In today’s demanding industrial environment, characterized by the constant need to optimize processes, reduce costs, and minimize environmental impact, choosing the right refractory coating system has become a strategic decision. Such choices not only affect the durability and safety of equipment but also directly influence energy efficiency and the sustainability of operations. Drytech refractory coatings stand out as a cutting-edge solution designed to address these challenges comprehensively.
The development of the Drytech range by Alfran reflects a clear approach: to offer unshaped refractory materials capable of withstanding extreme thermal conditions, with exceptional resistance to thermal shock, abrasion, and chemical attack, while also significantly reducing drying times and energy consumption. This technology is based on a ceramic bond system, free from cement, which eliminates the presence of chemically bound water and allows for greater efficiency during installation and commissioning.
In this article, Alfran explains in detail the key benefits of Drytech refractory coatings, highlighting their positive impact on productivity, sustainability, and operational management in industries such as cement, steel, energy, and oil & gas. These materials represent not just a technological evolution, but a true transformation in the way industrial refractory coatings are conceived.
Faster Drying and Operational Efficiency
One of the most valued aspects by our clients is the ability of Drytech concretes to enable faster and safer drying. Unlike conventional refractories with high cement content, Drytech technology does not contain chemically bound water. This means that all the liquid in the mix can be removed quickly and in a controlled manner at temperatures as low as 100°C.
This simplified process has several direct implications. First, it drastically reduces equipment startup time, which is crucial in contexts where technical shutdowns affect production and revenue. Second, it reduces the risk of explosions due to steam pressure, providing greater safety guarantees during critical drying phases.
In projects where speed is crucial, such as scheduled shutdowns or urgent maintenance, having a coating system that reduces drying times without compromising quality is a significant competitive advantage. Alfran has seen firsthand how this efficiency positively impacts the operational indicators of its clients, particularly in thermally demanding sectors like cement and steel.
Reduction of Energy Consumption
Energy efficiency is now a priority for all industries, both for economic and environmental reasons. In this context, Drytech materials offer up to a 50% reduction in energy consumption during drying, compared to conventional cement-based materials. This is because they require lower temperatures and less time to reach optimal service conditions.
With greater permeability, Drytech products allow for more efficient release of steam generated during drying, which means less internal pressure and, therefore, lower energy use to force this release. As a result, fewer resources are required to achieve operational conditions, optimizing the use of heating systems.
The benefit isn’t just energy-related. This reduction also translates into a lower need for auxiliary infrastructure (such as kilns or intensive heating systems), which leads to lower investment and less technical complexity during coating installation. For many industrial plants, this savings represents a direct and positive impact on their operational costs.
Sustainability and Emission Reduction
Aligning industrial production with sustainability criteria is an unavoidable need. Drytech refractory coatings actively help reduce the environmental footprint of facilities due to their low impact during the drying phase and increased durability during operation.
By reducing energy consumption, they also lower CO₂ emissions. This effect is particularly relevant in the context of the energy transition happening in sectors such as cement, where environmental regulations are becoming increasingly strict. The fact that these materials do not contain cement (one of the most carbon-intensive industrial products) further contributes to the sustainability of the process.
The greater durability of Drytech concretes, which better withstand thermal cycles and aggressive environments, allows for longer intervals between maintenance interventions. This reduces waste generation and the use of material and logistical resources, providing additional environmental benefits for industries’ sustainability efforts.
Reduced Maintenance and Greater Durability
Another key benefit of Drytech refractory coatings is their high resistance to the most severe operational conditions. Thanks to their optimized microstructure and the formation of ceramic bonds at low temperatures, these materials have lower porosity and excellent thermal stability.
This combination ensures that Drytech coatings perform exceptionally well against abrasion, thermal shock, and chemical attack, extending the lifespan of the coating and reducing the frequency of maintenance shutdowns. In the long run, this results in fewer interruptions, lower replacement costs, and greater availability of critical equipment.
The ability to apply Drytech materials using various methods (vibrocasting, guniting, pumping, or shotcrete) guarantees their versatility to adapt to different furnace, tower, boiler, or reactor configurations, facilitating installation and improving execution times without sacrificing performance.
Stock Management Optimization
A differentiating aspect of the Drytech range is that it contains no cement and, therefore, has no expiration date. This detail, which may seem minor, has a significant impact on inventory management and internal logistics for any industrial plant. Materials can be stored for longer periods without losing their properties, allowing for more flexible and efficient planning.
This feature also helps avoid waste and reduces the risk of material obsolescence, which is especially useful in environments where maintenance cycles are irregular or subject to unforeseen variations. It eliminates the pressure of having to consume materials within a specific time window.
The greater stability of the materials not only optimizes space and logistical resources but also simplifies decision-making and cost control. This way, companies can maintain a strategic reserve of materials without incurring penalties for expiration, aligning their management with operational efficiency principles.
The benefits of Drytech refractory coatings developed by Alfran go far beyond their excellent thermal performance. They represent a comprehensive solution that optimizes resources, improves productivity, reduces costs, and advances sustainability. Thanks to their technological foundation, these materials are set to play a key role in the present and future of industrial coatings.
For more information about the Drytech range or technical advice for its application in your plant, our team is available to assist you. At Alfran, we remain committed to protecting the heart of the industry.