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.
Related Posts
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?
- Reduced number of people. This highly improves safety operating conditions.
- High quality and performance. Accurate control of mixing liquid (WET PROCESS).
- High-speed installation: Average of 30 tons / 12h-shift.
- High efficiency & Energy Savings. < 10% losses.
This summer, we told you in a post about theoretical-practical workshops that had been held in Colombia.
In line with our commitment to ongoing training for clients, another series of sessions have been organized during the month of September. On this occasion, the sessions were held in Spain, with participants from different countries.
There were four days in which there was both theoretical and practical training. It began with a guided tour of the factory, to know the manufacturing equipment and sacking of materials. Additionally, the participants learnt about the manufacturing process for precast shapes.
After visiting the factory, the participants were also able to visit our laboratory, where they were explained some of the quality tests and the characterization of concretes, which we carried out in Alfran.
Following the dynamics of previous workshops, the participants had the opportunity to mix, vibrate, shoot and project via shotcrete, with their own hands, the different materials on a test panel.
Four days of training for the cement sector
Some of the subjetcs covered during these four days were the following:
- Theoretical training on joint systems.
- Theoretical training on the anchoring systems used.
- Alfran procedures: method of generation and implementation of Alfran procedures for the installation of refractories.
- Drying of refractories
- Planning of works in the cement sector.
- Thermographic analysis
- Theoretical training on Alfran Steel Tech materials technology.
- Gun-Mix systems: theoretical training of the application system and practice on the test panel. Explanation of the equipment and the factors that affect the installation of High Gun materials.
- Alfranjet installation system: theoretical training of the application system and practical training on the system assembly method. Practical training on test panels with explanation of the equipment and the factors that affect the installation of Alfranjet materials.
- Bricks installation system in a rotary kiln.
Of the training sessions, it is worth noting the commitment of the different collaborators. Multinational teamwork, Alfran Mode.
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.
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.
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 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
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.
ALFRAN commits to integrating the basic principles of health promotion at work. The Luxembourg Declaration, promoted by the European Network for Workplace Health Promotion (ENWHP), establishes the main principles of action and the reference frame for good management for workers’ health. With this certificate, ALFRAN reinforces its strong commitment to the health of all company collaborators.
Continuing with the goalof converting Health and Safety into a VALUE for Grupo Aldomer, we emphasize the importance of safety when working at height.
In Spain, around 50 workers die each year from blows as a result of falls, being the third most common form of fatal accident during work hours (10%), behind non-traumatic pathologies (44%) and traffic accidents ( 14%).
For the possible explanation and search for causes for this type of work accidents related to falls in height, we could find many different factors:
- Lack of training and information
- Use of personal protection equipment that is wrong or in poor condition.
In the specific case of working at height, worker training is essential, due to the complexity of the equipment intended for this purpose and its misuse; 25% of workers who at some point have to perform work with a risk of falling from a height, do NOT use the appropriate EPIS or PPE or use them in a scenario that requires a specific fall arrest system and with configuration and design parameters Associated with each situation. Depending on the Health and Safety campaign, we comment on the following:
Remember:
- Any work over 2 meters without effective protections (individual or collective) is prohibited.
- Hold the handrail on stairs and move carefully.
- Always keep 3 points of contact when using vertical ladders.
- The anti-fall PPE should only be used in cases where the protection of collective protections is not technically possible, since they do not prevent the materialization of the risk (fall in height), they simply reduce the consequences.
When using a harness:
- Adjust it properly. A badly placed harness can cause serious injury in the event of a fall.
- Check that it is in good condition and that it has no visible damage.
- Make sure you anchor to a sturdy point of sufficient height to stop the fall before impact. Whenever possible, do it above the head and on the same vertical, to reduce the drop factor and the pendulum effect.
- Do not jump between different levels.
- Do not run.
Before climbing a scaffold:
- Check that you have a green label with an effective date and follow all the indications reflected.
- Make sure the maximum scaffold load is adequate and respect it.
- Verify that the scaffold is not damaged and that it adapts to the needs of the work.
- Keep the hatch of the access ladder closed except when you are climbing or going down the stairs.
- Any modification of the scaffolding by personnel outside the specialized company that installs and certifies it is strictly prohibited.
In all work activities, to achieve an acceptable level of safety, it is vitally important to ensure and maintain adequate conditions of order and cleanliness. The lack of order and cleanliness in the facilities is a risk factor that deserves special attention since it is the cause of many accidents, falls due to stumbles or slips, bumps or steps on objects, and deterioration of equipment or facilities, which can lead to results other than those expected.
