Case Studies · Glass

Glass Furnace Crown High Emissivity Coating: 5% Energy Savings Sustained 36+ Months

Melting furnace crown and superstructure (chrome alumina)·Wool fiberglass plant

A wool fiberglass manufacturer coated the chrome-alumina crown and superstructure of a melting furnace operating above 1,600°C with Emisshield. Energy savings of 5% were sustained with no coating deterioration for more than 36 months, the project paid back within three months on energy alone, refractory ran cooler with lower chrome loss, and NOx fell.

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5% energy savings
: 36+ months, no deterioration
: ROI 3 months
: 1,600°C+ (2,900°F)

The Challenge

Specific energy above the batch line, crown refractory wear and chrome loss, and emissions at extreme melting temperatures.

What Was Applied

Emisshield on the crown and superstructure refractory, a simple application at rebuild or planned cold repair.

Technician spraying coating onto a glass melter crown

Why It Worked

The coated crown absorbs flame radiation and re-emits it downward into the melt across broader wavelengths instead of reflecting it into the exhaust, so the same pull rate needs less fuel and the crown runs cooler. See Glass.

Summary of Results

Metric	Before	After
Energy consumption	Baseline	−5%
Coating durability		No deterioration at 36+ months
Return on investment		Within 3 months (energy alone)
Temperature distribution	Baseline	Uniform
Refractory temperature and chrome loss	Baseline	Cooler; lower chrome loss
Thermal shock	Exposure	Protected
NOx and carbon footprint	Baseline	Reduced

Next step

Operating the Same Asset?

Rebuild or cold repair scheduled? Send us the campaign data. We project the result from comparable documented installations.

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