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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.

In 2024, Alfran Saudi Arabia took an important step in its expansion and consolidation in the region with its first repair and maintenance project at Jubail Energy Services Company (JESCO), a key player in Saudi Arabia’s energy industry. This project not only marked a milestone in terms of our presence in a strategic market but also demonstrated the technical capabilities and excellence of our refractory materials in highly demanding industrial environments, such as reheating furnaces.

At Alfran, we share all the details of Alfran Saudi Arabia’s project for JESCO, from the technical challenges encountered to the innovative solutions implemented. We also analyze the crucial role of the collaboration between Alfran and JESCO, which proved to be a model of success in project execution, and how this achievement strengthens Alfran’s position in the energy sector and other key industrial sectors. This project reinforces our commitment to excellence and innovation in the installation of refractory materials for the most demanding industries.

Thanks to our expertise in the design, manufacturing, and installation of refractory materials, we were able to deliver an effective solution, optimizing performance and ensuring the durability of the equipment. The success of this project has been a key factor in driving our expansion and building long-term relationships with major industrial players in the Middle East.

Introduction to Alfran’s Project in Saudi Arabia for JESCO

The Alfran Saudi Arabia project for JESCO was developed in a context of high demand for efficient and durable industrial solutions. JESCO, one of the leading companies in Saudi Arabia’s energy sector, continuously faces the challenge of maintaining its infrastructure in optimal conditions to ensure the stability of its energy production. The reheating furnace at this plant plays a critical role in this process, as it ensures the quality of treated materials and optimizes operational efficiency.

The choice of Alfran for this project highlights our reputation as a reliable supplier of refractory materials in the energy sector. Our experience in highly complex projects and the trust JESCO placed in us to carry out the maintenance of its reheating furnace reflect the level of quality and specialization we offer to our clients. This project not only showcases our technical capabilities but also our ability to adapt to the specific needs of each client, a hallmark of Alfran across all areas of operation.

Project Objectives for the Reheating Furnace

The main objective of the project was to ensure the efficient and safe operation of JESCO’s reheating furnace. These furnaces are vital for the material heating process, and their proper functioning is crucial for maintaining quality standards and energy efficiency at the plant.

By installing high-performance refractory materials, the furnace could operate at higher temperatures, extend the lifespan of the installations, and reduce the need for frequent maintenance. This resulted in a significant improvement in production times and optimization of operating costs, both key factors for any company in the energy sector.

Refractory Solutions

For this project, specially designed refractory materials were used to withstand the high temperatures and abrasion conditions typical of reheating furnaces. Among the most notable solutions were Alfran Tix 85 AS (dense castable) and Alfran Lite 10-14 (insulating castable), applied in the areas most exposed to extreme thermal conditions. These refractory materials are known for their high resistance to thermal shock, ensuring efficient furnace performance over extended periods while minimizing the risk of failures and the need for frequent maintenance.

Technical Challenges Overcome During the Project

One of the challenges was ensuring compatibility between the applied refractory materials and the specific operating conditions of the furnace. Thanks to Alfran’s extensive experience and technical expertise, solutions were adapted to ensure that the selected refractory materials were the most suitable for the industrial process. Continuous supervision and adjustments made throughout the project enabled us to successfully overcome these challenges.

Collaboration

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.

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.

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.

ALFRAN becomes part of the Aceros Inoxidables Olarra family thanks to the concession of the maintenance contract for the steel plant that the entity has in Vizcaya, País Vasco (Spain). With this agreement, ALFRAN will carry out all the tasks related to refractory materials in the main operating units of the plant, such as ladles, AOD equipment, electric furnace, tundish, etc. Achieving better performance both in plant productivity and in worker’s health and safety.

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 modernization and maintenance of infrastructure across industrial sectors. These advanced technologies not only enhance the precision 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 with innovative solutions for the industry, has embraced and refined robotic refractory demolition as part of its service offering. This commitment to innovation enables our company to tackle complex challenges and deliver optimal results to our clients. In this article, we take a closer look at what robotic demolition of refractories entails, its benefits, and some of Alfran’s notable success stories in this field.

WHAT IS ROBOTIC DEMOLITION?

Robotic demolition is an advanced method that uses remotely controlled robots to dismantle structures and materials. These robots are equipped with specialized tools such as hydraulic hammers, enabling them to carry out demolition tasks with unmatched precision and efficiency.

Unlike traditional demolition methods, which can be dangerous and less accurate, robotic demolition offers a range of significant advantages. Robots can operate in confined and hard-to-reach areas within industrial furnaces, where it would be risky for human workers. Moreover, their ability to handle heavy tools and perform repetitive tasks without fatigue leads to increased productivity and enhanced workplace safety when removing refractory materials.

BENEFITS OF ROBOTIC DEMOLITION

SAFETY AND EFFICIENCY

Safety is a key aspect. Robotic demolition significantly reduces the risk of injury by eliminating the need for workers to be in hazardous zones, particularly close to refractory linings. Robots are operated remotely from a safe location, allowing operators to supervise the process without exposure to danger—especially during hot refractory demolitions.

One of the greatest advantages of robotic demolition is efficiency. Robots can work continuously without breaks, significantly accelerating the demolition process. Their high precision also minimizes the risk of collateral damage to surrounding structures, which is critical in densely packed industrial environments.

ENVIRONMENTAL IMPACT

Robotic demolition also offers environmental benefits. These systems generate far less dust than traditional methods, contributing to a cleaner and safer work environment. Additionally, the precision of robotic demolition facilitates better recovery and recycling of refractory materials, supporting more sustainable practices.

ALFRAN’S SUCCESS STORIES IN ROBOTIC DEMOLITION

At Alfran, we have completed numerous successful projects using robotic demolition. These include work in preheater towers, furnaces, coolers, and other equipment in cement plants, as well as reverberatory furnace demolitions in the aluminum industry—all marked by a significant reduction in safety incidents and accidents.

In the steel sector, rolling mill furnace demolitions are common. Our robots accessed confined spaces and performed demolitions with a level of accuracy impossible to achieve using traditional methods. This not only led to faster completion times but also increased safety and reduced costs for our clients.

THE FUTURE OF ROBOTIC DEMOLITION AT ALFRAN

At Alfran, we are committed to the continuous innovation of our robotic demolition techniques. Our investment in research and development keeps us at the forefront of technology, ensuring we can offer our clients the most advanced and efficient solutions available. In addition to conventional robotic demolition equipment, we have developed our own CASTPECKER system—a breakthrough solution for vertical equipment demolition that eliminates the need for scaffolding and uses only hoisting.

Furthermore, the ongoing training and development of our personnel ensure our operators and technicians are

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.