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What Are Refractory Materials

A refractory material is one capable of withstanding extremely high temperatures without losing its physical and chemical properties. These materials are essential in numerous industrial processes, as they are used, directly or indirectly, in the manufacturing of most everyday products.

The main industries that depend on refractory materials include steel, glass, aluminum, copper, cement, energy, and petrochemicals, among others.

Key Properties of Refractory Materials

Refractory materials must meet certain properties to withstand the extreme conditions in each industrial sector. The main technical characteristics include:

• Resistance to compression and flexion: Ensures the durability of the material under intense mechanical loads.
• Thermal shock resistance: Crucial to endure sudden temperature changes without fracturing.
• Resistance to chemical attack and abrasion: Especially relevant in environments where refractory material is exposed to corrosive substances, such as alkalis, oxides, or acidic vapors.

Classification of Refractory Materials

Refractory materials are classified according to various criteria, adapting to the specifications of each industrial process:

• Presentation: Divided into shaped materials (bricks and preformed pieces) and unshaped materials (concretes, insulating ceramic fibers).
• Purpose: Classified as dense, for direct exposure to industrial processes, and insulating, which help retain heat within systems to reduce energy consumption and protect metal structures.
• Chemical composition: Includes silica, silica-alumina, magnesia systems, with additions of silicon carbide, zirconium, and special combinations providing specific properties for different types of chemical and thermal attacks.
• Chemical behavior: Indicates the reactive behavior of the material (acidic, neutral, or basic), depending on the materials it may interact with at high temperatures.
• Chemical nature: Most refractory materials are oxide-based, and research into new materials focuses on increasing their thermal and resistance capabilities.

Technological Innovations in Refractory Materials

Alfran has developed high-value innovations in refractory materials, including:

• Sol-Gel Technology in the Drytech® Range: An innovative technology replacing cement with colloidal silica, forming a ceramic bond at low temperatures. This technology increases the thermal and mechanical resistance of the material, reduces the risk of explosions during drying, and provides cement-free products without expiration dates, enabling better stock control. These materials are specifically designed for applications in the cement, steel, and petrochemical sectors.
• Steel-Tech® System: Designed to withstand extreme conditions of abrasion and high mechanical demand. This system combines ceramic and metallic materials, offering greater durability and resistance in highly demanding environments. It is particularly effective in areas of severe impact and abrasion, such as processes in the cement, copper, and aluminum industries.

Sustainability and Energy Efficiency

Alfran focuses not only on the durability and performance of its materials but also on their environmental impact. The Drytech® range, for instance, reduces CO₂ emissions by 50% during drying thanks to its lower liquid demand and high-permeability structure, allowing for faster and safer vapor release. This reduces the risk of accidents and contributes to a more eco-efficient operation aligned with the industry’s sustainability goals.

Certification and Regulatory Compliance

The quality of Alfran’s materials and processes is backed by ISO 9001:2015 certification, ensuring that the manufacturing and installation of refractory materials meet the highest quality standards. This commitment to excellence ensures that Alfran products not only meet but exceed industrial requirements for durability and resistance.

Refractory materials are fundamental components for the success and efficiency of numerous industrial processes. Alfran’s constant innovation, adaptability to extreme conditions, and focus on sustainability ensure that its products provide a comprehensive, durable solution for the

The WRA (World Refractory Association) has uploaded a video explaining the importance of refractory materials in our day to day. It is a very illustrative video for those people who do not know the strategic aspects of this sector.

Did you know that our day to day life would be unimaginable if refractory products did not exist?

And, what are reafractory products?

Let’s take the example of a car: it is made with steel, copper, glass, aluminum and plastics, among others. These materials are manufactured at very high temperatures. For example, iron is melted in an oven and transformed into steel by processes that reach 2,000 °C. In order that the walls of the furnace are not affected by these temperatures, they have a coating of refractory material. In the same way, these coatings are also used for the manufacture of glass, copper, aluminum and plastics.

And how do you get refractory materials to withstand such high temperatures? What are they made of? And how are they manufactured?

