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.

Download here more information: Alfran, refractory installation by pumping

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.

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.

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.

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.

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

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.

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.

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.

Alfran has acquired two autonomous demolition equipment. With this acquisition continues the bet for the modernization of the company. From Alfran, we keep seeking to offer our clients the most innovative methods.

Specifically, a Brokk 100 and a Brokk 180, to be able to cover demolition work in different areas. These autonomous demolition equipment are very versatile machines, which provide great advantages in demolition works:

• It minimizes the risk of incidents / accidents when dealing with autonomous machines with remote control (the presence of personnel within the equipment to be demolished is not necessary).
• Decrease of overexertion and fatigue of the personnel compared to manual demolition with hammers.
• Substantial improvement of yields by shortening demolition days.

Autonomous demolition equipment, one step more for the satisfaction of our clientes

These machines will allow us to satisfy the needs of our clientes in a faster and safer way, helping us to meet our Customer Service objectives and for Safety to remain a Value for Alfran.