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Emisshield

Resources · Case Study Library

High Emissivity Coating Case Studies

Documented Emisshield projects across heat-intensive industries: fired heaters, reformers, process tubes, flares, ladles, EAF roofs and deltas, boilers, burner tips, HRSGs, dryers, RTOs, glass crowns, and crematories. Every study follows the same structure: the operating challenge, the coating applied, and the measured result against the plant's baseline. Filter by industry or result type; each study links to the industry page that explains the mechanism.

01

Which case studies show the largest results?

  1. / 01Huntsman ethylene cracker. 12% fuel savings, roughly $1.5M a year, fiber shrinkage under 1%.
  2. / 02Seoul Shot quench furnace. 10.7% fuel savings, heat-up cut by more than two hours, production up 16.6%.
  3. / 03Apache Nitrogen process boiler. 15 to 20% more steam on 4 to 5% less gas; maintenance cycle 9 to 24+ months.
  4. / 04Redline auto-pour ladles. Service life doubled, 20,000 to 40,000 pours.
  5. / 05Water-cooled EAF roof. 500 to 940 heats, no water leaks, ROI inside six months.
  6. / 06E.ON biomass CHP. 10% more steam on 10% less fuel; NOx down 25%, CO down 45%.
  7. / 07Process-tube coking study. Decoke interval 9 to 30+ months.
  8. / 08Saudi Aramco flares. Flare life 4 to 6× and 7 to 10× across 50+ flares.

02

All documented case studies

Industry (10) × Result type (fuel and energy · production and throughput · run length and component life · emissions · temperature uniformity)

IndustryAssetCase studyProductsHeadline result
Hydrocarbon & ChemicalPrimary ammonia reformerCSBP, Kwinana, AustraliaST-17.2, DI-1+5% production; bridge wall below alarm
Hydrocarbon & ChemicalEthylene crackerHuntsman, TexasST-series12% fuel; ~$1.5M/yr
Hydrocarbon & ChemicalCeramic fiber (lab)Third-party ceramic fiber testingST-seriesShrinkage <1% vs 2 to 5%; +150°C duty limit
Hydrocarbon & ChemicalProcess tubesCoking study, TexasTube exterior coatingDecoke 9 to 30+ months
Hydrocarbon & ChemicalEDC/VCM cracking furnaceSABIC, Saudi ArabiaM-2, ST-3, ST-17+10% cracking rate; 2 to 6% energy
Hydrocarbon & ChemicalOil-field flaresSaudi AramcoFLM-2, FLM-6Life 4 to 6× and 7 to 10×
Hydrocarbon & ChemicalSteam-cracking pilotGhent University, IMPROOFST-series4.8% fuel measured; 7 to 12% modeled
Hydrocarbon & ChemicalEthylene furnaceEastman, TexasST-series6% fuel; +9% production
Hydrocarbon & ChemicalSulfur furnaceLaPorte, TexasRefractory coating5% fuel
Hydrocarbon & ChemicalTerrace-wall reformerTerra Industries, OklahomaST-17No shrinkage or ablation after 8 months
Hydrocarbon & ChemicalAmmonia reformer throatYara, SaskatchewanST-seriesAbrasion and catalyst contamination eliminated
Iron & SteelPlate heat-treating rollsWith DuraloyMetal coatingScale pickup eliminated
Iron & SteelAuto-pour ladlesRedline IndustriesSTG-120,000 to 40,000 pours
Iron & SteelGrey-iron ladlesConfidential foundryNon-sintered coating110 to 160 tons; up to 75% life gain
Iron & SteelAluminium melting-holding furnaceIndia's largest aluminium producerRefractory coating+545 t/month; dross down 10%
Iron & SteelShaft furnace support structureMinerva, OhioM-2No warping at 982°C
Iron & SteelPrecast EAF deltasIntegrated steel plantST-280 to 172 heats, +115%
Iron & SteelPrecious-metals arc furnaceEastman KodakRefractory coatingUniform 150°C shell; no cracking
Iron & SteelWater-cooled EAF roofConfidential mill, USAM-2500 to 940 heats; ROI <6 months
Iron & SteelRadiant tubeOxelösund, SwedenSintered metal coatingExit gas 500 to 430°C; life 3 to 5×
Iron & SteelMolten-zinc toolsOhio zinc refineryM-1, sinteredContamination eliminated
Iron & SteelShot-ball quench furnaceSeoul Shot, South KoreaM-2, ST-17, ST-310.7% fuel; +16.6% production
Iron & SteelAluminium furnace, third-party auditConfidential producerMT-7~9% less dross; $645,000 more output
Power GenerationGas-fired process boilerApache NitrogenRefractory and tube coating+15 to 20% steam; 4 to 5% less gas
Power GenerationBiomass CHP boilerE.ON, Mora, SwedenRefractory and tube coating+10% steam; NOx down 25%
Power GenerationBlack-liquor burner tipsRecovery boilerSintered coatingLife 7×
Power GenerationCoal burner tipsCoal-fired plantSintered coatingLife 3×; NOx reduced
Power GenerationHRSGCombined-cycle plantRefractory coating22% faster to temperature
Power GenerationMass-burn boilerWaste-to-energy facilityRefractory coatingMaintenance quarterly to semi-annual
Power GenerationOverhead conductorGeneral CableConductor coating (US 10332658B2)4.5% less resistive loss; 40-year life
EthanolRTOMidwest USAFiber and refractory coating1,209 BTU/gal; NOx down 5.2%
EthanolDDGS rotary dryersMidwest ethanol plantRefractory and tile coating7% better gas yield; ROI 5 months
GlassMelting furnace crownWool fiberglass plantRefractory coating5% energy over 36+ months
CrematoriesMain and afterburner chambersCremkote coated crematoryCremkote21% energy savings; ROI under one year

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