It starts from diverse raw materials of alumina or magnesia base that are baked in special ovens up to 1,800ºC, and this process makes the refractory properties appear. The refractory material can be supplied as non-conformed or shaped.

How are these refractory materials used?

The refractory material is transported and installed in the facilities of our customers. For the installation, a specialized refractory company is required.

And, how long can these installed refractory materials withstand such high temperatures?

The life time of the coatings usually depends on the industry, since they work at different temperatures. In the steel industry, the material usually lasts from a few hours to a few weeks, while in the glass industry it can last up to 10 years.

Once the coating has worn out, it is removed and recycled when possible.

The refractory industry covers the entire cycle, from the extraction of raw materials, to recycling.

Visit the WRA website (World Refractory Association) by clicking here.

In the dynamic and demanding industrial world, the need for safe and efficient solutions has never been more critical. Robotic demolition has become an essential tool for the modernisation and maintenance of infrastructure in industrial sectors. These advanced technologies not only increase the accuracy and safety of operations, but also reduce execution times, manpower requirements and associated costs.

alfran, a leader in the supply and installation of refractory materials, especially castables and innovative solutions for industry, has adopted and perfected robotic refractory demolition as part of its service offering. This commitment to innovation allows our company to tackle complex challenges and deliver optimal results for its customers. In this article, we will explore in detail what robotic refractory demolitions are, their benefits and some of alfran’s outstanding success stories in this field.

What are robotic demolitions?

Robotic demolition is an advanced method of demolition that uses remotely controlled robots to dismantle structures and materials. These robots are equipped with specialised tools, such as hydraulic breakers, which enable them to perform demolition tasks with unmatched precision and efficiency.

Unlike traditional demolition methods, which can be dangerous and less accurate, robotic demolition offers a number of significant advantages. Robots can operate in confined and hard-to-reach spaces in industrial furnaces, where it would be risky for workers. In addition, their ability to handle heavy tools and perform repetitive work without fatigue results in increased productivity and workplace safety when demolishing refractories.

Benefits of robotic demolition in refractories

Efficiency and safety

One of the major benefits of robotic demolition in refractory is efficiency. Robots can work continuously without the need for breaks, which significantly speeds up the demolition process. In addition, their ability to operate with high precision minimises the risk of collateral damage to surrounding structures, which is crucial in densely populated industrial environments.

Safety is another key aspect. Robotic demolitions significantly reduce the risk of injury to workers by eliminating the need for workers to be in hazardous areas, as they do not need to stand next to refractory linings. Robots can be remotely controlled from a safe location, allowing operators to stay out of harm’s way while supervising the work, particularly in hot demolition of refractory linings.

Environmental impact

Robotic demolitions also offer environmental benefits. When refractories are being demolished, these robots generate less of a dusty environment than traditional methods, helping to maintain a cleaner and safer working environment. In addition, the precision demolition allows for better recovery and recycling of refractory materials, contributing to more sustainable practices.

alfran robotic demolition success stories

At alfran, we have carried out numerous successful projects using robotic demolition. Projects such as the demolition of cement plant exchanger towers are characterised by the efficiency and reliability of our robotic technology in the elimination of safety incidents/accidents.
Another significant project was the demolition of a rolling furnace in a steel plant. The robots were able to access confined areas and perform the demolition with a precision that would have been impossible with traditional methods. This allowed not only faster work, but also increased safety and reduced costs for the client.

Future of robotic demolition at alfran

At alfran, we are committed to continuous innovation in our Refractory robotic demolition techniques. Our investment in research and development allows us to remain at the forefront of technology, ensuring that we can offer our customers the most advanced and efficient innovative solutions available. We have surface and vertical platform-free robotic refractory demolition equipment around the world.

In addition, ongoing education and training of our staff ensures that our operators and technicians are always prepared to handle the most complex challenges. We look to the future with plans to expand our refractory robotic demolition services, adopting new technologies and expanding our capabilities to meet the growing demands of t

Within the power generation industry, Alfran offers detailed engineering solutions for refractory materials supply, installation and drying for biomass boilers.

From Alfran´s Technical, Operations and Sales Departments and with the support of another company of the Group, Intec-Heat, for the drying of the refractory, we provide turnkey solutions.

