01
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
Why It Worked
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.
04
Summary of 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.