Case Study · Hydrocarbon & Chemical
Ceramic Fiber High Emissivity Coating: Third-Party Shrinkage and Temperature Testing
| Industry | Hydrocarbon & Chemical (laboratory validation) |
|---|---|
| Asset | Ceramic fiber modules |
| Customer or location | Third-party test program |
| Products used | Emisshield ST-series |
| Headline metric | Shrinkage <1% vs 2 to 5% |
| Secondary metric | +~150°C continuous-duty limit |
| Also measured | Cold face 6 to 10°C lower |
Independent testing evaluated how Emisshield affects ceramic fiber modules across fiber types and temperatures. Coated modules shrank less than 1% against 2 to 5% for uncoated fiber, tolerated continuous duty roughly 150°C higher, and ran 6 to 10°C cooler on the cold face.
01
What was the challenge?
Ceramic fiber linings shrink, dust, and lose insulation integrity at temperature, which shortens lining life and limits operating temperature. The test objectives were to determine whether the coating reduces shrinkage, raises the continuous-duty temperature limit, and lowers the cold-face surface temperature.
02
What was applied?
Six tests over a one-month period across fiber types and temperatures. Twelve thermocouples monitored hot-face and cold-face temperatures plus furnace and load conditions. Emisshield was applied to some fiber samples; others were left uncoated for comparison. In one comparison, 1-3/8 inch INSWOOL HP after 30 minutes at 2,500°F (1,371°C) showed 35 mm shrinkage uncoated against 5 mm coated.
03
What were the results?
| Metric | Uncoated | Coated |
|---|---|---|
| Shrinkage | 2 to 5% | <1% |
| Continuous-duty temperature limit | Baseline | ~150°C higher |
| Cold-face temperature | Baseline | 6 to 10°C lower |
| Size and shape retention | Degraded | Significantly better |
The coating extends the life of ceramic fiber linings, decreases downtime and maintenance, and allows operation at higher process temperatures.
04
Why did it work?
The coating seals the fiber surface and re-radiates absorbed energy rather than letting it drive the fiber to its shrinkage temperature; less energy is conducted through the module, so the cold face runs cooler. See How Emissivity Works.
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