnace operators can save up to 72 hours in reaching a temperature of 1,200 °C, even with a lining thickness of more than 100 mm. This innovation significantly reduces energy consumption during furnace operation.

For aluminium production, Calderys has long offered the specialised ALKON® range, a dedicated line of refractories developed for contact with aluminium. The Fast-Dry technology has now been seamlessly integrated into the ALKON® product family, further enhancing its performance.

Until now, fast-drying solutions were limited in their application and could not be used in all areas of a furnace. As a result, the furnace’s overall drying time was determined by the slower-drying areas. The new ALKON® FD range overcomes this limitation, as it is suitable for installation throughout the entire furnace. This enables Calderys to offer a comprehensive service with shorter heating-up times using a single product family, eliminating the need for multiple product ranges to cover an entire furnace.

“We are delighted to be able to demonstrate that ALKON® FD offers nothing but benefits and represents an important next step in our service offering for aluminium customers: heating-up speeds without compromising on refractory performance,” adds Bruno Touzo.

“ALKON® FD represents a comprehensive range of services and furnaces for our customers and enables a faster handover, resulting in fewer interruptions and higher productivity.”