NASA Spinoff

High-Temperature Coatings Offer Energy Savings

Available for use on new or existing substrates in any combustion process including metals, refractory (heat resistant material), ceramics, and high technology fabrics, Emisshield can provide significant savings for most energy consuming, producing, or related heat systems. According to its customers, Emisshield has permitted heat-driven industrial applications to experience up to a 15-percent energy savings, a 15-percent increase in production, more uniform heating, prolonged substrate life, and reduced downtime for maintenance. In fact, the company finds the harder a process is pushed, the greater the fuel savings and the faster the payback for using Emisshield.

“Another thing that happens is that by improving combustion of gasses and fuels, products are made with less energy, and that reduces air emissions,” says Olver. All of this is done with a coating that is about as thin as a kitchen garbage bag. The coating can be applied to items at an Emisshield facility, or onsite at a customer’s facility. “It’s unique because it is so easy to install, even in the field and for applications that have extreme requirements. We can go out, clean the surface, and then apply the coating.”

In hydrocarbon and chemical processing, Emisshield can be used to coat the combustion chamber and process tubes of high temperature cracking units, as well as lower temperature process heaters. Emisshield is applied to the process tubes and refractory walls, a combination that generates an increase in energy savings and production. Like applications in the hydrocarbon and chemical processing industry, power generation can also see similar benefits while promoting better air emissions. Such applications include biomass boilers, waste incinerators, natural gas boilers, heat recovery steam generators, and burners.

For metal production, applications include reheat furnaces, bell annealing furnaces, walking beam furnaces, electric arc furnaces, and others. The increase in combustion allows for a quicker heat up and cool down in an intermittent furnace, which saves manufacturers time and money. Emisshield is also used in a variety of multipurpose kilns including intermittent kilns and continuous kilns.

One of Emisshield’s most popular applications is in furnaces for making glass—everything from wine bottles to windshields. So far, the coating has been applied to 30 furnaces worldwide. “On these big glass furnaces, they are saving about 10 percent of their energy,” says Olver. “The payback for our clients making glass is always under a year.”

As the company moves forward, it strives to penetrate new market areas. Recently, the company started focusing on introducing Emisshield in the food processing industry. The company is working to apply the coating on the walls of ovens, baking pans, and burners for commercial bread baking. “We see lots of opportunities in this market, and are hoping to push into it in the next few years,” says Olver. “Emisshield could even be applied to the grills that people use at home. There are a lot of potential applications.”

The newest application, however, is for high solar absorptive materials for concentrated solar power generation stations. The company is currently working with an Israeli-U.S. company in this area.

“We started the root system with NASA, then the trunk, and now we’re growing our branches,” says Olver. “We wouldn’t be here if it weren’t for technology transfer from NASA.”

Emisshield® is registered by Emisshield Inc.