CALDERYS Expertise in Ferro-Alloys
Calderys has over 30 years of experience in the Ferro-Alloy industry. We are a leading supplier/installer in South Africa and are a regular supplier for Outokumpu designed Sinter Plants. 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. We offer refractory solutions for all aspects of the Ferro-Alloy industry including:
- Sinter plants
- Pre heaters
- Furnace roofs and ducting
- Feed chutes
- Tap hole repairs
- Tap hole clays
- Furnace revampings
We maintain close partnerships with furnace engineering companies and customers in an effort to:
- Reduce production costs by optimizing our refractory solutions
- Increase productivity and equipment availability by extending the service life and reducing the maintenance downtime
- Improve the health and safety standards through the use of environmentally friendly products
Our comprehensive range of products for Ferro-Alloy making is composed of alumina, carbon, and silicon carbide based products. It includes dense castables, self-flowing castables, dry gunning and shotcreting materials, ramming and plastic mixes, dry vibrating mixes, injection and grouting products, tap-hole clays, and prefabricated shapes.
Our innovation process is based on a world class R&D team, coupled with all of the Ferro-Alloy making dedicated employees, which 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.
Calderys has vast experience in the installation of refactory solutions for Sinter Plants throughout South Africa. Our installation teams perform repair work where necessary and make use of our latest technology, and installation, methods—which results in longer refractory life and less downtime.
With the latest new equipment and skilled labor, we build a number of pre-heater linings and also perform repair work where necessary.
Furnace roof and ducting
Our development and installation teams have installed furnace roofs and ducting onsite as well as on our premises. Using our extremely efficient drying-out equipment and skilled labor, some customers prefer to do the unit installation at our premises and transport it back to their facility. We continue to develop better refractory materials for these installations and improve the installation procedure.
In the last 5 years, Calderys has developed a very high abrasive material as an inner wear lining for the feed chutes, resulting in longer life and more cost effectiveness.
Because it is in our interest to obtain excellent performing ladles with an extended life, our teams work daily on improvements that will enable us to set better cost per ton of hot metal ratios. It is therefore important for us to make use of good performing products, reliable equipment, and skilled labor with supervision.
There are many different types of launders which vary from plant to plant, so we work very closely with people in the plants to install the best refractory material.
It is necessary from time to time to repair the taphole area. The tapblock and a small amount of bricks surrounding the block have to be broken out with the latest breaking equipment and then re-installed. Calderys is well-equipped to provide you with any kind of taphole reapri solution.
Tap hole clay
Calderys has a variety of clays, including environmentally friendly clay, to suit the customer's specific needs in terms of function and reliability. We work closely with the customer to establish the most effective method and alteration between the standard and re-constructive clays.
Calderys is the preferred installer for Graftech “Freeze Linings” for Turnkey projects and we also supply all of the Ceramic Refractories. For conventional linings, we coordinate with the client design to supply and install our latest monolithic linings.
With specialized technical support, including refractory and ferro-alloy making process knowledge, our experienced supervisors and installers provide expert technical guidance and the best suited installation equipment to ensure the best refractory performance during service.
Calderys employ 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.
Our engineering teams, dedicated to the Ferro-Alloy 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. 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 30 years of experience in the Ferro-Alloy industry, Calderys has the capability to become your integrated refractory partner and meet all your needs from solution design to implementation.
Blending technical knowledge with practical experience, our dedicated project managers provide the organization and coordination needed to support installation and special projects worldwide.Read more