Effects of coating roughness and biofouling on ship resistance and powering

Abstract

Predictions of full-scale ship resistance and powering are made for antifouling coating systems with a range of roughness and fouling conditions. The estimates are based on results from laboratory-scale drag measurements and boundary layer similarity law analysis. In the present work, predictions are made for a mid-sized naval surface combatant at cruising speed and near maximum speed. The results indicate that slime films can lead to significant increases in resistance and powering, and heavy calcareous fouling results in powering penalties up to 86% at cruising speed. The present estimates show good agreement with results from full-scale ship power trials.     

Impact of diatomaceous biofilms on the frictional drag of fouling-release coatings

Skin-friction results are presented for fouling-release (FR) hull coatings in the unexposed, clean condition and after dynamic exposure to diatomaceous biofilms for 3 and 6 months. The experiments were conducted in a fully developed turbulent channel flow facility spanning a wide Reynolds number range. The results show that the clean FR coatings tested were hydraulically smooth over much of the Reynolds number range. Biofilms, however, resulted in an increase in skin-friction of up to 70%. The roughness functions for the biofilm-covered surfaces did not display universal behavior, but instead varied with the percentage coverage by the biofilm. The effect of the biofilm was observed to scale with its mean thickness and the square root of the percentage coverage. A new effective roughness length scale (k_eff) for biofilms based on these parameters is proposed. Boundary layer similarity-law scaling is used to predict the impact of these biofilms on the required shaft power for a mid-sized naval surface combatant at cruising speed. The increase in power is estimated to be between 1.5% and 10.1% depending on the biofilm thickness and percentage coverage.     

Effect of barnacle fouling on ship resistance and powering

Predictions of added resistance and the effective power of ships were made for varying barnacle fouling conditions. A series of towing tests was carried out using flat plates covered with artificial barnacles. The tests were designed to allow the examination of the effects of barnacle height and percentage coverage on the resistance and effective power of ships. The drag coefficients and roughness function values were evaluated for the flat plates. The roughness effects of the fouling conditions on the ships’ frictional resistances were predicted. Added resistance diagrams were then plotted using these predictions, and powering penalties for these ships were calculated using the diagrams generated. The results indicate that the effect of barnacle size is significant, since a 10% coverage of barnacles each 5 mm in height caused a similar level of added power requirements to a 50% coverage of barnacles each 1.25 mm in height.     

Iodine-infused aeration for hull fouling prevention: a vessel-scale study

Biofouling is a significant economic and ecological problem, causing reduced vessel performance and increases in fuel consumption and emissions. Previous research has shown iodine vapor (I₂)-infused aeration to be an environmentally friendly method for deterring the settlement of fouling organisms. An aeration system was deployed on a vessel with hull sections coated with two types of antifoulant coatings, Intersleek^® 1100 (fouling-release) and Interspeed^® BRA-640 (ablative copper biocide), as well as an inert epoxy barrier coating, to assess the effectiveness of aeration in conjunction with common marine coatings. I₂-infused aeration resulted in consistent reductions of 80–90% in hard fouling across all three coatings. Additionally, aeration reduced the soft fouling rate by 45–70% when used in conjunction with both Intersleek^® and Interspeed^® BRA versus those coatings alone. The results of this study highlight the contribution of I₂-infused aeration as a standalone mechanism for fouling prevention or as a complement to traditional antifouling coatings.     

Analysis of long-term mechanical grooming on large-scale test panels coated with an antifouling and a fouling-release coating

Long-term grooming tests were conducted on two large-scale test panels, one coated with a fluorosilicone fouling-release (FR) coating, and one coated with a copper based ablative antifouling (AF) coating. Mechanical grooming was performed weekly or bi-weekly using a hand operated, electrically powered, rotating brush tool. The results indicate that weekly grooming was effective at removing loose or heavy biofilm settlement from both coatings, but could not prevent the permanent establishment of low-profile tenacious biofilms. Weekly grooming was very effective at preventing macrofouling establishment on the AF coating. The effectiveness of weekly grooming at preventing macrofouling establishment on the FR coating varied seasonally. The results suggest that frequent mechanical grooming is a viable method to reduce the fouling rating of ships’ hulls with minimal impact to the coating. Frequent grooming could offer significant fuel savings while reducing hull cleaning frequencies and dry dock maintenance requirements.     

