Case Study · Iron & Steel
Grey-Iron Ladle High Emissivity Coating: 45 to 75% Longer Ladle Life
| Industry | Iron & Steel |
|---|---|
| Asset | Pre-cast refractory ladles |
| Customer or location | Confidential grey-iron foundry, USA |
| Products used | Emisshield non-sintered coating |
| Headline metric | 110 to 160 tons poured |
| Secondary metric | Up to 75% life increase with subsequent coatings |
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.
01
What was 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.
02
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.
03
What were the 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.
04
Why did it work?
Reduced slag adherence and thermal shock preserve the refractory and the dam geometry, so pours stay clean longer. See Production Increase, component life.
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