Monitor Coatings Ltd (www.castolin.com), a surface engineering specialist based in North Tyneside (and part of the Castolin Eutectic Group), has been co-funded by Innovate UK to work with Cranfield University on coating developments.

The project, which began in September, involves using 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, thereby increasing the demand on heat-exchanger tubes.

The ‘ER-Sealcoat’ project aims to develop a low-cost method of producing customisable coatings suitable for 3-D geometries (internal and external) and able to resist high-temperature environments.

The 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 base-coat, producing a sealed surface with a bespoke chemical gradient capable of resisting fireside corrosion and high-temperature oxidation in aggressive conditions.

Spyros Kamnis, Monitor Coatings’ R&D manager, said: “I'm delighted that Innovate UK has been able to support this exciting project. 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.”