Monitor Coatings said it earned funding from Innovate UK to develop functional gradient design coatings in collaboration with Cranfield University. 

Monitor and Cranfield in September began a study which will use the process of exothermic reaction synthesis to modify low cost sprayed metallic surface coatings. The need to reduce CO₂ 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 customizable 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. 

“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,”  said Dr. Spyros Kamnis, Monitor Coatings’ R&D manager.