Our dense refractory castables, such as Tix 35 SiC or Cast 35 SiC, as well as the insulating refractory castable, Alfran Lite 10/14, are ideal for these biomass boilers.

We are available to our customers to offer, as we have done for over 100 years, our Industrial High Temperature Solutions.

Braskem Idesa awards Alfran with a performance result of 100% in the third quarter of 2020. One more time, we are recognized for our performance in the works related to refractories and thermal insulation, that we have been installing in the petrochemical installation, located in southeast Mexico.

Alfran offers specialized refractory solutions for the maintenance in lime furnaces, vertical cylinder or Maerz type. Our services include opening and closing inspection doors, scaffolding, demolition and cleaning, supply and installation of refractory materials.

We have a range of refractory castables, specially designed for lime furnaces, which can be installed by vibrocasting, such as ABR Clean + or by gunning, such as CAST 80 GL, in addition to our wide range of insulating castables.

We are available to our customers in the lime sector, to offer them, as we have done for more than 100 years, our Solutions in High Industrial Temperature.

The new global crisis originated by the Covid-19 has changed the world as we knew it. Now, the priority is to reduce the number of people involved in the installation process, to have enough distance between them, and to reduce the working time, to avoid risks of spreading the disease.

In this sense, Alfran recommends the best solution to install dense refractory castables: Alfranjet Shotcrete Technology. Alfran is #1 with Shotcrete Technology through its patented Alfranjet®, with more than 25 years of experience and worldwide references in Cement, Steel and Energy industries among others.

Why Alfranjet® Shotcrete?

1. Reduced number of people. This highly improves safety operating conditions.
2. High quality and performance. Accurate control of mixing liquid (WET PROCESS).
3. High-speed installation: Average of 30 tons / 12h-shift.
4. High efficiency & Energy Savings. < 10% losses.

The National Association of Manufacturers of Refractory Products, Materials an Related Services (ANFRE) held in Seville, between March 11 and 14, the II Edition of Refractories Engineering Course.

It is a course taught by and for members of ANFRE that aims to train new generations of employees.

The course combines theoretical and practical training to obtain a global vision of the sector. In addition, the participants had the opportunity to visit both Siderúrgica Sevillana and our Alfran plant in Seville.

The following topics are found in the content of this course:

• Refractory materials
• Introduction to the design of coatings
• Refractory application
• Drying, heating and cooling
• Safety and Quality Control

From Alfran, we want to thank the entire Association for the organization of these courses.

To combat the risks of accidents and damage to health, the application of technical and organizational measures is a priority. These measures are designed to eliminate risks at source or to protect workers through collective protection provisions.

When these measures are not enough, the use of personal protective equipment (PPE) is imposed. The PPE act fundamentally reducing the consequences derived from the materialization of the risk. The protective efficacy will depend on the adequacy of the individual protection equipment at the pre-existing levels of risk.

The correct selection and use of the appropriate PPE will minimize the consequences and damages should the risk materialize. Therefore, the mandatory use of them is of vital importance.

Awareness campaigns in Alfran

With the aim of raising awareness among all employees towards active behavior in the prevention of occupational hazards and advancing their integration at all levels, different Awareness Campaigns will be carried out during 2019.

For this, maximum involvement and collaboration is necessary, highlighting the members of the Health and Safety Committee, Delegates and Prevention Technicians, Intermediate Managers and Project Managers.

The Management and Prevention Department request the involvement of all to achieve the proposed objectives.

Alfran is a specialist in designing, supplying and installing refractories for aluminum melting furnaces.

We have a wide range of refractory castables, such as Tix-80 NW, Drytech 85 AL, Tix 55AL or Cast-60AL, among others, specially designed for the aluminium industry, as well as our insulating castables, Lite 10/14 and Lite 106. We carry out new construction or maintenance projects. On the other hand, another company of Grupo Aldomer, Intec-Heat is specialized in the drying of refractories, in this type of furnaces.

We are available to our customers in the aluminum industry, to offer them, as we have done for more than 100 years, our Solutions in High Industrial Temperature.