Dry-Free™｜Monolithic refractory used for lining and repairing various furnaces and incinerators

K-GenesisX™

Dry-Free™

Features
Advantages
CO₂ Emission Reduction Data
Interview

Dry-Free™

Features of Dry-Free™

Dry-Free™ is a monolithic refractory used for lining and repairing various furnaces and incinerators in steel and non-ferrous metal industries.
Conventional monolithic refractories require long drying time through furnace heating before use, causing operations to stop and creating idle time during heating.
Dry-Free™ is a groundbreaking monolithic refractory that eliminates the need for this drying process.

Dry-Free™ dramatically reduces heating time compared to conventional products — *The above graph is just an example. Heating time varies depending on the customer’s equipment, thickness of the installed monolithic refractories, and other factors.

Moreover, Dry-Free™ has been successfully selected for the top award of “Kitakyushu Eco Premium,” which is Kitakyushu City’s (Located in Fukuoka prefecture, Japan) designation for environmentally friendly products.

Presentation Materials and inquiries for Dry-Free™

Advantages of Dry-Free™

1 Improved furnace operation rate by eliminating the drying process

Conventional monolithic typically require a drying process of up to one week before furnace use, depending on the customer. With Dry-Free™, such long drying times become a non-requirement, and the furnace can be dried with just preheating before use.
This reduces operational stoppages (idling time), thereby increasing the furnace operation rate. This leads to improved productivity, reduced opportunity losses, and shorter construction periods.

2 Preventing explosive spalling during drying to reduce furnace damage and accident risks

Conventional monolithic refractories sometimes experience explosive spalling & damage caused by steam pressure building up inside the installed material when dried too quickly at high temperatures, and this highly disrupts stable operations. Therefore, it is necessary to dry slowly at low temperatures over a long period of time.
Dry-Free™, on the other hand, with its highly improved permeability, prevents buildup of internal steam pressure. This eliminates the risk of explosive spalling, allowing for safe use and stable operations.

3 Reduction of repair and replacement costs through longer service life

Dry-Free™ improves heat resistance, corrosion resistance, and crack & spall resistance.
As a result, it achieves longer service life and contributes to the reduction of customers’ service life cycle costs (LCC).

4 Reducing CO₂ emissions in the drying process

Dry-Free™ reduces CO₂ emissions through its non-requirement of drying, conventionally generated by the combustion of fossil fuels and other fuels necessary for drying.
This leads to fuel cost savings (such as on heavy oil and gas).

Presentation Materials and inquiries for Dry-Free™

CO₂ Emissions Reduction Data for Dry-Free™

Our customers in Japan who incinerate industrial waste have been able to reduce the use of Bunker A grade oil for drying operations by upto 48.3 kiloliters by adopting Dry-Free™.
This is equivalent to a maximum CO₂ reduction effect of 133 tons per construction project.

Amount of Bunker A grade oil used

Reduction of Bunker A grade oil by a maximum of approximately 48 kiloliters

CO₂ emissions

Maximum CO₂ reduction effect of approximately 130 tons

*Carbon dioxide emission factor (Bunker A grade oil): 2.75 t-CO₂/kl (Source: Ministry of the Environment “List of Calculation Methods and Emission Factors in the Calculation, Reporting, and Publication System”)

*CO₂ emission reduction effect varies depending on the drying process time and the type/amount of fuel used

Dry-Free™ Interview
（Team member Interviews）

Dry-Free™

Interview | A challenge that overturns conventional wisdom by eliminating drying process for monolithic refractories.

Conventional drying processes require 90 to 100 hours, during which time the temperature inside the furnace must be carefully controlled in tens of degrees Celsius increments. With the introduction of Dry-Free™, however, the drying process itself is no longer necessary, and the furnace can be started up with only the temperature rise necessary for incineration. As a result, start-up can now be accomplished in as little as eight hours.

Technical papers