Multifunctional Ceramic Antifouling, Erosion- and Corrosion-resistant Coating for Hydropower Applications

Hydroelectric power is the world’s largest source of renewable energy. These massive systems are designed for a 50+ year service life, but this can be shortened substantially by poor water quality and the presence of flowing debris, sediment, minerals, and micro- and macro-organisms. Biofouling (especially from invasive species), corrosion, and erosion (wear) of critical components can limit performance, increase operations and maintenance costs, and if left unchecked, lead to catastrophic failure causing millions of dollars of damage. When these effects are combined, both wear and performance degradation are accelerated – especially in aging structures. Metal, ceramic, polymeric and composite protective coatings can provide a barrier between the functioning element and the complex working environment faced by hydropower systems. Proper coatings can slow component degradation over time, minimize maintenance costs, and limit revenue-losing shutdowns. Today’s coatings are a compromise since they are generally optimized for a specific function (e.g., fouling release coatings are best at deterring mussel attachment but lack abrasion and gouge resistance while ceramic coatings provide excellent erosion resistance but have no antifouling properties). Over time, all components of a hydropower system are exposed to the same water and therefore all will, to a greater or lesser extent, experience the effects of biofouling, erosion, and corrosion. The Phase I effort will focus on engineered coatings that can address all three degradation mechanisms simultaneously. The company has developed a patented mixed-metal oxide ceramic powder that adds permanent antifouling and antibacterial/antiviral properties and improved mechanical strength to standard commercial paints and coatings without the need for light, heat, or electricity. The ceramic is fabricated from earth-abundant materials using a low-cost, scaled manufacturing process, is non-toxic, and does not leach into the environment (unlike some competing technologies). During the proposed Phase I effort the company will formulate, test, and optimize a series of silicone fouling release coatings, epoxies, and pure ceramic coatings mixed with its proprietary ceramic technology, coat on metal panels, and test both the mechanical (adhesion, erosion-, corrosion- and impact-resistance) and antifouling properties (including algae, bacteria, and barnacle adhesion) in the laboratory. Previous studies show that these tests, when performed correctly, correlate well with field demonstrations. A follow-on Phase II effort will focus on optimized coatings for specific applications in larger scale field experiments. Based on the results of preliminary experiments, these coatings should show enhanced erosion, corrosion, and biofouling resistance simultaneously. The company has already demonstrated that its ceramic technology has superior antifouling/fouling release and mechanical properties compared to state-of-the-art products without leaching into the environment. The ceramic is a drop-in replacement for today’s copper-based antifouling biocides and thus will allow it to address the approximately $7 billion annual antifouling paints and coatings market for ships, boats, and underwater structures, including hydropower systems. Complementary markets include medical/healthcare, building and construction, transportation, defense, and air/water filtration where the ceramic’s ability to inactivate pathogenic viruses and bacteria can limit the spread of diseases without harming the environment. The company’s scale-up partner has demonstrated the ability to manufacture multi-ton quantities of ceramics to address these markets.