Custom Lining Configuration

Define your own lining configuration to compare against the preset options. All values are fully editable.

Material Costs
Material Amount (kg) Price (/tonne or /unit) Cost (EUR)
/tonne 504.00
/unit 442.80
/tonne 753.35
/tonne 471.80
/unit 0.00
- fixed 0.00
Total Material Cost 2,171.95

Formula: Cost = (kg × Price/tonne) / 1000 or qty × Price/unit

Labour Costs (Work hours)
Activity Time (h) Cost/h (EUR) Cost (EUR)
31 744.00
31 372.00
31 62.00
31 372.00
31 62.00
Total 52 1,612.00

Formula: Cost = Time × Cost/h

Drying/Sintering Costs
Parameter Burner capacity Burner efficiency Avg. consumption
Gas consumption 17 kg/h % 14.00 kg/h
Parameter Value Unit
Drying / sintering time h
Cost sintering / lining 225.99 EUR

Formula: Avg. consumption = Burner capacity × Efficiency | Cost = Drying time × Cost/kg gas × Avg. consumption

Maintenance Costs
Parameter Value Unit
h maintenance + material per lining h
Cost maintenance top/lining 1,240.00 EUR

Formula: Cost = h maintenance × Labour cost × 2

CIF Specifics
Parameter Value Unit
Number of melts / lining melts
Tonnes / lining 1,620 tonnes
No. of linings annually 15.43 linings

Formulas: Tonnes/lining = Liquid capacity × Melts | Linings/year = Annual tonnage ÷ Tonnes/lining

Summary Custom Lining

Material cost€2,171.95
Labour cost€1,612.00
Heating cost€225.99
Maintenance€1,240.00
Cost / lining (EUR)€5,249.94

1. Conventional Lining

Material Costs
Material Amount (kg) Price (/tonne or /unit) Cost (EUR)
SILICA MIX 7 A 0,8 /tonne 504.00
Mica sheets /unit 442.80
GIBRAM /tonne 753.35
Spout material /tonne 471.80
Others /unit 0.00
Total Material Cost 2,171.95

Formula: Cost = (kg × Price/tonne) / 1000 or qty × Price/unit

Labour Costs (Work hours)
Activity Time (h) Cost/h (EUR) Cost (EUR)
Silica installation 31 744.00
Castable Installation 31 372.00
Making spouts 31 62.00
Sintering 0.00
Ramming spout 31 62.00
Others 31 0.00
Total 52 1,240.00

Formula: Cost = Time × Cost/h

Drying/Sintering Costs
Parameter Burner capacity Burner efficiency Avg. consumption
Gas consumption 17 kg/h % 14.00 kg/h
Parameter Value Unit
Drying / sintering time h
Cost sintering / lining 225.99 EUR

Formula: Avg. consumption = Burner capacity × Efficiency | Traditional linings use ~82% efficiency for 15h = 210 kg total gas

Maintenance Costs
Parameter Value Unit
h maintenance + material per lining h
Cost maintenance top/lining 1,240.00 EUR

Formula: Cost = h maintenance × Labour cost × 2

CIF Specifics
Parameter Value Unit
Number of melts / lining melts
Tonnes / lining 1,620 tonnes
No. of linings annually 15.43 linings

Formulas: Tonnes/lining = Liquid capacity × Melts | Linings/year = Annual tonnage ÷ Tonnes/lining

Summary Conventional Lining

Material cost€2,171.95
Labour cost€1,240.00
Heating cost€225.99
Maintenance€1,240.00
Cost / lining (EUR)€4,877.95

2. Improved Q Lining

Material Costs
Material Amount (kg) Price (/tonne or /unit) Cost (EUR)
SILICA MIX Q 15 /tonne 990.00
Mica sheets /unit 442.80
GIBRAM /tonne 753.35
Spout material /tonne 471.80
Others /unit 0.00
Total Material Cost 2,657.95

Formula: Cost = (kg × Price/tonne) / 1000 or qty × Price/unit

Labour Costs (Work hours)
Activity Time (h) Cost/h (EUR) Cost (EUR)
Silica installation 31 744.00
Castable Installation 31 372.00
Making spouts 31 62.00
Sintering 0.00
Ramming spout 31 62.00
Others 31 0.00
Total 52 1,240.00

Formula: Cost = Time × Cost/h

Drying/Sintering Costs
Parameter Burner capacity Burner efficiency Avg. consumption
Gas consumption 17 kg/h % 14.00 kg/h
Parameter Value Unit
Drying / sintering time h
Cost sintering / lining 225.99 EUR

