Case Studies · Iron & Steel

Aluminium Melting Furnace High Emissivity Coating: 545 Tonnes More per Month at India's Largest Aluminium Producer

60-ton natural-gas melting-holding furnace·India's largest aluminium producer (confidential)

One of two identical 60-ton gas-fired melting-holding furnaces was coated with Emisshield on its roughly thirty-year-old monolithic lining, and an independent engineering firm compared it with the uncoated furnace under matched conditions. The coated furnace improved heat retention by 12%, ran a 12°C higher melt temperature, produced 545 more tonnes of aluminium per month worth about $1.2 million, and generated 10% less dross despite the higher output.

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+545 t/month
: ~$1.2M added revenue
: Dross −10%
: Melt +12°C

The Challenge

Significant heat loss, dross formation, and energy consumption on an aging melting-holding furnace.

What Was Applied

Emisshield on the monolithic refractory lining of Furnace 2. Both furnaces were loaded with about 50 tons of molten aluminium and heated to 1,100°C; Thermwin Technologies measured temperature, production, and dross for the coated Furnace 2 against the uncoated Furnace 1.

Why It Worked

A coated lining re-radiates burner energy into the melt instead of the flue, so the bath holds temperature and melts faster on the same fuel; a steadier, hotter surface forms less dross. See Production Increase.

Summary of Results

Metric	Uncoated furnace	Coated furnace
Heat retention	Baseline	+12%
Melt temperature	Baseline	+12°C
Monthly production	Baseline	+545 tonnes
Revenue	Baseline	+~$1.2M
Dross formation	Baseline	−10% (despite higher throughput)

Next step

Operating the Same Asset?

Operating melting or holding furnaces? Send us the furnace data and dross history. We project the result from comparable documented installations.

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