Monitor Coatings Ltd, a Surface Engineering specialist in North Tyneside, England has been co-funded by the UK's innovation agency, Innovate UK, to work in collaboration with Cranfield University on a study which will use the process of exothermic reaction synthesis to modify low-cost sprayed metallic surface coatings. The need to reduce carbon emissions is pushing thermal power plants to use higher operating temperatures and biomass/waste derived fuels, increasing the demand on heat exchanger tubes. The ER-Sealcoat project aims to develop a low cost method of producing customisable coatings that can coat 3D geometries (internal and external) and protect against aggressive high temperature environments.
The seal coating is produced as a tailored slurry mix containing chemically active components, which react exothermically with the sprayed base coat. The heat released from this stored chemical energy enhances diffusion and intermetallic formation with the basecoat, producing a sealed surface with a bespoke chemical gradient capable of resisting fireside corrosion and high temperature oxidation in aggressive conditions such as biomass/waste fired advanced thermal power plant.
The ER-Sealcoat system would result in improved performance through its functional gradient design and ability to close surface breaking porosity and seal the coating, as a result reducing direct and indirect processing costs compared to current industrial coating methods.
Dr Spyros Kamnis, the Research and Development Manager of Monitor Coatings, said: "I'm delighted that Innovate UK have been able to support this exciting project, and help our organisation to turn strategic plans into reality. The Industrial Strategy Challenge Fund aims to bring together the UK's world leading research with business to meet the major industrial and societal challenges of our time. Monitor Coatings have ongoing, long-lasting collaboration with Cranfield University with outstanding return on productivity and performance by utilising the funds being available in a quality way."