ITC 100HT: High-Temperature Ceramic Base Coat — Specifications, Results, and Applications

ITC 100HT: High-Temperature Ceramic Base Coat for Refractory Protection

ITC 100HT is a high-temperature ceramic coating rated for continuous service up to 5,000°F (2,760°C). It is the primary product in the ITC Coatings line, designed to be applied directly to refractory brick, castable refractory, and ceramic fiber surfaces in furnaces, kilns, forges, ladles, and other high-temperature industrial equipment. ITC 100HT reflects up to 98% of radiant heat back into the working zone, extends refractory lining life 2–5x, and delivers documented fuel savings of 10–30%.

What ITC 100HT Does

ITC 100HT performs two critical functions simultaneously:

1. Radiant Heat Reflection: ITC 100HT reflects up to 98% of radiant (infrared) heat energy back toward its source — the working zone of the furnace, kiln, or process vessel. This means more of the fired energy stays where it belongs (heating the work piece or process) instead of passing through the refractory and escaping through the vessel shell. The result is measurable fuel savings, often 10–30% depending on the application.

2. Refractory Protection: ITC 100HT creates a hard, dense ceramic barrier on the refractory surface that protects against thermal shock, chemical attack, erosion from high-velocity gases, and mechanical abrasion. On ceramic fiber surfaces, the coating hardens the fiber face, prevents shrinkage and devitrification, and stops fiber erosion. This extends refractory and fiber life by 2–5x.

Technical Specifications

Maximum Service Temperature: 5,000°F (2,760°C) continuous

Heat Reflection: Up to 98% of radiant heat

Application Method: Spray, brush, or roller

Application Thickness: 20–30 mils on refractory; varies for veneer systems

Coverage Rate:

• Hard refractory (brick, castable): ~100 sq ft/gallon
• Ceramic fiber (blanket, board, module): ~70 sq ft/gallon
• Ceramic fiber veneer systems: ~40 sq ft/gallon

VOC Content: Zero — no volatile organic compounds

Curing: Cures in place during normal equipment heat-up. No separate curing oven required.

Surface Preparation: Clean surface free of loose material, dust, and contaminants. No heavy blasting required.

Compatible Substrates

ITC 100HT is designed for application to:

• Refractory brick (firebrick, high alumina, silica, magnesia, chrome)
• Castable refractory (conventional, low cement, ultra-low cement)
• Ceramic fiber blanket (all grades and densities)
• Ceramic fiber board
• Ceramic fiber modules
• Insulating firebrick (IFB)
• Gunned and rammed refractory

Documented Performance Results

Fuel Savings

• Nucor Steel Birmingham: $1,230,000/year fuel savings on a 115 TPH pusher reheat furnace (54.7 million BTU/hr reduction)
• McConway & Torley: 10% fuel reduction on austenitizing furnace (20.8 to 18.7 MCF/load)
• Brampton Brick: 10% fuel savings on a 300-foot brick kiln ($27,025/year)
• Norheat Inc.: 10% continued energy savings on retort furnace

Refractory Life Extension

• McConway & Torley: Refractory life extended 3–5x in heat treating furnace
• Salt River Materials Group: Cement kiln burner pipe lining life extended from 4 months to 12+ months (3x)
• TXI Cement: Baghouse steel shell life extended 4–5x (as part of three-product system)
• JSW Steel: LMF water-cooled roof life extended 1.5–2x

Temperature Uniformity

• McConway & Torley: Temperature uniformity improved 46% (±40°F to ±25°F)
• Brampton Brick: Start-up times reduced 50%

Heat Loss Reduction

• SDI Pittsboro: Skid pipe Delta T reduced from 26–38°F to 7–13°F (50–80% reduction), saving $33,857/year per skid pipe
• Nucor Steel: Shell temperatures reduced from 330–430°F to 228–342°F

Industries and Applications

Steel: Reheat furnaces (pusher, walking beam, rotary hearth), blast furnaces, hot blast stoves, ladle linings, tundish covers and linings

Cement & Lime: Rotary kiln linings, burner pipe refractory, preheater towers, calciners

Forge & Foundry: Forge furnaces, heat treating furnaces (austenitizing, normalizing, tempering), cupolas, induction furnace linings, ladle linings

Petrochemical: FCCU refractory, sulfur recovery unit linings, fired heater refractory, reformer linings, carbon black reactor linings

Nonferrous Metals: Aluminum reverb and holding furnaces, launder linings, anode baking furnaces, over-the-road ladle linings, crucible furnaces

Waste-to-Energy & Power: Boiler refractory linings, waste heat recovery unit linings (as part of three-product system with ITC 213 and ITC 296A)

Ceramic Fiber Applications: Any ceramic fiber surface in any industry — blanket, board, modules. Hardens fiber, prevents shrinkage and devitrification, stops erosion, reflects heat.

ITC 100HT Veneer System

The ITC veneer system is a specialized application method where small ceramic fiber squares (typically 1-inch) are coated with ITC 100HT and bonded to water-cooled surfaces. This creates a heat-reflective barrier on surfaces that cannot accept conventional refractory — such as water-cooled panels, roofs, and skid pipes in steel reheat furnaces. The veneer system has produced some of ITC's most dramatic results, including the $1.23M/year savings at Nucor and the $33,857/year savings per skid pipe at SDI.

How to Apply ITC 100HT

Step 1 — Surface Preparation: Ensure the refractory surface is clean and free of loose material, dust, grease, and contaminants. Remove any deteriorated or crumbling refractory. No heavy blasting is required.

Step 2 — Application: Apply ITC 100HT by spraying (preferred for large areas and uniform coverage), brushing, or rolling. Apply to a wet film thickness of 20–30 mils. For ceramic fiber, work the coating into the fiber surface to achieve full penetration of the top fiber layer.

Step 3 — Drying: Allow the coating to air dry. In ambient conditions, the coating will be dry to the touch within hours.

Step 4 — Curing: The coating reaches full hardness and performance during the first heat-up of the equipment. No separate curing oven or heat source is required. Follow normal startup procedures for your equipment.

Frequently Asked Questions: ITC 100HT

What is the maximum temperature for ITC 100HT?

ITC 100HT is rated for continuous service at 5,000°F (2,760°C), making it suitable for virtually any refractory application in industry, including the most extreme environments in steelmaking, cement production, and forge operations.

How much does one gallon of ITC 100HT cover?

Coverage depends on the substrate: 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. Actual coverage may vary based on surface porosity and application method.

Does ITC 100HT need a primer or base coat?

No. ITC 100HT is applied directly to the refractory surface with no primer or preparation coat. It bonds directly to brick, castable, and ceramic fiber substrates.

How long does ITC 100HT last?

ITC 100HT longevity depends on the application and operating conditions. In many installations, the coating has lasted 5+ years with no reapplication. The SDI Pittsboro veneer system, installed in September 2012, was still performing years after installation. Typical refractory linings protected by ITC 100HT last 2–5x longer than uncoated linings.

Can ITC 100HT be applied over existing coatings?

ITC 100HT can be reapplied over existing ITC coatings. For surfaces with other coatings, contact ITC Coatings for application guidance specific to your situation.

Is ITC 100HT the same as an emissive coating?

No. ITC 100HT is a reflective coating — it reflects radiant heat back into the working zone. Emissive coatings (such as Emisshield) increase the surface's ability to radiate heat. The two technologies serve different and complementary functions, and many facilities use both in different areas of the same equipment.

Order ITC 100HT: Contact ITC Coatings at info@itccoatings.com or call 904.759.0152