Development of Nanocoatings for Primary Heat Exchanger within Condensing Boiler to Allow Replacement of Aluminium Silicon Alloy with Aluminium to Reduce Carbon Emissions, Cost, and Fuel Usage

This study is to develop a nanocoating that will prevent corrosion and increase thermal conductivity in the primary heat exchanger of a condensing boiler.
Boiler manufacturers assert that aluminium heat exchangers are the preferred material to be used because of its low manufacturing costs and high thermal conductivity properties. Unfortunately, the corrosion which results from burning domestic gas on untreated aluminium heat exchangers means other alternative heat exchangers are used by boiler manufacturers.
As a result, many boilers ‘pre-heat’ the heat exchange surfaces (which wastes fuel) to avoid an unacceptable lag when the hot tap is turned on. The use of an aluminium exchanger with nanocoatings would reduce carbon emissions, and reduce production costs for manufacturers, and long term cost to end consumers.