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Himanshi Srivastava
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Jan 28,
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The anchoring design for industrial refractory linings must be done with great care and consideration. The use of inadequate refractory anchors can jeopardize the production process and the safety of the workers.
Our experience is in designing, manufacturing, and supplying refractory anchoring systems for use in high-temperature applications, among other things.
A specialty of the fastener maker refractory anchors, which makes fasteners for refractory anchorage in furnaces and process equipment, is high-temperature alloys and stainless steel fasteners. Stubborn anchor hardware is used to construct several anchoring devices, including die-stamped, wire-formed, and wielded anchors. This category comprises abrasion-resistant castable monolithic and ceramic fiber linings and abrasion-resistant castable monolithic and ceramic fiber linings. FibreCast manufactures a wide range of fasteners and products for refractory anchoring products. Firebrick, monolithic refractory, shotcrete, gunite, fireproofing, and ceramic fiber are some anchoring techniques available for use. In addition to being available in a wide range of shapes and sizes, anchors manufactured of refractory material can be custom designed to fulfill a wide range of needs.
All industries can benefit from FibreCast products, including refractory anchors, which are available from the company. As a result, we have maintained our position as the world&#;s top manufacturer, supplier, and marketer of refractory anchor goods: we produce superior products to those offered by our competitors. Because of these features, refractory anchors have saved tens of thousands of dollars in energy expenses while also reducing the amount of waste generated by their use. You&#;ve arrived at the end of your quest for refractory anchors because no such products are available on the market.
Benefits
Industrial furnaces, kilns, reactors, ovens, and containers can be used for various activities, including the production of steel. Normal operating conditions would result in the application&#;s exterior shell destruction. Heat, pressure, and chemical degradation-resistant materials are used as barriers due to this. Refractories, often known as refractory materials, are used in various applications.
To be effectively linked to the furnace or kiln shells, castable refractory materials, fiber insulation, and ceramic fiber modules all require anchoring systems to be installed. Stainless steel and nickel alloys are used to construct these devices, which can be employed for various applications.
· To keep the refractory in place, it should be secured to the wall.
· Thermal strains created by high temperatures might cause the walls to bow, causing them to collapse structurally in the end.
· Contribute to the weight of the refractory
There are several different types of reflective ancillary devices.
When you require high-quality refractory anchors, you can rely on Santura Engineering PVT LTD to meet your requirements. The fact that we are a leading refractory anchor provider allows us to deliver these fastening devices promptly in various sizes and configurations.
Refractory hardware must be constructed of the highest quality materials because it is subjected to the most significant amount of heat. Almost most of the high-temperature stubborn hardware manufactured by Santura Engineering PVT LTD is supplied from domestic mills. Refractory anchors made of stainless steel and nickel alloy are just two examples. Ordinary store-bought products aren&#;t always the most excellent remedy for every issue. Santura Engineering PVT LTD specializes in unique refractory anchoring systems that can be delivered in a short amount of time. If you have a well-established drawing or an idea that hasn&#;t been fully realized, our technical team can bring your concept to fruition in a timely and cost-effective manner.
Inspectors can ensure that items fulfill industry standards or specific client requirements by employing precise gauges in their work. An accompanying Material Test Report is included to verify the quality and consistency of the raw materials used for each shipment. Orders are submitted to pre-load audits before they are shipped.
Santura Engineering PVT LTD, Exporters and Suppliers in Saudi Arabia, was established in Mumbai, India, in January by Bharat Diwan as a private limited company. A metal scientist and fabricator, he applied his metal science and fabrication knowledge to transform an old-fashioned organization into a newer, more technologically advanced enterprise. To meet customer needs, Santura Engineering strives to deliver high-quality goods on time and fairly. This company has been manufacturing refractory anchors in India for many years, using furnace-mounted Sight Doors and Pipe Guides as the starting point. Our refractory anchor&#;s section consists of fasteners, anchors, steel fiber reinforcement, insulating materials, and stud welding systems, among other products. The refractory anchors produced by our company are among the best available in the United States.
Furnace Observation/Sight Doors and Explosion Doors, as well as foundation bolts, stainless steel pipe rings, spring hanger supports, and fabricated accessories, are all manufactured by our fabrication division. Based on a drawing provided by you, we may Refractory Anchors Manufacturers of stainless steel goods for you. Our engineers are committed to producing high-quality goods on every project they work on with us.
We&#;ve worked diligently to build a reputation for high quality, on-time delivery, and competitive pricing throughout our years in the refractory anchoring business. A wire-forming machine that can create 12,000 &#;V&#; shaped Refractory Anchors in a 10-hour shift was installed in our facility in the year . This has been completed. I appreciate your cooperation. Refractory Anchor items are available for use in various industrial refractory industries and come in several shapes and sizes. Customized designs are required in response to specific customer needs. Our staff scrutinizes every one of our customers&#; refractory anchor drawings to guarantee that they are executed with the highest level of precision possible for them. Our organization offers a diverse range of Refractory anchors custom-designed to meet specific requirements.
