International Colloquium on Refractories ICR® 2024
Refractory solutions for cement plants with alternate fuels & raw materials
Gaurav Sinha
As the cement industry pursues continuous improvement, it faces new challenges when alternative fuels and raw materials are introduced into production. Gaurav Sinha, a Ceramic Engineer with 13 years of expertise in Quality & Process Control of Refractories at Calderys, presented strong solutions for cement plants facing “Build Up” issues in kilns. By examining samples from different sections of the kiln system to understand the root cause of coating build up and refractory failure, the study recommends more compatible refractory materials to withstand these harsh operating conditions, optimizing the cement production process.
Use of metallurgical residues as potential raw materials for high-performance refractory castables
Mathilda Derensy
This theme of optimization extends into steelmaking, where the drive for carbon neutrality by 2050 and the pursuit of a circular economy spur research and innovation. Mathilda Derensy, a PhD student working with Calderys since 2023, shared her work on recycling metallurgical residues like vanadium-bearing slags into high-performance refractory castables. Her research demonstrated how using these by-products not only enhances castable strength at high temperatures, but also supports sustainability by reducing reliance on virgin raw materials.
Optimizing alumina-magnesia-carbon (AMC) brick performance in steelmaking ladle impact zones
Veli Kara
Building on the need for enhanced material performance, Veli Kara, a Science and Technology Manager at Calderys, presented his research on Alumina-Magnesia-Carbon (AMC) bricks for steelmaking ladle impact zones, showing how replacing white fused alumina with tabular alumina improves the bricks' strength and high-temperature performance. The study highlights the potential of alternative alumina sources like tabular alumina in AMC bricks, offering key insights for material selections in refractory design.
Discrete element method to optimize dry vibrating mixes
Hugues Lemaistre
Lastly, Hugues Lemaistre, a Ceramic Engineer specializing in Numerical Simulations at Calderys since 2010, introduced the Discrete Element Method (DEM) as a new way to optimize Dry Vibrating Mixes (DVM) used in furnace linings at foundries. His research focused on using DEM to find the best settings for DVM to make the linings denser and stronger. DEM utilizes simulation to analyze the various characters of DVM such as type of vibration, initial loading, or shape of the grain and their impacts on the densification of the linings. By providing an alternative to traditional experimental methods, Lemaistre’s findings not only improve furnace performance but also tie back to the overarching theme of continuous improvement and innovation that characterizes Calderys’ contributions to the refractory industry.
Together, these significant contributions illustrate Calderys' leadership in advancing refractory technologies, enhancing performance, and promoting sustainability across the steel, cement, and foundry industries. Each presentation underscores a commitment to innovation that not only addresses current challenges but also paves the way for a more sustainable future.