Case Studies · Iron & Steel

Grey-Iron Ladle High Emissivity Coating: 45 to 75% Longer Ladle Life

Pre-cast refractory ladles·Confidential grey-iron foundry, USA

A grey-iron foundry whose pre-cast refractory ladles lasted about 110 tons of poured iron coated them internally, including dam and pour spout, with a non-sintered Emisshield product. Coated ladles poured 160 tons before replacement, a 45 to 55% improvement, and later coatings delivered 75% life gains, with the dam unobstructed and casting quality up.

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110 to 160 tons poured
: Up to 75% life increase with subsequent coatings

The Challenge

Rapid ladle wear from molten metal and slag, with the foundry seeking longer life, less downtime, and better casting quality without altering production equipment.

What Was Applied

Ladles grit-blasted and cleaned, coated internally including dam and pour spout, returned to the same casting process and compared against uncoated control ladles by tons poured.

Why It Worked

Reduced slag adherence and thermal shock preserve the refractory and the dam geometry, so pours stay clean longer. See Production Increase, component life.

Summary of Results

Metric	Uncoated	Coated
Tons poured before removal	110	160 (+45 to 55%)
Life with subsequent coatings		+75%
Ladle dam	Erosion, obstruction	Unobstructed, no mechanical erosion
Casting quality	Baseline	Higher; fewer defects

Sintered products are expected to deliver larger gains.

Next step

Operating the Same Asset?

Replacing ladles on tonnage? Send us the ladle type and pour history. We project the result from comparable documented installations.

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