Our company is regarded as the TRUSTED name in the engineering refractory anchors industry by several of the world&#;s largest corporations in Italy, France, Mexico, Spain, Dubai, India, as well as the petrochemical, energy, shipbuilding, cement & lime stone stone stone, aluminum-copper-power, and petrochemical industries. If you&#;re looking for a reputed producer of refractory anchors, Santura Engineering Pvt Ltd in India is an excellent place to start.
Santura Engineering is a manufacturer and exporter of refractory anchors of stainless steel 310, 304, 316, 316L, Inconel, and Inconel alloy steels. Our refractory anchors have been utilized by EPC contractors working in the oil and gas, cement, iron and steel, and fertilizer industries in Thailand and the United Arab Emirates, among other places. We are well-positioned to assist you in your quest for Refractory Anchor producers around the region due to the proximity of our Mumbai, India headquarters to the Port of Nhava Sheva.
We offer two different finishes for our refractory anchors: the SS Hot Rolled finish or the Bright 2B finish. However, if you want unannealed anchors, we may provide a solution for annealed anchors as an alternative. According to Santura Engineering, refractory anchors should continuously be annealed before use.
Over the past few years, a series of unfortunate macroeconomic events have led to a severe supply disruption of refractory raw materials and related finished products. This imbalance in the market has led to unforeseen price volatility and reduced negotiation potential for prospective large-scale buyers.
Refractories are used in the manufacturing of iron and steel, petrochemicals, cement, and glass. Though the associated spend is not significant so as to classify it as a &#;head spend&#; category, refractories form a strategic component in the manufacturing process. This highly diversified category finds its manufacturing base in the APAC region, which is lately facing disruptions in the form of trade war and Coronavirus outbreak.
Category Definition: Refractories are minerals / altered ceramics designed to withstand high temperatures (over 600 degrees Celsius), and are used specifically as an insulation liner over hot surfaces in industrial manufacturing. They are also used in chemical applications due to their ability to withstand physical wear and corrosion caused by chemical agents. Refractories are manufactured from natural / synthetic materials, usually minerals of nonmetal origin, or combinations of compounds and minerals such as calcined alumina, chrome ore, magnesium, refractory grade bauxite, brown-and-white-fused-alumina, graphite, zircon, and silicon carbide.
Refractories (Type)
Refractories (Nature of use)
Acidic
Basic
Neutral
Special
Calcined Alumina
Fused Alumina
Calcined Bauxite
Fused Mullite
Andalusite
Sillimanite
Dead Burnt Magnesia
Fused Magnesia
Dead Burnt Dolomite
Chromite
Fused Spinel
Olivine
Kyanite
Refractory Clay
Pyrophyllite
Quartz
Silica sand
Fiber
Graphite
Refractory Supply Chain:
Most suppliers are involved in manufacturing both bricks and monolithic refractories that are consumed in different industries such as iron, steel, cement, glass, non-ferrous metals, and ceramics; among these, steel is the most predominant, with 60 percent of the total market share.
Transported through truck, rail, ship, and aircraft.
Intermodal shipping possesses the best characteristics of these various modes; this is four times more fuel-efficient than truck loads.
They &#;weigh out&#; before they &#;cube out.&#; As containers reach their mass limit before volume limit, they are transported in smaller container sizes in the range of 20, 40, and 45-ft.
Breakability factor is controlled by following standard blocking and bracing techniques.
Storage is in a cool, dry place, and at a minimum volume as these are a lead time of 10&#;12 weeks, with an average MOQ of about 5 to 15-ton.
Acidic refractories: 5 to 25-ton
Basic refractories: 1 to 25-ton
Neutral refractories: 3 to 15-ton
Special refractories: 1 to 5-ton
On an average, contracts are for a duration of 1&#;3 years with quarterly replenishment of products.
Refractory material failure depends on material selection and manufacture date, plant operations, material storage, mixing, installation, curing, and drying.
Refractory is replenished if the cost of energy loss value is not in accordance with the cost of insulating the system. Also called economic thickness, this takes into consideration cost of fuel, annual hours of operation, heat content of fuel, boiler efficiency, operating surface temperature, thickness of surface, cost of insulation, and average exposure to still air temperature.
Industry
Furnace Type
Replacement Timeline
Steel
Basic oxygen, Electric arc furnace casting ladles
20 minutes&#;2 months
Cement / Lime
Rotary Kiln
Annually
Non-ferrous metals
Copper-converter
1&#;10 years
Glass
Glass furnace
Up to 10 years
Energy / Environmental / Chemicals
Secondary reformer
5&#;10 years
*Source: Expert Interaction, Beroe Analysis, Supplier Interaction
Commodity
Refractory Consumed
(per ton of production)
Steel
10 to 15-kg
Aluminum
6-kg
Copper
3-kg
Cement
0.6-kg
*Source: Expert Interaction, Beroe Analysis, Supplier Interaction
Pricing
The price of refractories depends largely on four parameters, namely raw material, fixed, utility, and labor. Fixed and utility are microeconomics variables, whereas raw material and labor vary in accordance with supply-demand dynamics. Pricing for refractories can be locked on input cost (raw material cost plus contracts). Moreover, a cost plus incentive contract is established when the supplier is proactively engaging in technology that increases the life of a refractory product (e.g., developing a ceramic fiber refractory that can replace an existing product of the same specifications).
