01
The Challenge
The cracker needed to reduce fuel use and extend the life of its refractory. Emisshield was applied alongside other upgrades (new IFB in the lower radiant walls, new Z-Blok modules, new radiant tubes, low-NOx burners, and penetration seals) to evaluate energy-savings potential.
02
What Was Applied
Operating at about 1,150°C, the furnace received Emisshield ST-series products on the IFB and the Z-Blok modules, applied with a standard HVLP spray gun.
03
Why It Worked
Coated IFB and fiber re-radiate burner energy into the coils across a broader spectrum instead of reflecting it into the flue gas. Lower and flatter tube-wall temperatures slow coking; the sealed fiber surface stops shrinkage. See Energy Savings.
04
Summary of Results
| Metric | Before | After |
|---|---|---|
| Fuel consumption | Baseline | −12% |
| Annual cost | Baseline | ~$1.5M (US$1.47M) saved per year |
| Return on investment | 3 months | |
| Ceramic fiber shrinkage | 5 to 7% (normal) | <1% |
| Downtime | Baseline | Reduced 2 to 3× |
| Exterior unit temperature | Baseline | Lowered by >66°C |
Reduced coking and stabilized heat profiles delivered the fuel saving and consistent ethylene yield through reduced downtime, with longer refractory and ceramic fiber life and better temperature uniformity.