CALDERYS Expertise in Boiler

Calderys India has been associated with power industry since the time thermal power plants were set up in India. Our brands like Firecretes have been synonymous to ash hopper repairs of these power plants since decades. We have played the role of a dependable solution partner in the growth of power sector in India by working together towards their performance improvement while proposing most suitable services and solutions. Today our experience and expertise lies in handling Refractories for all types of boilers from concept to commissioning. We have worked with leading OEMs for working out a reliable and long lasting refractory solution for projects in India and overseas.

Today with ever growing power in industry in India, both captive and non captive power units are being added. These are being commissioned with improved technologies in an attempt to exploit available fuel to best possible extent. Needless to mention that this has not only put Refractories under pressure, but has brought it on centre stage. Our designers have worked out suitable refractory lining which meets above operating conditions and deliver desired performance. Today our brands like Accplast, Accmon, Accgun, Accmongun have become synonymous to refractories for new age power plant boilers. We are the most proven Indian company for handling Refractory jobs in power plants on turnkey basis.

Subsequent to merger with Calderys, we have access to their product range and expertise. Above strengths of Calderys India coupled with worldwide experience and presence of Calderys allows us to propose the most suitable and cost effective technical solutions that will attend to changes technological requirements as well as contribute to productivity and efficiency.

For the boiler industry, we focus our efforts on the following concerns:

  • Improving resistance to thermal shock, abrasion, and corrosion for units with different and newer technologies also.
  • Improving reliability, productivity and safety of equipment.

Products & Applications

We offer a full range of products and solutions based on our monolithic refractory range. Our product ranges cover materials for all types of boiler unit.

Tank melting and
holding furnaces

These units suffer from stresses such as severe abrasion, acid corrosion (due to burning of petcoke leading to production of high amounts of sulfur), CO corrosion(in the lower part of the combustion chamber creating cracking and spalling), and thermal shock. Because the quantities of burned fuels are regulated by the quantity of steam needed by the alternator, thermal cycling is very important in power plant boilers. This leads to thermal shock with stop & go's, which bring the temperature from 800°C/900°C to a minimum temperature of 200°C/300°C. It can occur anywhere between once a week to even ten times a day and can cause serious damage to the refractory lining if not designed accordingly. Calderys India has developed a dedicated range that meets the requirements of this specific boiler's wear condition. These are medium to low cement castables (LCC) having a high mechanical strength, high abrasion resistance, and high thermal shock resistance. They face various wear conditions with good service life. CO resistant versions are used when CO corrosion is a concern. Alkali resistant castables, with similar performing mechanical properties, are available if needed such as for biomass boilers. Our Plastic range of refractories under the brand name ACCPLAST, known for excellent abrasion resistance, is the answer to sulfur corrosion when petcoke is used.

Although the refractory lining must withstand these stresses, thermal conductivity to the tube-walls must also be maintained. SiC additions are used to customize the thermal conductivity of the lining, thereby optimizing energy recovery. Our range of Low cement castables offers products with SiC additions from 10% to 90% to fulfill this requirement.

Boilers also require short stoppages and fast installations. Calderys India was one of the first to come to the market with two dedicated product ranges adapted to the new gunning technologies ACCGUN and ACCMON GUN products with high abrasion and alkali resistance. Service life of these gunning mixes is similar to corresponding cast-vibrated products.

Our capabilities for this segment include:

  • Handling power plant refractory job on turkey basis. This includes:

    • Designing refractory lining in line with operating parameters. This covers Refractory lining and metallic parts like anchors etc.
    • Supplying materials both refractory and non refractories in line with BOM prepared.
    • Installation and commissioning. Here special attention is paid to panel size, expansion joints etc.
  • Trouble shooting and problem solving.

installation, commisioning & Turnkey maintenance

With specialized technical support, including refractory and power plant processes knowledge, experienced supervisors and installers, Calderys India provides expert technical guidance and the most suited installation equipment to ensure the best refractory performance during its service.

Our application & service set up based at Nagpur employs 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 best refectory performance.

Once in service, the refractory may require specific maintenance which again can be supplied depending on the customer needs. 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 boiler and power generation industries, help customers meet a wide range of requirements such as: refractory lining design, heat transfer calculation, quotation, planning, installation, dry-out.

Familiar with the specific processes of each type of units, 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, end users. Our strategic partnerships with the customers ensure that we develop market-oriented solutions. Due to our decades of experience in the boiler segment coupled with benefit of global presence of Calderys, Calderys India has the capability to become an integrated refractory partner to meet all the needs including solution providing, handling refractories design to implementation.

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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

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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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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 is a major cause of concern in the main equipments found in the thermal industry. There is a growing need for energy in response to the industrialization of many countries, and as a consequence power plants are now burning low cost fuels.

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