Refractories
Raw Material
Concerned Raw Material
Fixed / Indirect
Manufacturing Labor
Premium, Margin and other expense
Acidic
64 %
Calcined Alumina
Contact us to discuss your requirements of stainless steel fiber for refractory. Our experienced sales team can help you identify the options that best suit your needs.
Fused Alumina
Calcined Bauxite
Fused Mullite
Andalusite
Sillimanite
12 %
8 %
16 %
Basic
75 %
Dead Burnt Magnesia
Fused Magnesia
Dead Burnt Dolomite
Chromite
Fused Spinel
Olivine
10 %
7 %
8 %
Neutral
63 %
Kyanite
Refractory Clay
Pyrophyllite
Quartz
Silica sand
12 %
12 %
13 %
Mitigateable Risk
Accepted Risk
*Source: Beroe Database, Expert Interaction, Beroe Analysis
Refractory raw material, mostly minerals, are not traded in open exchanges. However, it is possible to track the price movement of highlighted materials through various databases. This helps in predicting the future once the buyer has a bird&#;s eye view of historical pricing and market sentiments. Similarly, currency can be hedged in order to avoid losses which may be attributed to unanticipated conversion ups and downs.
Liaoning province, which accounts for over to 80 percent of Chinese refractory material manufacturing (about 500 enterprises with more than production facilities ) is witnessing production halts due to reduced demand and logistics constrains post the Coronavirus outbreak.
Extended holidays and subsequent production drop did not have much impact on pricing because available inventory is being used up currently.
Though Liaoning province is accessible by road, exports are expected to resume by end of March mainly through Dalian and Yingkou port.
As some of the key ports affected are Shanghai, Tianjin, Huanghua, Lianyungang, Jingtang and Caofeidian, procurement managers should focus on short term (0-3 months) local sourcing so as to ensure supply security. This may come at a higher cost, but would reduce the risk of a &#;no-supply&#; situation. Globally, trading activity is expected to remain low mainly owing to markets being closed in China.
Category
Sub Category
Impact Assesment
Low
Medium
High
Alumina
High Alumina
Brown Fused Alumina
White Fused Alumina
Calcined Alumina
Bauxite
Refractory grade (85%)
Refractory grade (86%)
Refractory grade (87%)
Refractory grade (88%)
Zircon
Zirconia Refractories
Magnesia
DBM & FM
Incident
Risk Category
Risk Register
Mitigation Measure
Negative
External
Trade war
Regulation
Other force majeure
Contract to enlist &#;interim supplier change&#; as an &#;hold-to-exit&#; option in lieu of force majeure, till the condition fails to prevail. Buyer to maintain potential alternate from local / regional vendors. Alternate supplier to be awarded contract with immediate effect.
Alternatively, &#;Country of Origin&#; adjustments or &#;First-sale&#; can be requested in an unlikely event of trade war.
&#;Foreign trade zone&#; and &#;bonded warehousing&#; helps importers in maintaining efficient cash flow, avoiding customs duties, and maximizing operational savings. The realized savings can be shared with the buyer through a reduced premium.
Negative
Project
Raw material
Energy
Labor
Buyer to keep a track of input cost. Change in raw material cost is offset with margin / premium through a &#;long-term fixed-rate contract.&#;
Alternatively, buyer can support the refractory manufacturing organization by identifying suitable tier 2 suppliers and the realized savings can have a ripple-down effect.
Positive
Technology
Innovation
Buying decisions based on TCO can improve the life cycle of products and reduce overall consumption.
Positive
Inventory
Inventory reduction
Opportunity for VMI/stocking programs.
Positive
Sourcing
Tier 2 procurement
Due to fragmentation in space, there is a large range of applicable price negotiation levers to be employed.
Trade war and Covid-19 outbreak are unfortunate events that may lead to disturbance in availability and pricing of refractories. However, they are short-term events and does not necessarily translate to long-term price rise. An efficient buyer has insights into the operation of a refractory manufacturer and can thus capitalize on the savings that the manufacturer would realize through alternate measures. Alternatively, buyers must maintain a secondary list of suppliers, mostly regional (local sourcing).
Buyers prefer long-term fixed-rate contracts to ensure an uninterrupted supply of this strategically important material. However, it is beneficial to include a &#;force majeure&#; clause to support an interim supplier in case of a macroeconomic risk. The new supplier can be on a &#;cost plus&#; mode of contract.
Buyers keep track of input costs (raw material, energy, and labor) to ensure that there is no incident of overpricing by the manufacturer / seller. Negotiation levers could be input cost and margin-focused. Thus, a long-term contract of significant value with a tier 2 supplier would ensure better pricing.
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