Success Story

Cutting Downtime at a Rotary Kiln Maintenance Project in Norway

Calderys Rotary Kiln Project in Norway

Calderys Nordic continually demonstrates its ability and capacity to manage large and complex maintenance projects from A to Z. Calderys Nordic completed ahead of schedule the maintenance project for the plant of TiZir Titanium & Iron A/S in Tyssedal, Norway which produces 200 000 tonnes/year of titanium slag and 110 000 tonnes/year of high purity pig iron. 

The main goals for the maintenance work: 

  • Total refurbish of the rotary kiln (Length of 72m, diameter of 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, as 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-level expertise of project management and preparation, Calderys Nordic teams were able within a schedule of 24 days to:

  • Wreck 64 meters of slag out of the 72m length of the rotary kiln
  • Mark and weld over 12 000 anchors (See photo above)
  • Install over 2000m of joints
  • Deliver and install over 700 tonnes of refractories (instead of the 350 foreseen)

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 equipment.

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

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 high-performing castables that are also quick to install.

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