To achieve the goal of keeping the company “clean and tidy”, all staff must assimilate concepts such as:
1. Eliminate the unnecessary and classify the useful:
– Have the means to eliminate what is useless, prioritizing the elimination according to its usefulness.
– Classify according to utility and collect the useless in containers.
– Separate those elements that should not be in contact with others.
– In the case of flammable products, use metal drums with a fire-resistant lid.
– Machines with possible leaks must have a collection and drainage system.
– Act on the reasons why waste accumulates.
2. Store the material in appropriate places so that it can be easily located:
– Put everything in its place and eliminate what is useless.
– Collect tools on shelves that are easy to locate and identify.
– Designate the locations based on their functionality and speed of placement.
– Delimit and indicate the location of things.
– Classify waste properly.
3. Avoid dirtying and, if it gets dirty, clean immediately:
– Eliminate and control everything that can dirty.
– Cleaning is the means of controlling the state of things.
– Cleaning people must be properly trained and equipped.
– Quickly eliminate residues or substances that can contaminate and cause accidents.
– Avoid slippery floors due to oils or grease. Windows will be cleaned to allow light to enter.
– Keep changing rooms, showers, etc. clean.
– Involve staff in cleaning the environment.
– Control the critical points that generate dirt.
4. Generate work habits aimed at favoring order and cleanliness, etc:
– The characteristics of the floors, ceilings, etc. They shall be such as to allow easy cleaning.
– Standardize procedures by order and cleanliness.
–
Alfranpump and Its Application of Pumpable Refractory Concretes
In the search for more efficient and safer solutions for installing refractory linings, Pumpcrete has emerged as a revolutionary technology.
Primarily applied in industries such as cement and metallurgy, this technique enables the projection of pumpable refractory concretes, offering physical-chemical characteristics similar to vibrocasting but with additional benefits in terms of safety, speed, and durability. Alfran, always committed to innovation, has developed Alfranpump, a range of products specifically designed to maximize the advantages of this technology in demanding industrial conditions.
Advantages of Pumpcrete with Alfranpump
Alfranpump offers several key operational advantages for industrial sectors requiring durable refractory linings that can withstand high temperatures:
- Speed and application efficiency: Thanks to pumping technology, Pumpcrete enables the rapid and precise application of concrete, essential for reducing downtime in industrial facilities.
- Enhanced safety: Automated application reduces the need for direct handling, minimizing process-associated risks and the number of required operators. This creates a safer, more controlled work environment.
- High-quality finish: Unlike other methods, Pumpcrete applied with Alfranpump delivers a mirror-like finish. This not only improves the resistance of the lining but also enhances its durability in extreme conditions.
- Sustainability and energy efficiency: The use of Pumpcrete optimizes energy efficiency by allowing faster drying and better heat retention within facilities, contributing to process sustainability.
Pumpcrete Application Technology
Pumpcrete is characterized by high-pressure pumping systems that project refractory concrete in a uniform and controlled manner. During the process, the concrete, previously prepared with the necessary liquids and additives, is pumped and projected with great precision. This method excels in achieving high material compactness, minimizing porosity, and improving mechanical strength.
Alfranpump technology is optimized to meet the highest standards of quality and efficiency. Pumped refractory materials maintain performance comparable to vibrocasting, with the added advantage of a faster installation process that is less demanding in terms of human resources.
Operational Benefits of Alfranpump
- Reduced downtime: By enabling quick and precise application, Alfranpump minimizes equipment downtime in industrial facilities, which is essential for maintaining plant productivity.
- Resource optimization: Automated pumping technology significantly reduces the need for operational staff and associated costs, while also providing a safer work environment with less risk exposure.
- Durability and resistance in extreme conditions: Linings applied with Alfranpump are highly resistant to abrasion, thermal shock, and chemical attacks. This ensures the integrity and functionality of the linings under adverse operating conditions.
Success Stories and Applications
The applications of Alfranpump in sectors such as cement and metallurgy have proven to be particularly successful, extending the service life of refractory linings and improving operational efficiency. In cement kilns, for instance, refractory materials installed with Alfranpump have demonstrated exceptional resistance to thermal and mechanical wear, increasing the durability of the linings.
Similarly, in the steel industry, where linings must endure thermal shocks and high levels of abrasion, Alfranpump has enabled industrial plants to optimize maintenance processes, reduce costs, and enhance operational safety.
Alfranpump’s Pumpcrete technology represents an advanced and reliable solution for installing refractory linings in industries requiring high resistance and durability.
Thanks to its multiple advantages, such as reduced downtime, resource optimization, and a safer work environment, Alfranpump positions itself as an ideal alternative for demanding industrial sectors. Furthermore, it contributes to sustainability and energy efficiency, aligning with the modern industry’s current needs.