CALDERYS Expertise in Aluminium
Calderys has been working for over 60 years with successful activity in the worldwide Aluminium industry, where we are considered as a reference supplier for the primary and secondary industries as well as for the aluminum foundry industry. Our pioneering of innovative monolithic products, such as the ALKON® range, and our design solutions safeguard profitability thanks to better energy efficiency, reduced maintenance downtime, and longer repair cycles. Our worldwide presence and local experience allows us to offer the most suitable and cost effective technical solutions that will contribute to our customers' productivity and efficiency. In the aluminium industry, we focus our efforts on the following concerns:
- Ensure the safety, reliability, and productivity of the equipment
- Suppress corundum build-up
- Withstand mechanical abuse
We offer a full range of products and solutions based on our monolithic refractory ALKON® range (Aluminium Contact).
Equipment in the Primary Aluminium industry such as the anode baking furnace, alumina calcining rotary kiln and flash calciner, electrolysis cells, and foundry are all well known to Calderys. In recent years, Calderys has supplied materials for major projects such as precast top blocks of separating walls for anode baking furnaces in Qatar as well as a 800 000 ton/year anode furnace in Bahrain.
Furnaces and equipment featuring refractory lining that come into contact with liquid aluminium suffer from severe corrosion by corundum formation, which leads to build-up, and form mechanical abuse. Unit commonly affected by this severe corrosion are:
- Tank melting and holding furnaces
- Recycling furnaces
- Barrel melting furnaces
- Single chamber shaft melting furnaces
- Bi-chamber shaft melting furnaces
- Crucible induction & channel furnaces
- Dosing furnaces
- Road transport ladles
Calderys offers strong recent references in many European plants in France, Germany, Spain, Switzerland, etc. Calderys is also a leading supplier of the Aluminium industry in Japan and hold a strong position in China and Taiwan with the supply of full turnkey Aluminium plants as well as in the Middle East.
Calderys has developed a dedicated ALKON® range to solve the problems associated with these specific wear conditions. Our understanding of the corundum formation with new modern alloys containing magnesium, zinc, and other elements like strontium has led to the development of specific dense castables. These dense castables are not permeated by the modern alloys, thanks to special additives added to low cement castables. They also present low porosity and high mechanical strength to withstand the mechanical abuse during charging, cleaning, and dedrossing of the metal.
With the ALKON® CAST 204 and ALKON® CAST LB 85, Calderys has developed worldwide best sellers, with excellent anti-wetting properties and high mechanical strength to withstand the charging of ingots.
The ALKON® range also meets the needs of the aluminum industry which requires short stoppages and fast installations. Calderys was the first to bring to the market two dedicated product ranges, ALKON® SPRAYCAST for shotcreeting and ALKON® GUN L for low porosity dense gunning, designed specifically for new gunning technologies in low cement products with high corrosion and mechanical resistance. Calderys has also developed a specific range of Quick Dry monolithic refractory products which reduces the dry-out time by 50%.
With their extensive knowledge of the aluminum-making process, our experienced supervisors and installers can offer specialized technical support. Calderys provides expert technical guidance and the best suited installation equipment to ensure the refractory performance during service.
This can be applied to small, large, or turnkey projects alike depending on the customer requirements. Alternatively, we can support the customer's staff by supervision, project management, equipment, and also direct installation training.
Our aim is to ensure the best installation and dry-out of the refractory lining to achieve maximum performance.
Once in service, the refractory may require specific maintenance which can be furnished depending on the equipment. With its ALKON® range, Calderys has developed products for repairs by gunning, casting, and patching. In some cases, and depending on the situation, services may be available 24 hours per day, 7 days per week, ensuring minimum downtime for the customer—especially for unplanned emergencies.
Our engineering teams, dedicated to the Aluminium industry, help customers to meet a wide range of needs.
Starting with the shell design, we design a full lining with heat transfer calculations, show the intermediate and casing temperature, and define the thickness of the different layers:
The Calderys solution for the bath is a lining of ALKON® (Aluminium contact) castables, insulating castable (with non-wetting agent to prevent damage in case of accidental infiltration), then insulating boards.
Hot face dense castable featuring the following: good thermal shock resistance and alkali resistance, insulating layers, anchoring with anchor-bricks or metallic anchors, expansion joints. Burner blocks with ramming mixes to allow burner start-up at mid-drying schedule (carried out with external hot air generators).
Suspended with ceramic anchors, hot face with dense castable featuring good thermal shock resistance and insulating layers to ensure low external temperature under the metallic supporting beams.
Calderys provides engineering drawings, bill of materials, project quotation, planning, installation and dry-out.
Calderys is often invited to take part in the development of technical solutions covering precise specifications. Familiar with the processes of each customer, we are able to engineer a refractory solution, provide project management services, and advise on the proper installation techniques for new projects. Calderys has an excellent reputation for providing reliable solutions which have created many long-lasting relationships with our customers. Our strategic partnership with the customers ensures that we develop market-oriented solutions. With our 60 years of experience in the Aluminium industry, Calderys has the capability to become an integrated refractory partner and can meet all the needs from solution design to implementation.
Read about Calderys Deutschland’s installation of an 110t aluminum round melting furnace and a 110t holding furnace for Gautschi Engineering GmbH at their Chinese customer Xiashun.Read more
Discover ALKON® CAST NB 84 QD™, a recent development of the Calderys QD™ Technology, the aluminum contact material which reduces dryout requirements and maximize furnace availability.Read more
The ALKON® product range was specifically designed to solve the problems associated with wear conditions specific to the primary and secondary aluminum furnaces.Read more
The Calderys innovative Quick Drying No Cement Castables provide excellent mechanical strength, quick drying and fast heating capabilities, with no curing time, leading to savings in time and energy.Read more