Case Studies · Iron & Steel

Molten Zinc Tool High Emissivity Coating: Bath Contamination Eliminated at an Ohio Zinc Refinery

Steel skimmers, sampling tools, dross-removal implements·Zinc manufacturing facility, Ohio, USA

Steel skimmers, sampling tools, and dross-removal implements at an Ohio zinc facility were rapidly disintegrating in molten zinc, contaminating the bath and forcing expensive re-refining. The tools were lightly grit-blasted, coated on their outside surfaces with Emisshield M-1, and sintered at 815°C. Coated tools resist dissolution, the bath no longer needs refiring and reprocessing, and operators work more safely.

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Extended tool life
: Contamination eliminated
: Re-refining avoided

The Challenge

Prolong tool life, prevent contamination, and remove the need to remelt zinc.

What Was Applied

Tools shipped to the Emisshield laboratory, grit-blasted, coated with M-1, sintered at 815°C, and returned for use in molten zinc baths.

Why It Worked

The sintered ceramic surface separates the steel from the molten zinc while its emissivity keeps tool temperature uniform. See Products, sintered systems.

Summary of Results

Metric	Uncoated	Coated
Tool life	Rapid disintegration	Dramatically extended
Bath contamination	Ongoing	Eliminated
Re-refining	Required	No longer needed
Operator safety and efficiency	Baseline	Improved

Next step

Operating the Same Asset?

Tools or fixtures dissolving in molten metal? Send us the tool drawings and bath conditions. We project the result from comparable documented installations.

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