Calderys has successfully demonstrated the first full aluminium furnace relining using its Fast Dry (FD) and Steady Dry (SD) refractory technologies, achieving a reduction in dry-out time of more than 50%. The project involved the complete relining of a 25-ton aluminium melting furnace during a planned shutdown, enabling a faster return to production while lowering energy consumption during commissioning. The customer sought a solution that would minimise downtime, optimise relining costs and provide reliable operation for at least 12 to 15 months without requiring refractory repairs.

Following a detailed technical assessment, Calderys determined that a conventional refractory lining would not meet the customer’s performance targets. While its FD and SD technologies had already been proven in partial furnace repairs, a complete furnace relining using only these materials had not previously been implemented. Engineers evaluated moisture evacuation throughout the lining system, potential dry-out risks caused by restricted water drainage beneath the hearth, and the zoning requirements needed to withstand different thermal, mechanical and chemical operating conditions.

To address these challenges, Calderys engineered a fully integrated refractory concept using Fast Dry materials in high-risk metal-contact areas and Steady Dry products in upper structural sections to ensure controlled drying and long-term thermal stability. The lining incorporated CALDE® CAST GIBRAM FD for the sill, ALKON® CAST LB 85 FD for the hearth and lower walls, CALDE® CAST M 28 D HR SD for the upper walls and roof, and CALDE® CAST LX 58 SD for the lintel. A newly developed drainage system was also integrated to improve moisture evacuation throughout the lining.

In addition to supplying refractory materials, Calderys provided engineering design, installation supervision, on-site marking of drill locations and water evacuation paths, and technical guidance during commissioning and dry-out.

The project was completed without explosive spalling, cracking or repair requirements, while reduced burner runtime lowered both energy consumption and CO₂ emissions. The furnace has since returned to continuous operation without refractory-related issues, demonstrating the effectiveness of a fully integrated FD/SD refractory system for accelerated furnace commissioning.