Case Study · Iron & Steel
Aluminium Furnace High Emissivity Coating: Third-Party Audit Confirms 9% Less Dross and $645,000 More Output
| Industry | Iron & Steel (aluminium) |
|---|---|
| Asset | Melting-holding furnace |
| Customer or location | Confidential aluminium producer |
| Products used | Emisshield MT-7 |
| Headline metric | Third-party audit, six months of production data |
| Secondary metric | ~9% dross reduction (459.4 to 418.87 MT) |
| Also measured | $645,000 production gain over four months |
| Also measured | Melt +12°C |
A confidential aluminium producer commissioned an independent audit comparing an Emisshield MT-7-coated melting-holding furnace (Furnace 2) with an uncoated control (Furnace 1) over six months of production data. The coated furnace generated about 9% less dross, ran a 12°C higher melt temperature despite a heavier charge, cycled slightly faster, and delivered $645,000 more casting throughput over four months.
01
What was the challenge?
Quantify, independently, the performance improvements attributable to the coating: dross generation, casting throughput, melt temperature, cycle time, and refractory condition.
02
What was applied?
Emisshield MT-7 on Furnace 2; Furnace 1 uncoated. Dross and casting tonnages recorded monthly with melt temperature, cycle time, and refractory wear.
03
What were the results?
| Metric | Uncoated furnace | Coated furnace |
|---|---|---|
| Dross generated (audit period) | 459.4 MT | 418.87 MT (~−9%) |
| Dross reduction range | 6 to 10% | |
| Casting throughput | Baseline | +$645,000 over four months |
| Melt temperature | Baseline | +12°C despite higher charge |
| Cycle time | Baseline | Slightly shorter |
| Refractory life | Improvement anticipated, not yet quantified |
04
Why did it work?
A high emissivity lining returns more radiant energy to the bath, holding a hotter, steadier melt surface that forms less dross and melts a heavier charge in less time. See Test Data & Validation.
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