MARKET POTENTIAL. ANTI-CORROSION COATINGS Current global anti-corrosion market: $3 billion. Developmental stage: Applied research/proof of concept.

Transcription

1 MARKET Coatings Advances in CNT synthesis, purification, and chemical modification are enabling integration of CNTs in thin-film electronics and large-area coatings. Properties of CNTs of interest for coatings applications include their electrical conductivity, thermal conductivity, and mechanical properties. CNTs can be loaded with chemical agents for protective coatings (anticorrosion, antimicrobial, self-healing). They have been commercialized in anti-fouling marine coatings and anticorrosion coatings in the construction and oil & gas industry. APPLICATIONS AND ESTI- MATED TIME TO MARKET Transparent conductive films (Now) Marine coatings (Now) Anti-corrosion coatings (1 year) Medical and dental implant coatings (5 years plus) Anti-fogging coatings (3-4 years) Scratch-resistant coatings (Now) Anti-bacterial coatings (5 years+) MARKET POTENTIAL 54 The general coating industry has declined but specialized coating surface engineering sectors are witnessing strong growth driven by the needs of high-end industries, such as oil and gas and electronics. Nanocoatings are opening up new market opportunities in the global coatings arena. Properties such as anti-microbialism, thermal insulation, dirt and water repellency, hardness, corrosion resistance, flame retardancy, UV stability, anti-graffiti, self-cleaning, moisture absorbing, gloss retention and chemical and mechanical properties are improved significantly using nanostructured materials. Despite the market being affected by the global economic recession, product innovation and the need to meet stringent environmental regulations is driving market demand across a wider range of markets. Nanocoatings are likely to replace traditional coatings in the medium to long-term in end use segments such as packaging, anti-microbial, architectural, industrial manufacturing, marine, wood, auto refinish, transportation and protective coatings. The market for nanocoatings will grow across all sectors over the next 5-10 years, with the medical, electronics and displays (especially smart phones), interior and exterior household coatings and food processing markets all experiencing significant growth, driven by the need for improved sanitary facilities and also pushed by the vast improvements nanocoatings offer, from both a protective and destructive perspective. The military market will remain the largest market with anti-corrosion coatings increasingly applied. Anti-corrosion coatings and super hardness will also drive revenues in the oil and gas industry, for protective surfaces in pipelines and harsh environments and on drilling equipment. There is at least one commercial marine coating on the market that incorporates nanotubes to provide enhanced abrasion resistance. Formulations with nanotubes are also being investigated as anti-fouling coatings for marine applications and as additives for anti-static coatings where static discharge may otherwise be considered dangerous. They can be easily dispersed in, for example, plastic materials and improve their mechanical properties in such a way that significant weight reduction can be achieved at equal mechanical performances. However, CNTs have yet to be extensively incroporated into commercially available coating systems. ANTI-CORROSION COATINGS Current global anti-corrosion market: $3 billion. Developmental stage: Applied research/proof of concept.

2 55 Corrosion is a significant problem for industrial equipment, installations, and plants. As it is a slow process it can change, assuming many forms and arise very rapidly since it is triggered by environmental factors, such as oxygen and water, which cannot be eliminated. It is possible, however, to prevent corrosion, and nanocoatings are important as they can shift the focus of the problem from the protection against corrosion to its prevention. Main market drivers includes: constantly increasing requirements on the performance of anti-corrosion coatings rising cost awareness increasing environmental attention related to the reduction of solvent content growing application of surface tolerant protective coatings systems or coatings providing universal adhesion replacement of toxic inhibitors such as hexavalent chromium. The presence of corrosive chemicals and harsh operating and environmental conditions can result in structural failure or loss of containment, which can be costly in terms of repairs, lost or contaminated products, environmental damage, and potential risk to personnel. Corrosion is very costly and has a major impact on the economies of industrial nations companies. The annual direct cost of metallic corrosion in U.S. economy is estimated $300 billion and 200 billion in Europe. While there is an increasing need for more effective and less costly products, government regulations are also driving demand for lower content of chemicals in coatings. Therefore the need for new solutions is pressing. CNTs in anti-corrosion coatings Nanocoatings can be designed to be used on any steel substrate and could thus be applied to components from a wide range of markets. These markets include mining (ore processing, surface and underground mining, and drilling), utilities (seals, accessories, and bearings), defense, agriculture (tillage and planting), construction (drill bits, grinder hammer tips, and other hardware), shipping, energy (wind power at sea) and transportation (brakes, valve trains, bearings, and gears). CNTs and fullerenes have been developed for corrosionresistant coatings in oil and gas applications. Their mechanical properties are of great interest for refurbishing and lengthening the working life of equipment and pipelines. Incorporated into coatings, they protect structures like drilling platforms, bridges and metal construction from corrosion; they safeguard shut-off valves and pumping and compressor fixtures; they protect equipment for drilling, oil and gas extraction, and processing and refining from wear and tear. Drilling equipment in the oil and gas industry tends to wear down very quickly. Carbon nanotubes have been incorporated into marine

