Calderys

CUTTING DOWNTIME AT A LARGE MAINTENANCE PROJECT – TIZIR TITANIUM AT TYSSEDAL, NORWAY

Refractory installation

 
Calderys Nordic successfully demonstrates its ability and capacity to manage large and complex maintenance projects from A to Z. Calderys Nordic completed the maintenance of the plant of TiZir Titanium & Iron A/S in Tyssedal Norway which produces 200 000 ton/year titanium slag and 110 000 ton/year of high purity pig iron. The main target for the maintenance work was the:

- Total refurbish of the rotary kiln -- Length = 72m, Diameter = 5.8m
- Repairs in the quencher tower
- Repairs in the rotary cooler
- Repairs in the grate

The original schedule was a maintenance period of 3 weeks and discussions had been made with the customer prior to the project talking about the efficiency of the spraycast system. The rotary kiln had already been spraycasted so the customer was familiar with the method. On demand from the customer the scope of the supply was doubled versus the original one. Calderys, thanks to its plants and facilities, was ideally placed to produce, deliver and install this unexpected double tonnage, with no delay and optimum quality!

With its high expertise of project management and preparation, Calderys Nordic teams were able within a schedule of 24 days to:

- Dismantle and dig out of the rotary kiln 100 tons of slag and products remainders
- Wreck 64 meters of slag out of the 72m length of the rotary kiln (See picture)
- Mark and weld over 12 000 anchors (See picture)
- Install over 2000m of joints
- Deliver and install over 700 tons of refractories instead of the 350 tons forseen (See picture)

In parallel, the quench tower, rotary cooler and the grate were also repaired, sometimes with the help of a helicopter to lift some precast pieces and scaffoldings and safety equipement. (See picture)

As safety is of paramount importance for Calderys, innovative solutions were also implemented to protect from the fall of old materials during the wrecking: the Brokk machines operators were covered with a cage to be protected from the fall of pieces. (See pictures)

Thanks to its spraycast solutions, Calderys was able to reduce significantly the project duration. The Calderys product range allows the customer to be serviced with performing castables that are also quick to install.
The quencher was gunned with CALDE™ GUN F 65. This product resists better than the previous bricks due to its strong matrix.
The rotary cooler was casted with CALDE™ CAST NB 82 QD™ . This Quick Dry (QD™) product eases and shortens the dry-out of the rotary cooler which is usually difficult to dry.
The rotary kiln was gunned in 3.5 days, with 2 pumps/8 installers on a 24/24 basis. Calderys used 633 tons of CALDE™ CAST LF 50 A, specific anti-alkaline product, which has demonstrated over the years its performance in this rotary kiln.

The unique ability of Calderys to offer single sourcing for projects of this type has been recognized and utilized with great success by OEM’s, EPC’s, installation contractors, and end-users around the globe. Other recent projects have demonstrated the skills of Calderys to service its customers beyond expectations.

As the world leader in monolithic refractories, Calderys continues to develop not only innovative refractory products, but innovative refractory solutions.

See the photo report below
Wrecking of the Slag
Wrecking of the Slag
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Marking and welding of the anchors
Marking and welding of the anchors
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Installing the joints
Installing the joints
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Completion of the refractory installation
Completion of the refractory installation
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Delivering precast piece on top of the quench tower roof
Delivering precast piece on top of the quench tower roof
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Safety at every moment: steel cage to protect drivers from the fall of pieces
Safety at every moment: steel cage to protect drivers from the fall of pieces
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For more details, contact our experts!

About Calderys

Our mission is to help you meet your ever increasing production and productivity targets, whilst protecting the safety of your people and the integrity of your equipment. Our focus is to deliver safe, reliable and high performing refractory solutions customized to your needs. Our international production and sales facilities allow us to develop and deliver customized solutions based on monolithic and ready shape monolithic refractory materials worldwide in a fast, efficient, and safe manner.

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