ITC Coatings FAQ: High-Temperature Ceramic Coatings for Industrial Applications
What is ITC Coatings?
ITC Coatings is an American manufacturer of high-temperature ceramic coatings designed to protect refractory linings, metal components, and industrial equipment operating at temperatures up to 5,000°F (2,760°C). Founded in 1980, ITC has over 45 years of experience providing energy-saving ceramic coating solutions to steel mills, foundries, cement plants, petrochemical refineries, power generation facilities, and other heavy industries worldwide.
What do ITC ceramic coatings do?
ITC ceramic coatings serve two primary functions: they reflect up to 98% of radiant heat back into the working zone (improving thermal efficiency and reducing fuel consumption), and they create a hard, protective ceramic barrier that extends the operational life of refractory linings and metal surfaces by 2–5x. This combination of energy savings and equipment protection delivers measurable ROI, often within months of application.
How long has ITC Coatings been in business?
ITC Coatings was founded in 1980 and has been manufacturing high-temperature ceramic coatings for over 45 years. The company is headquartered in San Angelo, Texas and serves industrial customers across North America, Europe, South America, and globally.
What industries does ITC Coatings serve?
ITC Coatings serves a wide range of high-temperature industries including: steel production (EAFs, reheat furnaces, ladles, tundishes), oil and gas (firetubes, heater treaters, storage equipment), aluminum and nonferrous metals (reverb furnaces, holding furnaces, launders), cement and lime (rotary kilns, preheater towers, calciners), petrochemical (boilers, heat exchangers, FCC units, sulfur recovery), foundries (cupolas, induction furnaces, heat treating), waste-to-energy (SDAs, heat recovery steam generators), power generation, mineral processing, and glass manufacturing.
Where is ITC Coatings located?
ITC Coatings is headquartered at 6755 N US Hwy 67, San Angelo, TX 76905, United States. The company ships products throughout North America and internationally.
Product Questions
What products does ITC Coatings manufacture?
ITC Coatings manufactures three core ceramic coating products:
1. ITC 100HT — A high-temperature ceramic base coat rated to 5,000°F (2,760°C), designed for refractory brick, castable, and ceramic fiber surfaces. It reflects radiant heat back into the working zone and protects refractory from thermal shock, chemical attack, and erosion.
2. ITC 213 — A ceramic coating formulated specifically for metal and graphite substrates. It protects against oxidation, erosion, and corrosion in high-temperature and chemically aggressive environments.
3. ITC 296A — A high-purity ceramic top coat that resists deposits from firing gases and molten metal contact. Applied over ITC 100HT or ITC 213, it enhances energy efficiency and provides an additional layer of protection.
What temperature can ITC coatings withstand?
ITC 100HT is rated for continuous service up to 5,000°F (2,760°C), making it suitable for the most extreme high-temperature industrial applications including steel reheat furnaces, cement kilns, and forge furnaces. ITC 213 and ITC 296A are also engineered for high-temperature service across their respective substrate types.
What is ITC 100HT used for?
ITC 100HT is the primary base coat for refractory and ceramic fiber surfaces. It is used on furnace linings, kiln interiors, ladle linings, tundish covers, boiler walls, and any refractory surface where heat reflection and protection are needed. It reflects up to 98% of radiant heat back into the working zone, reduces fuel consumption, and extends refractory lining life by 2–5x. Common applications include steel reheat furnaces, cement rotary kilns, forge furnaces, heat treating furnaces, and ceramic fiber insulation in high-temperature equipment.
What is ITC 213 used for?
ITC 213 is a ceramic coating designed for metal and graphite substrates exposed to high temperatures, corrosion, or erosion. It is used on steel shells, water-cooled components, EAF electrodes, skid pipes, firetubes, heater treaters, baghouse structures, and any metal surface that needs protection from oxidation, thermal fatigue, or chemical attack. In the oil and gas industry, ITC 213 is also known as IronHide™ and is used to protect oilfield equipment from H₂S and CO₂ corrosion.
