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<p>Efficient and reliable heating systems are essential for maintaining the performance of above-ground pipelines in cold regions to prevent freezing-related damages and financial losses. Conventional heating cables lose efficiency due to poor thermal contact with the pipe surface. In contrast, coating-based heating systems produced via thermal and cold spray processes provide superior heat transfer and performance. Given this superiority, this study compares the design, development, and techno-economic aspects of three generations of coating-based heaters aimed at de-icing and thermal maintenance applications of carbon steel pipes.&#xa0;In all three generations, an alumina or alumina-titania insulating layer was first flame-sprayed onto the pipe. The first-generation heater used a flame-sprayed Ni-Cr layer over the entire alumina layer. The second generation used a cold-sprayed helical Tin element over uniform alumina. The third generation used a straight Tin element cold-sprayed onto a narrow alumina strip, noticeably simplifying fabrication and maintenance.&#xa0;Performance evaluations and cost analyses revealed that cold-sprayed heaters outperformed both earlier thermal spray-based heaters and conventional heating cables. Notably, the second-generation system demonstrated a 55% reduction in fabrication costs compared to the first-generation, while the third-generation system offered an additional 53% cost savings. The third-generation design streamlined production, reducing raw material and labor needs, while also lowering environmental impact through reduced powder use and minimal combustion emissions.&#xa0;The results show that the latest coating-based heating system is a strong alternative to conventional heating cables, offering better performance, lower costs, and improved sustainability, along with easier on-site repairability for steel pipes in cold regions.</p>

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Impact of Design and Thermal Spray Techniques on the Techno-Economic Implications of Coating-Based Pipe De-Icing Systems

  • 期刊论文

  • 发表日期：

    2026年2月24日

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  • M. Rezvani Rad,
  • P. Menghesha,
  • M. O. Jarligo,
  • A. McDonald

摘要

Efficient and reliable heating systems are essential for maintaining the performance of above-ground pipelines in cold regions to prevent freezing-related damages and financial losses. Conventional heating cables lose efficiency due to poor thermal contact with the pipe surface. In contrast, coating-based heating systems produced via thermal and cold spray processes provide superior heat transfer and performance. Given this superiority, this study compares the design, development, and techno-economic aspects of three generations of coating-based heaters aimed at de-icing and thermal maintenance applications of carbon steel pipes. In all three generations, an alumina or alumina-titania insulating layer was first flame-sprayed onto the pipe. The first-generation heater used a flame-sprayed Ni-Cr layer over the entire alumina layer. The second generation used a cold-sprayed helical Tin element over uniform alumina. The third generation used a straight Tin element cold-sprayed onto a narrow alumina strip, noticeably simplifying fabrication and maintenance. Performance evaluations and cost analyses revealed that cold-sprayed heaters outperformed both earlier thermal spray-based heaters and conventional heating cables. Notably, the second-generation system demonstrated a 55% reduction in fabrication costs compared to the first-generation, while the third-generation system offered an additional 53% cost savings. The third-generation design streamlined production, reducing raw material and labor needs, while also lowering environmental impact through reduced powder use and minimal combustion emissions. The results show that the latest coating-based heating system is a strong alternative to conventional heating cables, offering better performance, lower costs, and improved sustainability, along with easier on-site repairability for steel pipes in cold regions.