Engineered antifouling microtopographies: kinetic analysis of the attachment of zoospores of the green alga Ulva to silicone elastomers

Microtopography has been demonstrated as an effective deterrent to biofouling. The majority of published studies are fixed-time assays that raise questions regarding the kinetics of the attachment process. This study investigated the time-dependent attachment density of zoospores of Ulva, in a laboratory assay, on a micropatterned and smooth silicone elastomer. The attachment density of zoospores was reduced on average 70–80% by the microtopography relative to smooth surfaces over a 4 h exposure. Mapping the zoospore locations on the topography revealed that they settled preferentially in specific, recessed areas of the pattern. The kinetic data fit, with high correlation (r ² > 0.9), models commonly used to describe the adhesion of bacteria to surfaces. The grouping of spores on the microtopography indicated that the pattern inhibited the ability of attached spores to recruit neighbors. This study demonstrates that the antifouling mechanism of topographies may involve disruption of the cooperative effects exhibited by fouling organisms such as Ulva.     

Mini-review: Marine natural products and their synthetic analogs as antifouling compounds: 2009–2014

This review covers 214 marine natural compounds and 23 of their synthetic analogs, which were discovered and/or synthesized from mid-2009 to August 2014. The antifouling (AF) compounds reported have medium to high bioactivity (with a threshold of EC₅₀ < 15.0 mg ml^?1). Among these compounds, 82 natural compounds were identified as new structures. All the compounds are marine-derived, demonstrating that marine organisms are prolific and promising sources of natural products that may be developed as environmentally friendly antifoulants. However, this mini-review excludes more than 200 compounds that were also reported as AF compounds but with rather weak bioactivity during the same period. Also excluded are terrestrial-derived AF compounds reported during the last five years. A brief discussion on current challenges in AF compound research is also provided to reflect the authors’ own views in terms of future research directions.     

Natural products as antifouling compounds: recent progress and future perspectives

Since early 2008, an increasing number of countries have ratified an international treaty to ban the application of antifouling (AF) coatings based on organotin compounds (eg tributyltin (TBT) and triphenyltin). As a result, the demand for environmentally friendly, non-toxic or low-toxicity AF compounds and technologies (green AF agents) has become an urgent reality. Marine coatings based on Cu₂O and various other biocides have a negative impact on the environment and they must eventually be replaced by new, effective, and environmentally friendly AF compounds. This mini-review describes important AF compounds discovered from a variety of organisms from 2004 until mid 2009, and discusses recent and general trends in the discovery of AF compounds. Finally, a perspective on the future of AF compound development is presented. The discussion is aimed at updating scientists and engineers on the current challenges facing AF research.     

The use of aeration as a simple and environmentally sound means to prevent biofouling

Biofouling is a major problem faced by marine industries. Physical and chemical treatments are available to control fouling, but most are costly, time consuming or negatively affect the environment. The use of aeration (ie continuous streams of air bubbles) to prevent fouling was examined. Experiments were conducted at three sites with different benthic communities. Experimental panels (10 cm × 10 cm; PVC and concrete) were deployed with or without aeration. Aeration flowed continuously from spigots 0.5 m below the panels at a rate of ～3.3 to 5.0 l min^?1. After 1 and 4 weeks, aerated PVC panels from all sites had significantly less fouling than non-aerated controls. Aeration reduced fouling on both the PVC and concrete surfaces. Fouling was reduced on panels directly in bubble streams while panels 30 cm and 5 m away had significantly more fouling. Thus, under the conditions used in this study, aeration appears to be an effective and simple way to prevent fouling.     

Drag-reducing riblets with fouling-release properties: development and testing

The manufacture and preliminary testing of a drag-reducing riblet texture with fouling-control properties is presented. The commercial fouling-release product Intersleek® 1100SR was modified to manufacture riblet-textured coatings with an embossing technology. Hydrodynamic drag measurements in a Taylor–Couette set-up showed that the modified Intersleek® riblets reduced drag by up to 6% compared to a smooth surface. Barnacle settlement assays demonstrated that the riblets did not substantially reduce the ability of Intersleek® 1100SR to prevent fouling by cyprids of Balanus amphitrite. Diatom adhesion tests revealed significantly higher diatom attachment on the riblet surface compared to smooth Intersleek® 1100SR. However, after exposure to flow, the final cell density was similar to the smooth surface. Statically immersed panels in natural seawater showed an increase of biofilm cover due to the riblets. However, the release of semi-natural biofilms grown in a multi-species biofilm culturing reactor was largely unaffected by the presence of a riblet texture.     

