CALDE® GUARD: a state-of-the-art full foundry concept
The CALDE® GUARD concept combines the following elements:
- a boron-free silica solution for furnace lining, called SILICA MIX BF
- a precast top ring for higher mechanical strength
- the casting, installation and service of these combined products
All of this is handled on behalf of the customer directly by Calderys, in-house at its foundry service center, before installation of the overall equipment is done at the customer’s site.
Supporting foundries’ sustainability goals
As a responsible partner, Calderys aims to support its customers in their sustainability challenges.
Boron is an additive traditionally used to manipulate the sintering temperature of silica, which is an important step in the refractory lining process of a coreless induction furnace (CIF). This step is defined by the application of heat to materials to form a mechanical bond. Sintering gives refractory customers more control, allowing them to tailor silica-based products to their needs.
Calderys has developed a boron-free refractory solution (the SILICA MIX BF) that supports healthier manufacturing practices, while displaying the same benefits of higher productivity than the conventional product.
Calderys has decades of experience in manufacturing silica-based refractories for foundry furnaces. In fact, the group can rely on its own quarry (located in Sweden) which is just a few minutes away from Calderys’ production plant. Foundry customers benefit from a secure and steady supply when it comes to the SILICA MIX product range.
Improving installation times
In addition to offering healthier refractory solutions, there are important considerations in furnace installation. Gert Karlsson, EMEA Foundry Technical Director at Calderys, explains how the Group went beyond product selection:
“When refractory materials aren’t fully sintered, they will be mechanically weak. This is a result of the melt level not reaching the top of the furnace. Hence, foundry operators must use a standard castable for lining the top of the furnace. Furnaces are loaded from the top – so a strong top ring is needed for material strength to withstand abrasive and mechanical force.”
However, standard castables are subject to dry-out time. This halts production and delays equipment availability for customers. Using a precast top ring reduces this dry-out time, allowing customers to return to production more quickly.
Gert continues: “The precast top ring is already dried out – it’s ready to go, shortening the installation time. A crucial advantage for the customer is that Calderys does all this in-house before handing anything over to the customer. That means the casting and lining are done in the same controlled environments every time so we can always ensure a perfect result.”
Product consistency is just one of the benefits customers can expect from CALDE® GUARD. The entire concept works together to deliver significant time savings for customers, explains Håkan Andersson, Director of Sales for Foundries EMEA at Calderys.
“A stronger lining means more melt per lining, so less frequent re-lining and overall, less downtime throughout the installation process. As there are no sintering agents required for the product to be ready to use, this increases equipment availability.”
As well as the time saved by improving installation efficiency, customers can expect to perform relining less frequently – all of which means reduced costs, energy usage and ultimately improved sustainability performance.
A top-level option
Ultimately, CALDE® GUARD is a unique, high-level concept. Part of what makes it such a valuable prospect is the dedicated care that Calderys provides for its customers.
Håkan concludes: “We provide customers with the full package for this concept: customization, installation and training. We don’t leave the customer with it until we’ve run through a few installs with them, ensuring they have the proper knowledge of the product so that they can make use of its full potential.”
Please find below the English, the German, the Portuguese, the Turkish and the French versions of the Press Release: