CALDERYS Expertise in Steel
Calderys has been working for over 60 years with successful activity in the worldwide steel industry, where we are considered a reference supplier by servicing most of the steel producers. Our pioneering implementation of innovative monolithic products and design solutions will safeguard profitability thanks to better energy efficiency, reduced downtime, and shorter repair cycles. Our worldwide presence and local experience allows us to propose the most suitable and cost effective technical solutions that will contribute to our customer's productivity and efficiency. For our customers in the steel industry, we focus our efforts on the following concerns:
- Safety, reliability, and productivity of equipment
- Steel quality and cleanliness
- Energy efficiency
- Strict environmental regulations
We supply alumina products as well as basic solutions with our CALDE™ MAG range. These include products, equipment and personnel for cast-in-situ applications, dry mixes, prefabricated shapes, standard gunning, low-porosity dense gunning, shotcreting and spray solutions. Our solutions have given excellent performances, both technically and economically, in steel plants for many years.
Our innovation process is based on a world class R&D team, coupled with all the steel-making dedicated employees, that 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.
We provide various solutions for the maintenance by hot of the bottom, trunnion, mouth by gunning mixes as well as the hot repair with a self flowing castable of the impact area improving significantly the performance. Linings suffer various stresses depending upon the zones concerned -Corrosion and slag penetration in the bottom, thermal spalling in the upper cone (tuyeres zone and the charging side), abrasion and mechanical damage in the charging zone. As a consequence, the most important point is the quality of the fine fraction and the binding systems of the basic monolithic refractories used for the maintenance and repairs of the working lining. Depending upon the process, specific binding systems are used for the AOD and converters gunning and casting mixes, that provide the closest porosity of the matrix as possible as well as the highest mechanical strength to the whole so as the product would be the less affected as possible by the abrasion and the mechanical damage also involved in the wear factors of such materials.
Electric Arc Furnace AC and DC
For new furnaces, the complete initial refractory lining includes the bottom DVM, precast or cast-in situ delta section, and the launder. For worn furnaces, we offer various maintenance solutions such as internal dry gunning and repairing the banks by fettling. Calderys masters perfectly all the steps of an EAF repair including the delivery of manipulators. Our latest development - CALDE™ MAG DRY K 85 is a versatile product which gives its best performance in small capacity, ultra high power furnaces operating at high temperature. Its is recommended for hot maintenance of bottoms thanks to its sintering properties below 1200°C. It also provides optimized service life due to improved corrosion resistance.
Calderys most used products:
- CALDE™ MAG GUN G 89
- CALDE™ MAG DRY K 85
We propose high-performance solutions for the steel ladle in every type of size (from the first installation to the maintenance) to ensure total reliability, achieve long campaigns, and reduce the maintenance downtime. Our comprehensive range for the wall and bottom is composed of aluminous and spinel forming/containing, products. This includes dense castables, self-flowing castables, dry gunning and shotcreting materials, ramming and plastic mixes, and precast ready shapes. For other equipment, such as covers, we propose well adapted products which provide quick and easy application as well as long service life.
Calderys most used products:
- CALDE™ CAST UB
- CALDE™ FLOW MA 92
- CALDE™ CAST LC 95 SP
- CALDE™ CAST LM 62 Z
We have been engineering and manufacturing purging plugs for over 30 years and have always had one of the most innovative product lines. We offer customized solutions based on a complete range of purging plugs under the brand name CALDE™ PLUG, adaptable to all systems. Our plugs integrate different technologies and are able to meet all types of processes (Integrated Pisot and Valve, exchangeable manually or with extractor, etc…). We produce and supply purging plugs in several varieties of directed porosity and also plugs with non-directed porosity.
We provide various precast lance solutions for the pretreatment of pig iron (desulfurization) and remain today one of the most innovative companies with adequate performance and expertise. Steel lances for argon bubbling, and even heavy steel treatment processes (LF, Vacuum, CAS, IR-UT) with adapted design, are part of our solutions for secondary metallurgy.
We supply customized types of suitable materials for main devices such as covers (VTD, VOD, LF) and bells CAS (CAS-OB). These are able to provide long service life and withstand various operating conditions. Snorkel linings need good mechanical characteristics plus a low porosity. We provide particularly adaptable castables for the first installation, called precast snorkel, and perform maintenance using alumina (or magnesia) using our special hot gunning mixes. These treatments provide the customer with a significant extension of snorkel life.
Calderys most used products:
- CALDE™ MAG CAST K 94
Is the head of the ternary metallurgy and is becoming more important in obtaining the best quality of steel products. We provide permanent lining that ensures safety during a long campaign. We have particularly developed our offering to meet the changes of new steel casting processes.
For the wear lining, Calderys is able to propose the full range of possible solutions including basic sprays (olivine and magnesia based) and hot or cold setting DVM (dry vibratable materials). Adapting a range in Magnesia-content (55% to 95%) for each type of installation we can customize any type of tundish processing. We also supply accessories for the tundish industry, combining an optimum flow in the tundish with optimum steel quality. We offer dams, weirs, baffles with oriented holes, and flow diffusers. Also, we sell argon diffusers and annular patented porous well blocks- CALDE™ BLOCK TUNDISH WB, which are contributing, efficiently and strongly, to the steel cleanliness as well as the decrease of hydrogen percentage.
Calderys most used products:
- CALDE™ CAST LX 58
- CALDE™ MAG SPRAY G72
With specialized technical support, including refractory and steel-making processes knowledge, experimented supervisors and installers, Calderys provides expert technical guidance and the most suited installation equipment to ensure the best refractory performance during service.
Calderys 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 dryout 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 Steel 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 60 years of experience in the steel industry, Calderys has the capability to become your integrated refractory partner and meet all your needs from solution design to implementation.
In general safety lining of a steel ladle is made up of relatively lower quality materials. As a result it cannot withstand liquid metal/slag attack in the event of working lining failure.Read more
Aimed at optimizing steel cleanliness in the tundish and the improvement of hydrogen removal, this solution has been tested and proven effective in major steel plants.Read more
This extremely efficient shotcreting technology can achieve properties similar to casting, but with efficiency and installation speeds that exceed normal gunning methods.Read more
Acknowledging the criticality and importance of Purging in secondary metallurgy, Calderys India has come up with a state- of- art manufacturing line at Nagpur, India.Read more