In a world inundated by new technologies and increasing energy needs, it’s no wonder we’re on a never-ending quest for more efficient and sustainable power. Power generation is a tough business, and even the smallest inefficiencies or component breakdowns can cost hundreds of thousands of dollars. 

Whether a power plant utilizes nuclear, gas, or coal to function, it demands equipment and coatings that can withstand monumental pressure. These plants often operate in harsh environments prone to high temperatures and quick turnaround times. Enduring these extreme conditions is essential to protecting the lifespan and bottom line of components such as steam turbines, generators, and boilers. Thermal spray coatings allow power plants the luxury of time by safeguarding their most important assets against the ravages of wear, corrosion, thermal pressure, and high-temperature oxidation.

What are Thermal Spray Coatings?

Thermal spray coatings are heat-resistant treatments that can be applied to power plant parts to protect them from extreme temperatures, corrosion, and oxidation. Specialized thermal coatings applied through thermal spray processes reduce heat transfer to the underlying substrate, insulating critical components from extreme thermal exposure. 

The use of thermal spray coatings is common in power plants as the heat created by energy generation can increase the operating temperature of the part by several hundred degrees. By lowering metal surface temperatures while maintaining high gas or steam temperatures, these coatings help prevent thermal fatigue, oxidation, and material degradation. As a result, power plants can push operating temperatures higher without sacrificing component integrity, directly improving efficiency, performance, and overall system reliability.

What Power Plant Parts Benefit From Thermal Spray Coatings?

Thanks to the heat resistance and anti-corrosive nature of thermal spray coatings, many power plant components can benefit from their application. Some commonly coated power plant components include but are not limited to:

• Gas and steam turbines

• Generators

• Compressor components

• Rotors and ducts 

• Valve stems

• Blades/Buckets

• Diaphragms

• Spill strips and snout pipes

How Thermal Spray Coatings Boost Efficiency

Unplanned downtime may not seem like a critical problem, but even just an hour of component failure could cost a natural gas plant anywhere from $30,000–$250,000. These costs are further exacerbated in nuclear power plants due to their enormous energy output. Thermal spray coatings play a critical role in power plant efficiency as they allow components to operate at higher temperatures and minimize the effects of both heat transfer and thermal expansion. 

These coatings shield underlying metal components such as valves, blades, and turbines from damage inflicted by extreme temperatures. Power plants commonly operate at higher temperatures because doing so increases the efficiency of converting heat into electricity, resulting in greater power output. In fact, a study from Harvard University and the University of Virginia found that thermal spray coatings were particularly beneficial in improving the efficiency of gas turbines. This is noteworthy, as gas turbines usually consume vast quantities of fuel, resulting in higher costs for both plants and consumers.

Lastly, using thermal spray coatings can lead to reduced fuel consumption and carbon emissions. Since thermal spray coatings pave the way for greater efficiency, more power can be generated from the same amount of fuel, which means less fuel is needed and emissions are reduced. 

How Thermal Spray Coatings Enhance Reliability

Efficiency may protect your bottom line, but reliability paves the way for long-lasting success. Power plants equipped with thermal spray coatings are looking to the future, as these protective barriers enhance the longevity and reliability of parts.

One of the major contributing factors to reliability is longer component life. Power plant parts are heavily exposed to erosive environments thanks to the steam they produce. The barrier offered by thermal spray coatings has been specifically designed to resist erosion, cavitation, oxidation, and corrosion. This built-in resistance significantly extends the service life of parts and also decreases the need for costly repairs and replacements. By reducing daily wear, maintenance costs decrease, which in turn supports more reliable energy production. A power plant that is free from mechanical failure or unplanned downtime can properly plan their repair cycles and rely on peak component performance at all times.

How Does HTS Coatings Help?

HTS Coatings has worked with several power plant facilities to help protect their most essential  parts. Thanks to our decades of hands-on-experience and critical thermal spray coatings knowledge, we understand the unique challenges that come with energy generation. From coal plants to wind turbines, our coating solutions perform well in the harshest environments and stand up to the high quality standards of the nuclear power sector. Whether you need a quick turnaround for a corroded valve or simply want to extend the lifespan of your rotor shaft, thermal spray processes can be an invaluable tool in increasing the efficiency and reliability of your power plant.

Reach out to HTS Coatings today to learn more about our exciting work in the energy industry and determine which thermal process may be best for you!