Case Study · Iron & Steel
EAF Delta High Emissivity Coating: Service Life Up 115% at an Integrated Steel Plant
| Industry | Iron & Steel |
|---|---|
| Asset | Pre-cast electric-arc furnace deltas |
| Customer or location | Integrated steel plant |
| Products used | Emisshield ST-2 (patented) |
| Headline metric | 172 heats average |
| Secondary metric | +115% vs upgraded refractory |
| Also measured | 1,560 to 1,650°C |
Pre-cast ultra-low-cement deltas near the arc and scrap charge were cracking early from thermal shock, lasting about 40 heats, and only 80 after an upgrade to a spinel-containing castable. Coating the hot faces and electrode ports with Emisshield ST-2 raised average life to 172 heats, a 115% improvement, by shielding the surface through the initial heats so the castable could sinter properly.
01
What was the challenge?
Early cracking limited delta life and the plant wanted more longevity without redesigning the furnace.
02
What was applied?
Emisshield ST-2 on the deltas' hot faces and electrode ports, operating between 1,560 and 1,650°C.
03
What were the results?
| Metric | Uncoated (upgraded castable) | Coated |
|---|---|---|
| Average delta life | 80 heats (40 with original castable) | 172 heats |
| Life increase | +115% | |
| Early thermal-shock cracking | Recurring | Eliminated |
| Maintenance and replacement interval | Baseline | Reduced; extended |
The coating let the spinel-containing castable develop full strength, maximizing the refractory investment.
04
Why did it work?
The coated surface resists abrupt temperature spikes from arc flare during the first heats, the period when thermal shock does its damage, and re-radiates into the melt thereafter. See Production Increase, component life.
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