Formula: Avg. consumption = Burner capacity × Efficiency | Traditional linings use ~82% efficiency for 15h = 210 kg total gas

Maintenance Costs
Parameter Value Unit
h maintenance top/lining h
Cost maintenance top/lining 930.00 EUR

Formula: Cost = h maintenance × Labour cost × 2

CIF Specifics
Parameter Value Unit
Number of melts / lining melts
Tonnes / lining 1,800 tonnes
No. of linings annually 13.89 linings

Formulas: Tonnes/lining = Liquid capacity × Melts | Linings/year = Annual tonnage ÷ Tonnes/lining

Summary Improved Q Lining

Material cost€2,657.95
Labour cost€1,240.00
Heating cost€225.99
Maintenance cost€930.00
Cost / lining (EUR)€5,053.95

3. CALDE® GUARD Concept

Material Costs
Material Amount (kg/qty) Price (/tonne or /unit) Cost (EUR)
SILICA MIX Q BF /tonne 620.00
Mica sheets /unit 442.80
Q 15 BF RIGID /tonne 453.00
Spout material /tonne 0.00
Precast Spout /unit 400.00
Top ring - fixed 1,600.00
Total Material Cost 3,515.80

Formula: Cost = (kg × Price/tonne) / 1000 or qty × Price/unit

Labour Costs (Work hours)
Activity Time (h) Cost/h (EUR) Cost (EUR)
Silica installation 31 744.00
Top ring installation 31 15.50
Sintering 31 46.50
Ramming spout 31 62.00
Others 31 0.00
Total 28 868.00

Formula: Cost = Time × Cost/h

Drying/Sintering Costs
Parameter Burner capacity Burner efficiency Avg. consumption
Gas consumption 17 kg/h % 17.00 kg/h
Parameter Value Unit
Drying / sintering time h
Cost sintering / lining 18.30 EUR

Formula: Avg. consumption = Burner capacity × Efficiency | CALDE® GUARD uses 100% burner capacity for only 1h = 17 kg total gas (92% less than traditional)

Maintenance Costs
Parameter Value Unit
h maintenance top/lining h
Cost maintenance top/lining 124.00 EUR

Formula: Cost = h maintenance × Labour cost × 2

CIF Specifics
Parameter Value Unit
Number of melts / lining melts
Tonnes / lining 2,100 tonnes
No. of linings annually 11.90 linings

Formulas: Tonnes/lining = Liquid capacity × Melts | Linings/year = Annual tonnage ÷ Tonnes/lining

Summary CALDE® GUARD Concept

Material cost€3,515.80
Labour cost€868.00
Heating cost€18.30
Maintenance cost€124.00
Cost / lining (EUR)€4,526.10

Rapport

Compilation - Cost Breakdown
Component Custom Lining Conventional Lining Improved Q Lining CALDE® GUARD Concept
Material cost €2,171.95 €2,171.95 €2,657.95 €3,515.80
Labour cost €1,612.00 €1,240.00 €1,240.00 €868.00
Heating cost €225.99 €225.99 €225.99 €18.30
Maintenance cost €1,240.00 €1,240.00 €930.00 €124.00
Cost / lining (EUR) €5,249.94 €4,877.95 €5,053.95 €4,526.10

Formulas: Material = Σ(kg × price/tonne)/1000 | Labour = Work hours × Labour rate | Heating = Drying time × Cost/kg gas × Gas consumption | Maintenance = Hours × Labour rate × 2 | Total = Material + Labour + Heating + Maintenance

Derived Metrics
Metric Custom Conventional Improved Q CALDE® GUARD
Cost / lining (EUR) €5,249.94 €4,877.95 €5,053.95 €4,526.10
Cost refractory / tonne iron (EUR) €3.24 €3.01 €2.81 €2.16
Annual cost (k EUR) €81.02k €75.28k €70.19k €53.88k
CIF downtime/lining (h) 67 67 67 29
CIF downtime annual (h) 1,033.95 1,033.95 930.56 345.24
CO2/lining (kg) 627.90 762.45 627.90 50.83
Annual CO2 emissions (kg) 9,689.81 11,766.20 8,720.83 605.12

Formulas: Tonnes/lining = Liquid capacity × Melts | Linings/year = Annual tonnage ÷ Tonnes/lining | Cost/tonne = (Cost/lining × Linings/year) ÷ Annual tonnage | Annual cost = Cost/tonne × Annual tonnage ÷ 1000 | Downtime/lining = Work hours + Drying time | CO2/lining = 2.99 × Gas consumption × Drying time

Theoretical Metrics (incl. maintenance)

These projections include maintenance hours in addition to work and drying time, providing a comprehensive view of total operational impact.

