Calderys

CALDERYS Expertise in Iron

 

CALDERYS Expertise in Iron

With over 60 years of experience in the iron industry, Calderys is the European leader and a significant player worldwide. Our innovative, high performance, modular and adaptable monolithic solutions cover every step of the iron process; from coke and ore preparation, to blast furnaces, and finally, hot metal transport. Thanks to close partnerships with our customers, our solutions contribute to increased productivity and quality in the iron making processes and also help to meet the reliability and safety requirements by:

  • Increasing the availability of the production equipment by extending the service life and reducing the maintenance downtime
  • Reducing unit cost of hot metal by continuous optimization of the refractory solutions
  • Improving the health and safety conditions by pushing the development of harmless and environmentally friendly products like our resin-bonded tap-hole clays

Products & Applications

Our comprehensive product range for Iron-making is composed of alumina, carbon, and silicon carbide based products. It includes tap-hole clays with our dedicated range CALDE™ TAP, dense castables, self-flowing castables, dry gunning and shotcreting materials, ramming and plastic mixes, dry vibrating mixes, injection and grouting products, and prefabricated shapes.

Our innovation process is based on a world class R&D team, coupled with all the iron-making dedicated employees, that designs customized solutions in anticipation of future needs. Personalized training programs are also organized in our plants and contribute to a closer co-operation with our customers.

Coke oven & sinter plants

We provide various solutions based on different installation techniques, such as pre-cast ready shapes for coke oven doors or sinter plant roofs, ramming mixes for first installation in sinter plant, and gunning mixes for general maintenance in coke plants.

Blast furnace

We supply complete and modular solutions to extend the campaign length. For new furnaces, the complete initial refractory lining includes high technology refractory materials depending on the type of staves coolers (cast-iron or copper). For furnaces in operation, this is achieved by various maintenance solutions as internal dry or wet gunning, grouting from the bosh to upper stack area and injection in the tap-hole and hearth zones. Should the product be shotcreting or dry gunning, Calderys masters perfectly, via its dedicated team, all the steps of a BF repair should it be needed via platform or via robotic application. Every year, Calderys completes approximately 10 blast furnace repairs.

Calderys most used products for Blast Furnace repairs:

  • CALDE™ GUN F 55 CO
  • CALDE™ SPRAYCAST F 60 R
  • CALDE™ INJECT MF 50 G3
  • CALDE™ INJECT G S 55

Casthouse floor

Casthouse Floor
Casthouse Floor
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We propose high-performance solutions for main, secondary, and tilting runners (from the first installation to the maintenance) to ensure total reliability, achieve long campaigns, and reduce the maintenance downtime. We are considered as the world leader in monolithic refractory for runners. For other casthouse floor equipment, such as runner covers, we propose well adapted products which provide quick and easy applications as well as long service life.

Calderys most used products:

  • CALDE™ CAST G 6 P
  • CALDE™ RAM G B 58S15
  • CALDE™ GUN G M 33 GSP

Tap-hole

Blast Furnace
Blast Furnace
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For tap-hole opérations(plugging, drilling, casting) we have been engineering and manufacturing tap-hole clays for over 30 years and remain today one of the world leaders in tap-hole clay technology with our CALDE™ TAP range. Over 60 holes are plugged with our tap-hole clays, in 20 different countries. We offer customized solutions based on a complete range of tap-hole clays. Our tap-hole clays integrate different technologies (European and Japanese) and are able to meet all types of furnace and tap-hole operating conditions. We pay special attention to the requirements concerning health and safety by pushing the development of harmless and environmentally friendly products.

Calderys most used products:

  • CALDE™ TAP 321 BQH
  • CALDE™ TAP 335 CMS
  • CALDE™ TAP J 240

Hot metal transport

We provide various monolithic products and installation techniques (casting, gunning, shotcreting) to increase the campaign length and reduce the cost per unit of the torpedo cars and straight iron ladles.

Iron treatment

We supply customized types of desulphurization lances that are able to provide long service lives and withstand various operating conditions.

Installation, Commissioning and Turnkey Maintenance

With specialized technical support, including refractory and iron-making processes knowledge, experimented supervisors and installers, Calderys provides expert technical guidance and the best suited installation equipment to ensure the best refractory performance during service.

Calderys employs dedicated skilled staff and the latest advances in refractory installation equipment. This can be applied to large, small, and turnkey projects alike depending on the requirement. Alternatively, we can support the customer's own staff by supervision, job management, equipment, and also direct training.
Our aim is to ensure the best installation and dry-out of the refractory so that the customer gets maximum performance.

Once in service, the refractory may require specific maintenance which again can be supplied depending on the customer requirements. 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 in times of unplanned emergencies. For example, in the case of casthouse runners, Calderys is servicing, worldwide, dedicated maintenance contracts from 1 to several years, in more than 30 plants.

Turnkey new Projects

NEW PROJECTS CAPABILITIES

Our engineering teams, dedicated to the Iron industry, help customers meet a wide range of needs such as: refractory lining design, heat transfer calculation, job quotation, installation, dry-out, and start-up/operating instructions & planning.

Calderys is often invited to take part in the development of a technical solution to cover specific needs. We are present in over 75 runners in 20 countries which brings us to be familiar with the specific 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. We have an excellent reputation for providing reliable solutions and thus have created many long-lasting relationships with our customers. Our strategic partnership with the customer ensures that we develop market-oriented solutions. Due to our 60 years of experience in the Iron industry, Calderys has the capability to become your integrated refractory partner and meet all your needs from solution design to implementation.

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Focus

Tap-Hole | Leading Solutions

Case studies 01

A range of tap-hole clays engineered to meet the demands of the blast furnace industry, the CALDE™ TAP products increase productivity, safety, efficiency, and the service life of the BF hearth.

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BF Hearth Grouting |

Case studies 01

Calderys develops innovative and efficient solution which seals holes and reinforces refractory linings; ideal for repairing hot spots on the blast furnace shell and gas tracking around the tap-hole.

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BF Repairs |

Case studies 01

The Calderys robotic gunning repair solutions aim at increasing the flexibility of furnace operations while reducing downtime. The installation is performed by robot for better safety.

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JOBS / Careers

Related companies: www.imerystc.com, www.imerys-toiture.com, www.imerys-structure.com, www.ikf-solutions.com