Calderys at UNITECR 2025: Driving innovation for a smarter, more sustainable refractory future

From October 27 – 30, 2025, in Cancun, Mexico, HWI and Calderys teams will present seven technical papers at UNITECR 2025, a biennial global hub where refractories experts unite to drive sustainable innovation. The contributions reflect the Group’s deep commitment to sustainability, innovation, and advancing intelligence-based solutions across the full refractory lifecycle. With the aim to assist our clients in their energy transitions and boost efficiency, HWI and Calderys’ experts have conducted the following studies focusing on three main areas:

Focus 1: Sustainability & Recycling

Evaluating the impact of recycled magnesia carbon refractories on furnace lining performance
Author: Samantha Garnier (HWI, A Member of Calderys)

This study explores how recycled magnesia-carbon bricks affect the quality and performance of new bricks in steel furnaces. It evaluates how impurities in reclaimed materials impact mechanical and thermal behavior, with the aim of optimizing recycling in refractory production.
Enhancing recycled refractory quality by lining design and steelmaking practice
Author: David Hartwich (HWI, A Member of Calderys)

Focuses on improving the recyclability of magnesia-carbon bricks through smarter lining design and operational practices. The study identifies methods to enhance the quality of recycled aggregates, reducing the need for high-purity virgin materials and improving circularity in steelmaking.

Focus 2: Hydrogen & Decarbonization

Impact of refractory composition on the yield of reduction by hydrogen
Authors: Gaurav Sinha, Saumen Sinha, Indranath Chakraborty, Rajesh Bisen, Pratanu Nag, Kazi Asif Ahmed (Calderys India)

This paper examines how hydrogen as a reducing agent can deteriorate oxide-based refractories. It identifies key factors like raw material selection and mineralogy that influence resistance to hydrogen corrosion in high-temperature environments.
Effect of the use of hydrogen on refractories installed in DRI processes and the associated carbon impact

Author: Michael Clark (HWI, A Member of Calderys)

Analyzes how the transition to higher use of hydrogen in Direct Reduced Iron (DRI) reactors impacts refractory wear and the carbon footprint of associated refractory solutions. Offers guidance on materials that can support the steel industry's decarbonization goals.

Focus 3: Material Science & Testing Innovation

Numerical modeling of pressure build-up in castable specimens during explosive spalling tests

Authors: Hirotaka Goto, Atsushi Sasaki, Kazuaki Komiya (Calderys Japan)

A study on modeling moisture migration and pore pressure build-up during drying of castables. Emphasizes the importance of bonding systems like colloidal silica for safer, energy-efficient drying.
Impact of bulk & matrix chemistry on thermomechanical properties of dense refractory bricks

Authors: Gaurav Sinha, Saumen Sinha, Indranath Chakraborty, Pratanu Nag, Kazi Asif Ahmed (Calderys India)

This study correlates the creep behavior of Alumino-Silicate Bricks and Castables with matrix composition and liquid viscosity. The study also introduces new insights into secondary creep prediction through mineralogical and thermodynamic analysis.
Development of a unidirectional sintering test for EAF hearth DVM characterization
Author: Ben Burk (HWI, A Member of Calderys)

Introduces a new sintering test to evaluate a refractory dry vibratable mass for DC steel furnace bottoms. The test aids in developing high-performance mixes by simulating real heat gradients, enabling longer refractory campaigns.
Shotcrete solutions in blast furnace refractory repairs: An evaluation of technology advancements in India

Authors: Santosh Upadhyay, R Chokkar (Calderys India)

The study showcases Calderys India’s development and deployment of shotcrete technology for blast furnace repairs, highlighting robotic and manual application techniques and tailored refractory materials. Shotcrete repairs extend lining life, reduce downtime, and improve safety and environmental compliance compared to traditional methods. The technology is now a trusted, advanced maintenance strategy in Indian integrated steel plants.
Refractory lining assessment with finite element analysis for carbon black hot air duct

Authors: Amol Kinkar, R Chokkar, Bhagirathi Singh, Hugues Lemaistre (Calderys India, Australia, France)

This paper reports a successful assessment and redesign of refractory linings in hot air ducts used in carbon black production. Using finite element analysis (FEA) and computational fluid dynamics (CFD), researchers identified failure modes and heat loss issues with brick linings and proposed a monolithic lining with flexible anchors and insulation to reduce temperature drop and stress, improving durability and thermal efficiency. This solution has been effectively applied in a plant setting.

With expertise from all around the world, HWI and Calderys are proud to contribute to this global forum and continue pushing boundaries of refractory innovation.

👉Full program available on UNITECR website: https://unitecr2025.com/program

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