Metric Custom Conventional Improved Q CALDE® GUARD
Theoretical downtime/lining (h) 87 87 82 31
Theoretical annual downtime (h) 1,342.59 1,342.59 1,138.89 369.05

Formula: Theoretical downtime = Work hours + Drying time + Maintenance hours

Compare vs CALDE® GUARD

Select which lining concept to compare against CALDE® GUARD:

vs
CALDE® GUARD €4,526.10/lining

⚡ Quick Analysis: CALDE® GUARD vs Conventional

€21.40k
28.4% savings
689h
66.6% reduction
9,085 kg
93.8% reduction

Formulas: Cost savings = Annual cost (selected) − Annual cost (CALDE®) | Downtime reduction = Annual downtime (selected) − Annual downtime (CALDE®) | CO2 reduction = Annual CO2 (selected) − Annual CO2 (CALDE®)

📊 Break-even Analysis: CALDE® GUARD vs Conventional

Explore scenarios where Conventional lining could become more cost-effective than CALDE® GUARD. Each scenario isolates one variable while keeping others at their default values.

Scenario 1: Labour Cost

CALDE® GUARD saves on labour (28h vs 52h) and maintenance (2h vs 20h). At very low labour costs, this advantage diminishes.

€5/h€60/h
Conventional €4,877.95
CALDE® GUARD €4,526.10
CALDE® GUARD wins Break-even at €7.79/h

Formula: Cost/lining = Material + (Work hours × Labour rate) + Heating + (Maintenance hours × Labour rate × 2)

Scenario 2: CALDE® GUARD Material Cost

CALDE® GUARD materials cost more (€3,515.80 vs €2,171.95). If material costs increase further, the cost advantage could flip.

0.5x2.0x
Conventional €4,877.95
CALDE® GUARD €4,526.10
CALDE® GUARD wins Break-even at 1.10x

Formula: CALDE® GUARD cost = (Base material cost × Multiplier) + Labour + Heating + Maintenance

Scenario 3: CALDE® GUARD Maintenance Hours

CALDE® GUARD requires far less maintenance (2h vs 20h for Conventional). If this increases significantly, the advantage shrinks.

0h30h
Conventional €4,877.95
CALDE® GUARD €4,526.10
CALDE® GUARD wins Break-even at 7.67h

Formula: Maintenance cost = Maintenance hours × Labour rate × 2

Scenario 4: CALDE® GUARD Durability (Melts/Lining)

CALDE® GUARD lasts longer (350 melts vs 270). If durability decreases, more linings are needed annually, increasing total cost.

100500
Conventional (annual) €75,277
CALDE® GUARD (annual) €53,881
CALDE® GUARD wins Break-even at 251 melts

Formula: Annual cost = Cost/lining × (Annual tonnage ÷ (Liquid capacity × Melts/lining))

📋 Summary: When does Conventional win?

Scenario Current Value Break-even Point Likelihood
Labour cost €31/h €7.79/h Very unlikely
Material cost multiplier 1.0x 1.10x Possible
Maintenance hours 2h 7.67h Unlikely
Melts per lining 350 251 Unlikely

🌍 CO2 Impact Analysis: CALDE® GUARD vs Conventional

Discover the environmental and financial benefits of reduced CO2 emissions with CALDE® GUARD.

Time to CO2 Savings Milestone

See how quickly CALDE® GUARD pays off environmentally. Set your CO2 reduction target and see when you'll reach it.

10 tonnes500 tonnes
Conventional CO2/year 9,690 kg
CALDE® GUARD CO2/year 605 kg
🏆 Reach 50 tonnes saved in 5.5 years Annual CO2 savings: 9,085 kg

Formulas: CO2/lining = 2.99 × Gas consumption × Drying time | Annual CO2 = CO2/lining × Linings/year | Years to target = Target ÷ Annual savings

Rising CO2 Price Impact

EU CO2 prices are rising from ~€75/ton today towards €150-200+/ton by 2030. See how this amplifies CALDE® GUARD's cost advantage.

€50/ton€300/ton (2030+)
Conventional CO2 cost/year €727
CALDE® GUARD CO2 cost/year €45
💰 Extra annual savings from lower CO2 €681 At €150/ton: €1,363/year extra

Projected savings at future CO2 prices

2025 €88/ton €800/yr
2027 €120/ton €1,091/yr
2030 €165/ton €1,499/yr

Formula: CO2 cost/year = (Annual CO2 emissions ÷ 1000) × CO2 price/ton | Savings = CO2 cost (selected) − CO2 cost (CALDE®)