Case Study · Glass
Glass Furnace Crown High Emissivity Coating: 5% Energy Savings Sustained 36+ Months
| Industry | Glass |
|---|---|
| Asset | Melting furnace crown and superstructure (chrome alumina) |
| Customer or location | Wool fiberglass plant |
| Products used | Emisshield refractory coating |
| Headline metric | 5% energy savings |
| Secondary metric | 36+ months, no deterioration |
| Also measured | ROI 3 months |
| Also measured | 1,600°C+ (2,900°F) |
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.
01
What was the challenge?
Specific energy above the batch line, crown refractory wear and chrome loss, and emissions at extreme melting temperatures.
02
What was applied?
Emisshield on the crown and superstructure refractory, a simple application at rebuild or planned cold repair.
03
What were the 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 |
04
Why did it work?
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.