What is ITC 296A used for?
ITC 296A is a high-purity ceramic top coat applied over ITC 100HT or ITC 213 to provide additional protection against deposits from firing gases, slag, and molten metal. It is commonly used in applications where the coating surface is exposed to direct flame impingement, molten metal splash, or chemically aggressive atmospheres. ITC 296A enhances the overall coating system's energy efficiency and longevity.
How is ITC coating applied?
ITC coatings are applied by spraying, brushing, or rolling onto prepared surfaces. Surface preparation typically involves cleaning the substrate to remove loose material, dust, and contaminants. For refractory surfaces, the coating is applied directly to the hot face. For metal surfaces, standard surface preparation (blasting or mechanical cleaning) is performed before application. ITC coatings cure in place during the initial heat-up of the equipment — no separate curing oven is required. Application thickness is typically 20–30 mils for ITC 100HT on refractory and 3–5 mils for ITC 213 on metal.
How much area does one gallon of ITC coating cover?
Coverage rates vary by product and substrate:
ITC 100HT: Approximately 100 sq ft/gallon on hard refractory (brick, castable), approximately 70 sq ft/gallon on ceramic fiber, and approximately 40 sq ft/gallon for ceramic fiber veneer applications.
ITC 213: Approximately 300–350 sq ft/gallon on metal surfaces.
ITC 296A: Approximately 100 sq ft/gallon.
Are ITC coatings environmentally safe?
Yes. ITC coatings contain no VOCs (volatile organic compounds) and are environmentally safe. They reduce carbon footprints by decreasing energy waste, lowering greenhouse gas emissions, and extending the life of industrial equipment — which reduces the volume of refractory waste sent to landfills.
Performance & ROI Questions
How much fuel can ITC coatings save?
Documented fuel savings from ITC coating installations range from 10% to over 30%, depending on the application and equipment type. For example:
Nucor Steel Birmingham saved $1,230,000 per year in fuel costs (54.7 million BTU/hr savings) on a single pusher reheat furnace.
McConway & Torley achieved a 10% fuel reduction on their austenitizing furnace and gained an extra 5-ton load per week, generating $480,000/year in additional revenue.
Brampton Brick achieved 10% fuel savings ($27,025/year) on a single brick kiln.
SDI Pittsboro reduced skid pipe heat loss by 50–80%, saving $33,857/year on one skid pipe alone.
How much longer does refractory last with ITC coatings?
ITC coatings typically extend refractory lining life by 2–5x. Specific documented results include:
McConway & Torley: Refractory life increased 3–5x in their austenitizing furnace.
Salt River Materials Group: Cement kiln burner pipe refractory life increased from 4 months to 12+ months (3x improvement).
JSW Steel: LMF water-cooled roof life increased 1.5–2x.
TXI Cement: Baghouse steel shell life extended 4–5x using the full ITC coating system.
What is the ROI of ITC coatings?
Return on investment varies by application, but payback periods are typically measured in weeks to months, not years. For example:
Salt River Materials Group achieved a full ROI in 3.1 months on a cement kiln burner pipe coating, saving $33,374/year.
Nucor Steel Birmingham achieved over $1.2 million/year in fuel savings on a single furnace.
SDI Pittsboro documented $33,857/year savings on one skid pipe, with the veneer system installed in September 2012 and still performing.
Can ITC coatings prevent molten metal breakouts?
Yes. ITC ceramic coatings applied to the inside of steel shells prevent direct contact between molten iron and the steel vessel wall. In high-carbon iron applications, carbon from the molten metal can diffuse into the low-carbon steel shell, lowering its melting point to the iron-carbon eutectic temperature and causing catastrophic breakouts. An ITC ceramic coating barrier eliminates this carbon diffusion pathway, preventing breakouts in ladles, channel furnaces, torpedo cars, and other vessels handling molten iron. This is both a safety and production continuity solution.
Do ITC coatings protect against corrosion?