An experimental investigation into the surface and hydrodynamic characteristics of marine coatings with mimicked hull roughness ranges

Abstract

There are limited scientific data on contributors to the added drag of in-service ships, represented by modern-day coating roughness and biofouling, either separately or combined. This study aimed to gain an insight into roughness and hydrodynamic performance of typical coatings under in-service conditions of roughened ships’ hull surfaces. Comprehensive and systematic experimental data on the boundary layer and drag characteristics of antifouling coating systems with different finishes are presented. The coating types investigated were linear-polishing polymers, foul-release and controlled-depletion polymers. The data were collected through state-of-the-art equipment, including a 2-D laser Doppler velocimetry (LDV) system for hydrodynamic data in a large circulating water tunnel. Three coating systems were first applied on flat test panels with ‘normal’ finishes in the first test campaign to represent coating applications under idealised laboratory conditions. In order to address more realistic roughness conditions, as typically observed on ships’ hulls, ‘low’ and ‘high’ roughness densities were introduced into the same types of coating, in the second test campaign. The data collected from the first test campaign served as the baseline to demonstrate the effect on the surface roughness and hydrodynamic drag characteristics of these coating types as a result of ‘in-service’ or ‘severely flawed’ coating application scenarios. Data collected on coatings with a range of in-service surface conditions provided a basis to establish correlation between the surface roughness characteristics and hydrodynamic performance (roughness function). The findings of the study indicate that the estimations of drag penalties based on well-applied, relatively smooth coating conditions underestimate the importance of hull roughness, which although undesirable, is commonplace in the world’s commercial fleet.     

Reduction of barnacle recruitment on micro‐textured surfaces: Analysis of effective topographic characteristics and evaluation of skin friction

This study investigates five designed micro‐textured surfaces and their effects on barnacle fouling and hydrodynamic drag. Three of the micro‐textures were developed in the present study and evaluated together with two commercial riblet films. All micro‐structures were arranged as longitudinal grooves with different profile depths, widths and angles of inclination. In field tests the recruitment of the barnacle Balanus improvisus on micro‐textured surfaces and smooth controls was evaluated. All micro‐textured surfaces reduced recruitment, and the most efficient texture reduced recruitment by 98%. For some micro‐textures the reduction of recruitment declined as settlement intensity increased. In a correlative analysis, the trigonometric inclination of the micro‐structures explained most of the recruitment reduction. The steepest angle of inclination caused a massive reduction in barnacle settlement. Surface micro‐structures may affect the boundary‐layer flow and the hydrodynamic drag (skin friction) of the surface. The skin friction was empirically measured in a flow channel using a sub‐set of the tested micro‐textures. The measurements of skin friction showed that the orientation of the microstructures is important, with a minimum friction when the grooves are parallel to the flow. For one of the micro‐textures the skin friction was ca 10% lower compared to a hydraulically smooth surface. It is concluded that, depending on the flow speed, micro‐textures will not significantly increase skin friction when arranged parallel to the flow, even at moderate protrusion through the viscous sub‐layer.     

Cold spray metal embedment: an innovative antifouling technology

The study demonstrates that embedment of copper particles into thermoplastic polymers (polymers) using cold spray technology is an effective deterrent against fouling organisms. Two polymers, high-density polyethylene (HDPE) and nylon were metallised with copper powder using cold spray technology. After 250 days in the field, Cu-embedded HDPE and copper plate controls were completely free of hard foulers compared to Cu-embedded nylon and polymer controls which were heavily fouled with both soft and hard fouling. Antifouling (AF) success is related to the interaction between the properties of the polymers (elastic modulus and hardness) and the cold spray process which affect particle embedment depth, and subsequently, the release of copper ions as determined by analytical techniques. Embedding metal using cold spray equipment is shown to be an effective AF technology for polymers, in particular those that are difficult to treat with standard AF coatings, with efficacy being a function of the interaction between the cold spray metal and the polymer recipient.     

Marine antifouling from thin air

The dynamic relationship between the settlement behaviour of marine biota (cells, spores, larvae) and the longevity of an entrapped air layer (plastron) on submersed superhydrophobic surfaces was systematically investigated. Plastron lifetime decreased with increasing hydrophobic polymer loadings, and was correlated with the settlement rate of a range of fouling species of varying length scale, motility and hydrophobic/hydrophilic surface preference. The results show that the level of fouling on immersed superhydrophobic surfaces was greater when plastron lifetimes were minimal, regardless of the length scale, motility and the surface preference of the organisms. This is the first direct demonstration of the broad-spectrum attachment-inhibiting properties of a plastron on an immersed superhydrophobic surface.     

Antifouling properties of tough gels against barnacles in a long-term marine environment experiment

In the marine environment, the antifouling (AF) properties of various kinds of hydrogels against sessile marine organisms (algae, sea squirts, barnacles) were tested in a long-term experiment. The results demonstrate that most hydrogels can endure at least 2 months in the marine environment. In particular, mechanically tough PAMPS/PAAm DN and PVA gels exhibited AF activity against marine sessile organisms, especially barnacles, for as long as 330 days. The AF ability of hydrogels toward barnacles is explained in terms of an ‘easy-release’ mechanism in which the high water content and the elastic modulus of the gel are two important parameters.     