3 coatings for anti-corrosion. These coatings allow for improved integrity of barrier films due to lower pigment loading and CNT reinforcement. They also display improved improved durability and modulus understress and impact and abrasion resistance.tesla NanoCoatings ( supplies corrosion control coatings incorporating carbon nanotubes for marine markets. However, silica nanoparticles, aluminium, Nanorystalline Carbide, Diamond like Carbide and metal dichalcogenide, TiN nanocrystallites embedded in amorphous Si 3 N are more widely used nanomaterials for anti-corrosion applications. It has been demonstrated that graphene coatings retard microbially-induced galvanic corrosion (MIC) of metals for extended periods of time (2700 hours) as they prevent access of microbes to the surface, form a protective barrier and protect the surface from microbial byproducts that enhance Ni dissolution. A recent study however indicated that although graphene ( offers effective short-term oxidation protection, over long time scales it promotes more extensive wet corrosion than that seen for an initially bare, unprotected surface. CONDUCTIVE COATINGS Current global conductive coatings market: >$2.5 billion. Developmental stage: Commercialized/near market. Transparent conducting oxides (TCOs) are thin films of metal oxides that exhibit both optical transparency and electrical conductivity. They have become widely used in applications such as solar cells, light emitting diodes, and liquid crystal displays. The transparent electrodes and transistors sector is worth billions of dollars and markets include e-paper, flexible displays, touchscreens, haptic user interfaces and solar cells. Transparent conductive films have been incorporated into sensors on touchscreen technologies and as protective coatings on consumer electronics. Nanomaterials may allow for the replacement of existing electrically conductive materials such as indium tin oxide (ITO) that is in short supply, expensive and limited in its use with flexible substrate. Conductive and anti-static coatings are used throughout the aircraft industry for applications ranging from electrostatic discharge (ESD) to electromagnetic interference (EMI) and radio frequency interference (RFI) shielding. CNTs in conductive coatings CNT films and inks have been developed for transparent conductive coatings for applications in electronics and batteries due to their high electrical and thermal conductivity. Transparent conductive film or glass is a key component for many optical-electronic devices such as organic light emitting diodes (OLED), organic photovoltaic solar cells (OPV), liquid crystal display (LCD) panels and touch panels. The most critical requirements for transparent conductive film or glass are low sheet resistance and high transparency. Due to manufacturing and quality requirements, indium tin oxide (ITO) film or glass is most commonly used for optical-electronic devices in the current market. However, indium is a rare-earth material, and is expensive. Low-cost wet coating processes have been utilized for coating nanoscaled conductive media such as CNT on PET film (Silver nanowires are also used). Conductive film or glass coated with CNT is hindered by dispersion problems and as a result single-wall CNT (SWNT) are favoured over multi-wall CNT (MWNT). However these materials are also extremely expensive. It has been demonstrated that CNT-coatings are coating is effective in providing EMI shielding in a broad frequency range. CNT based coating showed good shielding effectiveness and absorption performances (60%-90%) across a wide frequency range. Nanoshield is produced by Eikos, Inc. ( for EMI shielding applications. Eikos employs proprietary water-based inks to make nanotube coatings. ANTI-BACTERIAL COATINGS Current global anti-bacterial coatings market: $6.5 billion. Developmental stage: Applied research. Infection control is of great importance and requires a high level of hygiene. Hospitals, pharmaceutical production units, food factories etc. need to be rigorously disinfected in order to destroy pathogenic microbes. Applications for antimicrobial coatings include medical products, packaging materials, or filters used in air-conditioning systems. Microbial contamination of water also poses a major threat to public health too. With the emergence of microorganisms resistant to 56