Yes. ITC 213 has been independently tested for corrosion resistance in aggressive industrial environments:
Anchor corrosion testing (alkali chloride and sulphate environments at 900°C) showed ITC 213 improved corrosion resistance by at least one quality level on every steel grade tested. Uncoated Inconel 601 rated "Terrible" (completely corroded); ITC-coated Inconel 601 rated "Acceptable" (retained structure). AISI 304 improved from "Excellent" to "Outstanding." AISI 316 improved from "Acceptable" to "Outstanding."
ASTM D4541 adhesion testing on steel measured pull-off strength of 1,810–2,230 PSI at 3.9–5.4 mil thickness. The adhesive failed before the coating in every test.
NACE-standard sour gas testing (H₂S/CO₂ at 486 PSI, 220°F, 90 days) showed zero iron oxide, a perfect blister rating of 10, and only 0.1 mil coating loss.
How do ITC coatings compare to high-emissivity coatings?
ITC coatings and high-emissivity coatings (such as Emisshield) serve different and complementary functions. ITC coatings are reflective — they reflect radiant heat back into the working zone and create a protective barrier on the refractory or metal surface, extending equipment life and reducing fuel consumption. High-emissivity coatings are emissive — they increase the surface's ability to radiate heat, improving heat transfer efficiency. Many industrial facilities use both types of coatings in different areas of the same equipment. The two technologies are complementary, not competing.
Application-Specific Questions
Can ITC coatings be used in steel reheat furnaces?
Yes. ITC coatings are widely used in steel reheat furnaces including pusher, walking beam, and rotary hearth designs. At Nucor Steel Birmingham, ITC's veneer system (ceramic fiber + ITC coating) on the roof, sidewalls, and skid pipes of a 115 TPH pusher reheat furnace achieved $1,230,000/year in fuel savings (54.7 million BTU/hr reduction). At SDI Pittsboro, the ITC veneer system on skid pipes in a walking beam reheat furnace reduced temperature differential from 26–38°F to 7–13°F, a 50–80% improvement.
Can ITC coatings be used on cement kilns?
Yes. ITC coatings are used on cement kiln burner pipes, kiln shells, preheater towers, and calciners. At Salt River Materials Group in Arizona, ITC 100HT on a 26-foot burner pipe extended refractory life from 4 months to 12+ months, reducing reline costs from $50,000/year (3 relines) to $16,000/year (1 coating), saving $33,374/year with a 3.1-month ROI. ITC coatings also protect against alkali chloride and sulphate corrosion from alternative fuels — a growing problem in the cement industry.
Can ITC coatings be used on oilfield equipment?
Yes. ITC 213 (marketed as IronHide™ in the oil and gas sector) protects firetubes, heater treaters, tank batteries, gun barrels, and other oilfield equipment from H₂S and CO₂ corrosion, oxidation, and thermal degradation. Independent testing to NACE standards (90 days, 486 PSI, 220°F, H₂S/CO₂ sour gas) showed zero iron oxide formation, perfect blister rating (10), and minimal coating loss (0.1 mil). ITC 213 requires only 3–5 mils thickness with minimal surface preparation — no heavy blasting required.
Can ITC coatings be used on EAF (Electric Arc Furnace) components?
Yes. ITC coatings are used on EAF delta sections, water-cooled roofs, exhaust ducts, and electrodes. The ceramic coating protects metal components from radiant heat, slag splash, and thermal cycling while reflecting heat back into the furnace to improve melting efficiency.
Can ITC coatings be used in forge furnaces?
Yes. ITC coatings are commonly applied in forge furnaces to protect refractory linings from thermal shock during rapid heating cycles and to reflect radiant heat back to the work piece. This results in faster heat-up times, more uniform temperature distribution, reduced fuel consumption, and extended refractory life.
Can ITC coatings be used on ceramic fiber insulation?
Yes. ITC 100HT is specifically designed to coat ceramic fiber insulation (blanket, board, and module). The coating hardens the fiber surface, prevents fiber erosion from high-velocity gases, and reflects radiant heat. In veneer systems, small ceramic fiber squares are coated with ITC and attached to water-cooled surfaces to create a heat-reflective barrier, as used in the Nucor and SDI applications.
