Calderys

CALDERYS Expertise in Cement and Lime

 

CALDERYS Expertise in Cement and Lime

Calderys has been working for over 100 years with successful activity in the worldwide Cement industry and the lime industry, where we are considered as a reference supplier by all major cement producers as well as by the 10 top worldwide specialized engineering companies including Chinese ones. Our pioneering implementation of innovative monolithic products and design solutions safeguard profitability thanks to regular operating conditions, reduced 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 customer's productivity and efficiency. For the Cement industry, we dedicate our efforts toward the following concerns:


And for the lime industry, our efforts are concentrated on

  • Safety, reliability, and productivity of equipment
  • Abrasion resistant lining
  • Corrosion by alkali resistant lining

Products & Applications

Products and Applications Cement

Cement Plant-Gunning installation
Cement Plant-Gunning installation
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We offer a full range of products and solutions based on our monolithic refractory range. Calderys provides monolithic refractory solutions for the following units of the cement plant:

  • Heat Exchangers,
  • Precalciners,
  • Inlet Chambers
  • Firing Hoods
  • Noserings
  • Burner Lances and Coolers

All units suffer from severe abrasion and strong corrosion by alkali , sulphur and chloride, coming from the raw meal, the fuels and alternative fuels. Calderys has developed a dedicated product range that meets the requirements of the specific cement plant wear conditions for abrasion and corrosion. Against abrasion, Calderys offers the CALDE™ CAST GIBRAM which is used worldwide for its high mechanical strength and abrasion resistance. To withstand corrosion, specific materials (such as Silicon Carbide or Zircon) can be added to inscrease the alkali resistance of the castable. For example, the CALDE™ CAST NA 48 SA QD, a Quick Dry product developed specifically for the cement plant, demonstrates high resistance to alkali. In addition, a family of low cement castables with an alkali resistant matrix has recently been developed and installed with excellent results. It does not contain any additives, which are often known to decompose in special conditions (high temperatures, sludge burning, etc…)

The cement industry also demands short stoppages and fast installations. Calderys was the first to bring to the market two dedicated product ranges adapted to the new gunning technologies—CALDE™ SPRAYCAST for shotcreeting and CALDE™ GUN L for low porosity dense gunning. Both ranges are low cement products with high abrasion and alkali resistance. Calderys has also developed a specific range of Quick Dry monolithic refractory products which can reduce by 50% the dry-out time.

Product and Applications Lime

We offer a full range of products and solutions based on our monolithic refractory range. Units found in the different types of lime plants such as

  • Rotary kilns for the paper industry and steel lime,
  • Heat Exchangers,
  • Precalciners,
  • Inlet Chambers
  • Kiln Hoods
  • Noserings
  • Burner Lances and Coolers
  • Vertical shaft kilns

all suffer from severe abrasion (see our Focus on Abrasion) and medium corrosion by alkali (see our Focus on Alkali corrosion), coming from the raw lime and the fuels. Low cement castables have high mechanical strength and present high abrasion resistance. Specific additives in low cement castables, such as a mixture of Sic and Zircon, can increase their alkali resistance.

Installation, Commissioning and Turnkey Maintenance

Well aware of refractory and Cement and lime-making process knowledge, our experienced supervisors and installers provide expert technical guidance and the best suited installation equipment to ensure the refractory performance during service.

This expertise can be applied to small, large, and turnkey projects alike depending on the requirement. Alternatively, we are able to support the customer's own staff by supervision, project management, equipment, and direct installation training. Our aim is to ensure the best installation and dry-out of the refractory lining so that the customer gets maximum performance.

Once in service, the refractory may require specific maintenance which can be provided according to the customer requirements. Calderys is servicing from 80 to 100 cement repairs or revamping a year. 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.

Turnkey new Projects

Our engineering teams, dedicated to the Cement and Lime industry, help customers meet a wide range of needs such as: a full refractory lining design with monolithics, mixed lining bricks and monolithics, heat transfer calculations, quotations, planning, installation, dry-out.

Calderys is often invited to take part in the development of a technical solution. 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 is continuously servicing customers in their operations worldwide such as taking in charge a turnkey operation in Cyprus for a Chinese customer. Such high standards examples have build Calderys excellent reputation for providing reliable solutions which have created many long-lasting relationships with our customers. Calderys is ordered 3 to 4 new lines a year. Our strategic partnerships with the customers ensure that we develop market-oriented solutions. Due to our 100 years of experience in the Cement industry, Calderys has the capability to become the integrated refractory partner and can meet all the needs from solution design to implementation.

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Focus

Gunning | Low Porosity

Case studies 01

The Calderys innovative Low Porosity Dense Gunning installation technology can improve jobsite installation efficiency by approximately 50 percent.

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Quick Dry | Product Range

Case studies 01

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.

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Alkali Corrosion | Calderys Solutions

Case studies 01

Calderys designs products to increase Alkali resistance. Learn why some castables are enriched with special additives and how others can combat corrosion with a special matrix design.

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Abrasion | Calderys Solutions

Case studies 01

Calderys designs products to increase Alkali resistance. Learn why some castables are enriched with special additives and how others can combat corrosion with a special matrix design.

Read more

JOBS / Careers

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