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Ceramic Coating

Industrial re-heat furnace coating for energy savings.

A patented water based sol-gel ceramic coating for protection and life extension of new or existing refractory linings in industrial boilers, incinerators, furnaces, and steam generation process equipment. 

Properties :

  1. Energy Efficiency Increase 7-9% average
  2. Effectively seals porosity of substrate. Prevents vapor phase gasses and carborization byproducts from condensing inside refractory lining, thus inhibiting internal damage due to chemical attack and physical stress of the insulating structural material.
  3. Operating temperatures to over 3,500◦F.
  4. Hot gas ablation resistant & fly ash [and other air borne particulate] abrasion resistant – ASTM C704 @1.6
  5. Thermal shock resistant.
  6. Chemically and mechanically bonded to substrate. Will take normal flexing of substrate.
  7. Simple application procedure. Applied at room temperature using commercial spray apparatus or manual brushing/rolling. Simple clean-up using water.
  8. No volatile organic contaminants (VOC’s). No heavy metal or environmental concerns, all metals present are in inactive oxide form.

Areas of Applicability :

Solcoat is applied directly on all types refractory linings. Typical areas of application are:

  1. Combustion Chamber Refractories Energy saving, set point reduction, cold face temperature reduction 35° – 50°C

Measure Wall and Roof temperature :

After shutdown → Reduce temperature set point of zone 3, 4

  • Slit 4: reduce by 10°C
  • Slit 3: reduce by 10°C
  • Slit 2: reduce by 10°C

Reduce NG 0.7 Nm3/tonnage, Saving 30,000 Nm3 last month. Can save 343,700 Nm3/year

Carbon emission reduce :

  • CO2 emission = 2.01 tCO2/KNm3

From RHF improvement

  • Can reduce NG = 343,700 Nm3/year
  • Can reduce CO2 emission = 690.8 tCO2/year

Additional data :

  • Cold Face Temperature Reduction of 50 C
  • Reduce Set Point from 1170C to 1160C in 2 zones: Soak   Zone & Heating Zone
  • 2.8% energy savings for coating 25% of furnace

– Extrapolation to >8% if entire furnace is coated

Furnace Manufacturer: Danieli Italy.

Compare Coating :

Item Solcoat Vesuvius Emisspro
1. High emissivity coating Yes Yes Yes
2. Temperatur reduced (%) 20%** 12% ~5%***
3. Reference plant NatSteel, SCSC** SISCO NTS
4. Emissivity 0.92 0.95 0.85 - 0.95
5. Project cost 1.10 MB* 1.24 MB 2.40MB
6. Compare saving with Solcoat 0 -0.4 MB Not compare