In the demanding environment of the refractory industry, where intense thermal processes are common, having the right materials is a key factor. Not only do they directly influence operational efficiency, but they can also determine the technical and economic viability of the entire plant. This is why the selection of these materials must be made thoughtfully, considering both performance and durability.
Shotcrete technology for industrial refractory applications has made significant strides in recent years, becoming a reference technical solution compared to traditional methods such as vibrocasting or conventional guniting. This article by Alfran explains the main innovations developed, focusing on the evolution towards greater strength and efficiency, and how Alfran is leading this technological shift.
From the introduction of systems like High Gun® and Gunmix®, to developments with nanotechnology such as the Drytech® range, the new materials and installation methods have allowed for substantial improvements in the compactness, homogeneity, and durability of refractory linings. These solutions are targeted at high-demand sectors like cement, steel, diesel, and energy, where continuous operation and reducing downtime are crucial for profitability.
This advancement extends beyond the product characteristics and into the installation approach. Systems like Alfranpump® enable concrete to be installed more quickly, with fewer workers, and under better safety conditions. These developments not only meet a technical need but also reflect Alfran’s commitment to continuous innovation and protecting the core of the industry.
The Evolution of Shotcrete: Beyond the Conventional
For decades, conventional guniting was the standard method for applying refractory materials in high-temperature industries. However, it had significant limitations: high rejection rates, loss of fine particles, and, above all, inferior mechanical performance compared to methods like vibrocasting. With the advent of high-pressure guniting and the Gunmix® system, this scenario has changed radically.
The key to this evolution lies in the advanced design of projection equipment and optimized formulations with lower cement content and superior compactness. These advancements allow for a homogeneous projection with a significant reduction in open porosity, resulting in much more efficient thermal and mechanical performance. The electronic control of the process via intelligent modules ensures installation meets demanding parameters, improving both quality and traceability of the work carried out.
Industrial Applications of New Refractory Concretes
Shotcrete technology for industrial refractory applications is designed to adapt to a wide range of operational environments. In the cement industry, for example, its application in critical areas such as heads, entrance arches, and coolers has shown a significant improvement in the service life of linings. Success stories such as the Drytech® range in cement kilns have achieved reductions of up to 50% in CO₂ emissions during drying, as well as a decrease in the risk of explosions.
In steelmaking and energy, the materials developed by Alfran can withstand extreme conditions of abrasion, thermal shock, and impact. Thanks to sol-gel formulations, the microstructures obtained offer low porosity and high dimensional stability even at temperatures above 1500°C. This represents a key competitive advantage for processes such as casting or biomass boilers, where unplanned interruptions can lead to significant economic losses.
Benefits of New Shotcrete Technologies
Among the main benefits are improvements in mechanical strength and thermal efficiency, but also logistical and safety aspects. Solutions like High Gun® and Gunmix® offer installation speeds up to five times faster than vibrocasting, with material losses under 10% and drastically reduced drying times. This allows our clients to resume operations more quickly and with fewer risks.
The Alfranpump® system has transformed the way high or hard-to-reach work is performed. Its high-pressure pumping technology eliminates the need for lifting heavy loads, reducing the number of workers required and significantly lowering workplace accidents. Since the materials, like those from the Drytech® range, have no expiration date, stock management is optimized, and losses due to expiration are eliminated.
The Future of Shotcrete Technology: Trends to Follow
The main lines of development focus on nanotechnology, sustainability, and automation. Alfran continues to invest in R&D to offer cement-free shotcretes, with no expiration, lower water demand, and the ability to dry at low temperatures. This aligns with the sustainability goals of our clients, who seek to minimize their carbon footprint without sacrificing operational efficiency.
The automation of installation processes, along with the integration of electronic modules in projection systems, will allow for greater process control and complete traceability in the coming years, facilitating quality audits and predictive maintenance.
The application of artificial intelligence to predict the behavior of materials in service is expected to further customize the solutions offered, consolidating Alfran as a global leader in shotcrete technology for refractory industrial applications.
Shotcrete technology for industrial refractory applications represents a decisive step forward in the search for more efficient, safe, and sustainable solutions for the cement, steel, energy, and diesel industries. Through developments like High Gun®, Gunmix®, Alfranpump®, and Drytech®, Alfran has transformed not only the way refractory materials are applied but also the performance they offer in extreme operational conditions.
Thanks to a vision focused on innovation, continuous improvement, and technical excellence, our solutions enable clients to increase the durability of their equipment, reduce downtime, and optimize their production processes. In an increasingly demanding industrial context, having a partner like Alfran, which integrates experience, technology, and commitment, is synonymous with reliability and long-term performance.