01
The Challenge
Abrasive slag and intense heat wore out the ladles after about 20,000 pours. Management wanted longer ladle life and lower maintenance cost without redesigning the process.
02
What Was Applied
Ladles were grit-blasted and cleaned, then coated by HVLP spray with STG-1 across the entire refractory lining, including the dam and pour spout. No sintering was needed. Ladles returned to service at 704°C and were compared with uncoated control ladles.
03
Why It Worked
STG-1's sealed high emissivity ceramic face absorbs preheat energy efficiently and presents a surface that slag does not wet, while its thermal-shock tolerance protects the lining through pour cycles. See Production Increase, component life.
04
Summary of Results
| Metric | Uncoated | Coated |
|---|---|---|
| Service life | ~20,000 pours | 40,000 pours |
| Run count | Baseline | +200% |
| Slag adhesion and chemical corrosion | Constant | Dramatically reduced |
| Thermal-shock cracking and repair frequency | Recurring | Reduced |
Coated ladles remained in service twice as long, with substantial maintenance savings; ease of application and immediate return to service made the coating cost-effective.