The Importance of Coating Durability

High emissivity coatings are designed to improve radiant and conductive heat transfer in fired heaters, resulting in better process efficiency, and reducing fuel consumption. In the harsh operating environments of fired heater furnaces, where temperatures routinely exceed 1000°C (1800°F), the durability and longevity of high emissivity coatings are vital. Ensuring their long-lasting performance requires particular attention to surface preparation, application techniques, and stringent quality control measures.

Professional Surface Preparation is Key

Surface preparation is key to the successful performance of a high-emissivity coating. Contaminants such as rust, mill scale, and existing coatings can severely compromise the adhesion and performance of the new coating. Neglecting this critical step can lead to premature coating failure, potentially resulting in unplanned shutdowns and costly repairs.

At IGS, we understand the significance of surface preparation and employ industry-proven methods tailored to the specific conditions of each fired heater. Highly-trained technicians meticulously clean and prepare the surfaces, ensuring optimal adhesion and long-term durability of the high-emissivity coatings.

Precision Coating Application Techniques

The application of high-emissivity coatings in fired heaters demands precision and expertise. These coatings must be applied uniformly and consistently to maintain their emissive properties and withstand extreme thermal cycling and corrosive environments.

IGS specializes in applying high emissivity coatings on-site during turnarounds, with 40 years of successful experience. IGS technicians are some of the most experienced in the industry; all project managers have a minimum of 5000 hours of field experience. Using advanced application methods, our teams ensure precise coverage and thickness control, resulting in coatings that perform optimally and extend the operational life of fired heaters.

Quality Assurance for Coatings

Achieving lasting durability and performance with high emissivity coatings depends on rigorous quality control measures. From incoming material inspections to post-application testing, IGS adheres to stringent quality standards to ensure every coated surface meets or exceeds industry specifications. Since 2019, IGS has scored 4.85 out of 5 for quality commitment, surveying 226 customers.

Cetek coatings are manufactured by IGS for exclusive use by our crews. They are not sold to third parties for application by inexperienced applicators, as can often happen with many coatings and other products.

Our quality assurance process includes a first-class manufacturing facility, with complete QA/QC established procedures. Other items, include:

• Thorough inspections of the prepared surfaces before coating application
• Continuous monitoring of application parameters, such as temperature and humidity
• Post-application testing, including coating thickness measurements
• Comprehensive documentation and traceability for every coated component

By maintaining strict quality control standards, IGS guarantees the long-term durability and performance of high emissivity coatings, safeguarding your investment and minimizing unplanned downtime.

Over 40 Years of Proven Success

For more than four decades, IGS has been at the forefront of applying high-emissivity coatings in industrial fired heaters. Our extensive experience with Cetek coatings has enabled us to continually develop best practices and refine our techniques, ensuring optimal durability and longevity for our clients.

Whether you require coating services for new construction or during scheduled turnarounds, IGS has the expertise and resources to deliver results. Our commitment to quality, safety, and customer satisfaction has earned us a reputation as a trusted partner in the industry.

Maximize Your Fired Heater’s Efficiency and Lifespan

Don’t compromise on the durability and performance of your fired heater’s high emissivity coatings. Contact us today to schedule a consultation and learn how our high emissivity coating services can maximize your fired heater’s efficiency, reduce fuel costs, and extend its operational lifespan.

Read our high emissivity coating case studies.