4 multiple antimicrobial agents there is also an increased demand for improved disinfection methods. The classical biocides function in coatings is to either inhibit the growth of bacteria (biostatic) or by kill them (biocidal). New legislations and the aforementioned possibility of bacterial mutation have forced coating manufacturers to seek new alternatives. Today, more emphasis is placed on the development of bio-repulsive (without killing) antibacterial coatings. A wide variety of organic or inorganic biocides are available commercially and these demonstrate a wide variety of biocidal and biostatic mechanisms. CNTs in anti-bacterial coatings SWNTs possess high anti-microbial activity in addition to their exceptional optical, electrical, mechanical and thermal properties. They exhibit strong antimicrobial activity toward Gram positive and Gram negative bacteria, as well as bacterial spores. The mechanism is related to the impairment of pathogen cellular function by destruction of major constituents (e.g., cell wall), interference with the pathogen cellular metabolic processes, and inhibition of pathogen growth by blockage of the synthesis of key cellular constituents (e.g., DNA, coenzymes and cell wall proteins). ANTI-ICING COATINGS Current global anti-iclng coatings market: $200 million. Developmental stage: Prototype/proof of concept. The icing of surfaces is a major problem which impairs the function of those surfaces and incurs significant costs. For example, the ice storm of 2008 caused serious damage to power systems in Southern China, with more than 100 billion yuan ($16 billion) in direct economic losses. Ice and wet-snow adhesion and excessive accumulation on exposed structures and equipment is well known as a source of numerous types of failures and malfunctions in cold-climate regions. Industries affected include machine building, aviation, power transmission, maritime, trains, automotive, refrigeration, construction and wind turbines. The effects of icing include increased weight, impaired function of equipment, longer maintenance time and downtimes and human safety issues. According to the Environmental Protection Agency, 25 million gallons of deicing agents are applied to aircraft at U.S. commercial airports each year. The aviation industry is also using energy-intensive pneumatic and electric anti-icing systems on aircraft to prevent ice formation on wings and other surfaces. Also in numerous other machine construction and structural technology applications, surface freezing can cause malfunctions, such as in antennas and wind turbine wings. CNTs in anti-icing coatings Nanocoatings are under development for several applications. IceWind is a 4million euro project funded by the Norwegian Research Council that is investigating the use of carbon nanotubes in a coating or film absorb MW radiation and generate heat for anti-icing of wind turbine blades. More than 5% of annual production loss is due to icing in cold climates. SAAB ( has filed a patent to use graphene for de-icing airplanes. The graphene layer would be embedded in a heating jacket covering the aircraft. ANTI-FOULING COATINGS Current global marine coatings market: $4-5 billion. Developmental stage: Commercialized. Biofouling is a major problem in the marine industry. Marine coatings are in service to protect structures such as ships and platforms or sensors. By settling on ship hulls, mussels, barnacles and algae can substantially increase ship weight up to several tons within a short time thus leading to a higher resistance during transport, higher fuel consumption - even on long hauls. Typically, marine coatings are tributyltin self-polishing copolymer paints containing toxic molecules called biocides. They have been the most successful in combating biofouling on ships, but their widespread use has caused severe pollution in the marine ecosystem. Nanocoatings are an entirely non-toxic alternative, which reduces the adhesion strength of marine organisms, facilitating their hydrodynamic removal at high speeds. Another major advantage is the reduction of maintenance costs. The ban on organic tin compounds for use as antifouling agents to prevent organic growth has necessitated relative frequent cleaning of the coating surface on the ship s hull to ensure cost-effective transport. The smoothness and greater hardness of nanoscale coatings provide better durability and extends the cleaning cycle. Since biofouling represents a substantial maintenance expense for hydro-kinetic systems, anti-fouling nanocoatings could potentially provide an important value-added solution for these systems. 57

