01
The Challenge
Quantify energy savings, confirm coating performance under operating conditions, and support modeling for industrial-scale application, with energy intensity and emissions reduction at the core of the program.
02
What Was Applied
Emisshield on the radiant walls and ceiling of the two cracking cells, operating from 700 to 980°C; preheat cells uncoated as control. Thickness, surface preparation, and application followed field protocols. Thermal and process data were gathered over repeated cracking cycles and benchmarked against uncoated operation under identical load and severity.
03
Why It Worked
Higher wall emissivity increases radiant transfer to the coils at the same firing, so the pilot met the same conversion on less fuel. See Research & Innovation.
04
Summary of Results
| Metric | Uncoated | Coated |
|---|---|---|
| Fuel consumption (steady state) | Baseline | −4.8% |
| Feed conversion and outlet temperature | Baseline | Unchanged |
| Refractory emissivity (independent lab) | ~0.4 | ~0.95 |
| Coating performance range | Stable 700 to 980°C | |
| Full-scale projection (CFD and radiative modeling) | 7 to 12% energy savings |
The results validate both Emisshield's performance and the predictive models used to guide industrial adoption, with lower CO2 emissions.