Dynamic hydration layer and ion-release synergy in coatings: Unraveling the key to sustainable anti-scaling during boiling and energy conservation

Scale deposition severely degrades the heat-transfer efficiency of industrial equipment, leading to substantial energy wastage. While several advanced scalephobic surfaces have been developed to mitigate scaling, their poor stability under harsh operating conditions hinders practical implementation. Herein, we report a dynamic hydration layer-synergistic ion-releasing (DHLIR) coating that exhibits exceptional energy-saving potential, enabled by ultrahigh scale resistance under boiling conditions. The DHLIR coating was facilely fabricated via a combined spraying and heat-treatment process, utilizing aluminum phosphate (AP) as the inorganic binder, titanium dioxide (TiO₂) nanoparticles as the structural reinforcement phase, and hexagonal boron nitride ( h BN) nanosheets as the thermally conductive filler. Notably, the superior scalephobic performance of the DHLIR coating stems from two key mechanisms: the surface hydration layer minimizes mineral ion adsorption, while the released scale inhibitors reduce scale adhesion. Furthermore, the DHLIR coating demonstrates robust durability under extreme environments, including high temperatures, abrasion, and corrosive liquids. In a simulated industrial boiler setup, the DHLIR coating conserved approximately 15.3 % of energy compared to stainless steel. This work thus presents a promising strategy for anti-scaling and energy conservation in boiling environments.