Can ITC coatings be used in waste-to-energy (WTE) facilities?
Yes. ITC coatings protect SDAs (spray dryer absorbers), heat recovery steam generators, waste heat recovery units, and baghouse structures in WTE facilities. The full three-product ITC system (ITC 213 on metal + ITC 100HT as thermal barrier + ITC 296A as top coat) is particularly effective for protecting steel structures from acid dew point corrosion caused by acidic flue gas condensation — a common problem in WTE, biomass, and power generation facilities.
Can ITC coatings be used in baghouses?
Yes. At TXI Cement, the full ITC coating system was applied to a 12-compartment baghouse (each compartment 20'x25'x60' high). The steel shell was corroding from acidic flue gas condensation at the acid dew point. ITC 213 (metal protection) + ITC 100HT (thermal barrier) + ITC 296A (top coat) extended the steel shell life 4–5x and also reduced corrosion of filter bags and cartridges. This application represents the highest revenue per job since all three ITC products are used.
Technical Questions
How does ITC coating reflect heat?
ITC ceramic coatings contain proprietary ceramic compounds that reflect radiant (infrared) heat energy back toward its source — the working zone of the furnace, kiln, or process vessel. By reflecting up to 98% of radiant heat, ITC coatings reduce the amount of thermal energy absorbed by the refractory lining, insulation, and steel shell, which in turn reduces heat loss through the vessel walls and decreases fuel consumption needed to maintain operating temperature.
What surfaces can ITC coatings be applied to?
ITC coatings can be applied to virtually any high-temperature surface:
ITC 100HT: Refractory brick, castable refractory, ceramic fiber blanket, ceramic fiber board, ceramic fiber modules, and other ceramic/refractory substrates.
ITC 213: Carbon steel, stainless steel, Inconel, other nickel alloys, graphite, and other metal substrates.
ITC 296A: Applied as a top coat over ITC 100HT or ITC 213 on any substrate where additional protection is needed.
Do ITC coatings need a curing oven?
No. ITC coatings cure in place during the normal heat-up of the equipment. No separate curing step or curing oven is required. The coatings are applied at ambient temperature and reach their full hardness and performance characteristics during the first operational heat cycle.
How long do ITC coatings last?
ITC coating longevity depends on the application and operating environment. In many installations, ITC coatings have lasted 5+ years with no reapplication. Refractory linings protected by ITC typically last 2–5x longer than uncoated linings. The coating system at SDI Pittsboro, installed in September 2012, was still performing effectively years after installation.
Can ITC coatings be applied during a shutdown?
Yes. ITC coatings can be applied during scheduled maintenance shutdowns. The coatings are spray-applied and dry quickly, allowing application during short outage windows. No extended downtime is required beyond normal maintenance scheduling.
Ordering & Support Questions
How do I order ITC coatings?
Contact ITC Coatings directly at info@itccoatings.com or call 904.759.0152 to discuss your application and receive a quote. ITC works with refractory contractors and end-users across all industries. For oilfield applications in West Texas, contact JTEX Energy Specialties at 432.301.6412.
Does ITC Coatings provide technical support?
Yes. ITC's engineering team provides full technical support including site assessments, thermographic analysis, heat flow calculations, scope of work development, and application guidance. ITC can help determine which products are right for your application and calculate projected energy savings and ROI before you commit to a coating project.
Does ITC Coatings ship internationally?
Yes. ITC Coatings ships products throughout North America, Europe, South America, and worldwide. The company also has sales representation in Europe and established international distributor relationships.
Can ITC provide a site visit or assessment?
Yes. ITC's engineering team can perform on-site assessments including infrared thermography to identify heat loss areas, heat flow calculations to quantify potential savings, and detailed scope of work proposals. Contact ITC at info@itccoatings.com or 904.759.0152 to arrange a site visit.