5 Areas in marine coatings that nanocoatings will impact include: Cargo holds: Abrasion resistance Cargo tanks: Chemical resistance Underwater hull: Fouling control Decks: Hard wearing, impact and chemical resistance Ballast tanks: Corrosion resistance. Nanocoatings reduce the flow resistance between the ship s hull and the water, thereby enabling a significant reduction in fuel consumption and carbon dioxide (CO2) emissions. Nanotechnology water based, anti-foul marine paints offer super hydrophobicity (less fuel consumption), are durable, water repellent, UV resistant, fungus / algae / bacteria resistant, thermally insulating, elastomeric, anti-sticking and -corrosive (up to hours of salt spray). They provide a high resistance to weathering (UV, fungus, water, dirt, etc.) and any blistering over standard marine coatings. Nanocoatings find application in military and commercial steel ship hulls and steel, aluminum or fiberglass boat hulls, making them non-susceptible to permanent adhesion of marine fouling organisms such as barnacles, sea-grasses etc. When organisms such as bacteria, barnacles and algae stick to the surfaces of ships it is a costly nuisance. These biofouling organisms mean that ships burn 40% more fuel at an annual cost of more than 5 million for businesses, as well as an incalculable cost to the environment. CNTs in anti-fouling coatings Carbon nanotubes have been incorporated into marine coatings for anti-corrosion. These coatings allow for Improved integrity of barrier films due to lower pigment loading and CNT reinforcement. They also display improved improved durability and modulus understress and impact and abrasion resistance. Graphene is also under investigation for application in protective marine coatings as an environmentally friendly alternative to hexavalent chromium. US naval vessels coated with nanomaterials such as CNTs more than five years ago still show virtually no signs of biofouling. FLAME-RETARDANT COATINGS Current flame-retardant coatings market: $2-3 billion. Developmental stage: Near market/commercialized. The global need for fire-retardant materials is growing. Regulations are compelling manufacturers in the household sector, electronics, building and construction, transportation etc. to meet increasingly stringent standards of fire safety. Commercialised products that benefit from flame retardants include plastic enclosures for consumer electronics, printed circuit boards, wire and cable, electrical connectors, foam insulation, foam seating in furniture, automobiles and textiles. CNTs in flame-retardant coatings MWNTs have been incorporated into flame-retardant coatings for plastics and textiles as an agent providing non-flammability to products and coating layers. THERMOCYL is a range of CNT dispersions that provide thermal protection on any substrate form Nanocyl. MW- CNTs improve thermal stability and provide a char layer for flame retardancy. These coatings can reduce insulation weight in automotive and aerospace applications. MWNTs have been demonstrated to reduce peak heat release rate; formation of network-structured protective layer; reduced rate of pyrolysis; and increased the limiting oxygen index. PRODUCT DEVELOPERS Advanced Marine Coatings AMC is a Norwegian paint company producing and marketing next generation marine coating with Nano Carbon Tubes using a new unique patented technology. MCoating The company produces MC LioCyl Sys Fouling Release Paint System incorporating CNTs for anti-fouling maring coatings. Nanocyl Nanocyl s range of eco-friendly, fouling release paints designed for all major marine coating applications, such as ship hulls, oil rigs, and underwater intake valves. Tesla NanoCoatings, Inc. The company s corrosion technology, called Teslan, is a two-coat system consisting of a primer and topcoat developed in collaboration with the U.S. Army Engineer Research and Development Center, Construction Engineering Research Laboratory (ERDC-CERL). The two-part (resin and catalyst), solventborne primer contains fullerene CNTs hollow, tube structures that are electrically conductive and allow zinc particles to remain in electric contact. The topcoat is available as epoxy, polyurethane, or polyaspartic. 58

6 Table 13: Global revenue estimates for coatings sector impacted by carbon nanotubes Frank and Sullivan DoE ORNL Nanomarkets BioAmber Global Water Intelligence Potential surface antimicrobial market 2020: $25 billion Cost to United State for Pipe Corrosion and Fouling Transmission pipelines: $6-8 billion Residential plumbing cost: $276 billion Bridge corrosion: $7 billion Protective coatings global market: $1.13 billion with 3.4% CAGR Global conductive coatings market 2012: $9 billion Global conductive coatings market 2019: $19 billion Global de-icing coatings market 2011: $500 million Global biofouling market 2012: $650 million 2016: $1 billion IPPIC In terms of value, the marine coatings market was worth approximately $4 billion in 2007, or roughly four percent of the total global coatings market, on a volume of 840 million liters and will be worth $4.7 billion in 2012 on a volume of 904 million liters. 59