Using ultraviolet light for improved antifouling performance on ship hull coatings

Abstract

A two-part study was designed to investigate the efficacy of using UVC to prevent biofouling in the context of ship hull coatings. The first study determined the frequency of UVC required for a coating that does not have any additives (epoxy). It was found that 1?min/day was effective at preventing hard fouling but not biofilm development. The second study addressed several variables: coating type (epoxy, copper, fouling release), frequency of UVC (no exposure, continuous exposure, 1min/6h, 1?min/day), and distance from the lamp (25 and 50?mm). Continuous UVC exposure resulted in no biofouling settlement but it did damage the copper coating. Intermittent UVC exposure was effective at preventing biofouling recruitment to both the copper and the fouling release coatings. Variations were observed with regards to the fouling composition, especially biofilms, sedimentary tubeworms and barnacles, suggesting tolerances within the community.     

The adhesive strategies of cyprids and development of barnacle-resistant marine coatings

Over the last decade, approaches to the development of surfaces that perturb settlement and/or adhesion by barnacles have diversified substantially. Although, previously, coatings research focussed almost exclusively on biocidal technologies and low modulus, low surface-free-energy ‘fouling-release’ materials, novel strategies to control surface colonisation are now receiving significant attention. It is timely, therefore, to review the current ‘state of knowledge’ regarding fouling-resistant surface characteristics and their mechanisms of action against settling larvae of barnacles. The role of the barnacle in marine fouling is discussed here in the context of its life cycle and the behavioural ecology of its cypris larva. The temporary and permanent adhesion mechanisms of cyprids are covered in detail and an overview of adult barnacle adhesion is presented. Recent legislation has directed academic research firmly towards environmentally inert marine coatings, so the actions of traditional biocides on barnacles are not described here. Instead, the discussion is restricted to those surface modifications that interfere with settlement-site selection and adhesion of barnacle cypris larvae; specifically, textural engineering of surfaces, development of inert ‘non-fouling’ surfaces and the use of enzymes in antifouling.     

The effect of end‐group substitution on surface self‐assembly of peptides

Biofouling, the undesirable accumulation of organisms onto surfaces, affects many areas including health, water, and energy. We previously designed a tripeptide that self‐assembles into a coating that prevents biofouling. The peptide comprises three amino acids: DOPA, which allows its adhesion to the surface, and two fluorinated phenylalanine residues that direct its self‐assembly into a coating and acquire it with antifouling properties. This short peptide has an ester group at its C‐terminus. To examine the importance of this end group for the self‐assembly and antifouling properties of the peptide, we synthesized and characterized tripeptides with different end groups (ester, amide, or carboxylic group). Our results indicate that different groups at the C‐terminus of the peptide can lead to a change in the peptide assembly on the surface and its adsorption process. However, this change only affects the antifouling properties of the coating toward Gram‐positive bacteria (Staphylococcus epidermidis), whereas Gram‐negative bacteria (Escherichia coli) are not affected.     

Development of the initial diatom microfouling layer on antifouling and fouling-release surfaces in temperate and tropical Australia

Diatoms are a major component of the slime layers that form on artificial surfaces in marine environments. In this article, the role played by diatoms during the pioneering stages of colonization of three marine antifouling (AF) coatings, viz Intersmooth 360®, Super Yacht 800® and a fouling-release (FR) coating Intersleek 700®, was investigated. The study was conducted over three distinct seasons in two very different marine environments in Australia, ie temperate Williamstown, Victoria and tropical Cairns, Queensland. Diatom fouling occurred more rapidly on the FR coating Intersleek 700, compared to both biocidal AF paints. However, colonization by diatoms on all three coatings was generally slow during the 16-day study. Benthic diatoms do not subsist by floating around in the water column, rather they only gain the opportunity to colonize new surfaces when they either voluntarily release or are displaced from their benthic habitat, thereafter entering the water column where the opportunity to adhere to a new surface presents itself. However, once settled, fouling diatoms grow exponentially from the site of attachment, spreading out until they populate large areas of the surface. This mode of surface colonization correlates more with an ‘infection’ type, epidemiology model, a mechanism that accounts for the colonization of significant regions of the coating surface from a single fouling diatom cell, forming ‘clonal patches’. This is in comparison to the bacterial colonization of the surface, which exhibits far more rapid recruitment and growth of cells on the substratum surface. Therefore, it is hypothesized that fouling diatoms may be characterized more by their ability to adhere and grow on surfaces already modified by bacterial biofilms, rather than on their strength of adhesion. Cell morphology and the ability to avoid shear may also be an important factor.