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Researchers at BITS-Pilani Hyderabad campus, in collaboration with University West (Sweden), have discovered that coating materials originally developed to protect gas turbine components from corrosion can significantly enhance electricity generation in microbial fuel cells — devices that use bacteria to produce power from organic waste. Using High-Velocity Air Fuel (HVAF) spraying technology, commonly employed in industrial and aerospace applications, the team applied chromium-nickel carbide coatings to carbon steel electrodes. These coatings made the electrodes more durable and efficient for bioenergy applications. Remarkably, the HVAF-sprayed electrodes delivered a 30-fold increase in power output compared to the uncoated ones, stated a press release issued on Friday. “Microbial fuel cells can convert waste into electricity, but their performance often suffers due to corrosion and instability,” explained BITS Pilani’s Sanket Goel. “By using advanced coatings, we have made them tougher, more reliable and more viable for practical use in wastewater treatment and decentralised power systems.” The modified surface not only resisted corrosion but also promoted bacterial attachment — a key step in electricity generation in microbial fuel cells. “Repurposing materials and processes originally developed for protecting gas turbines and combustion engines toward green energy production opens exciting possibilities,” said University West’s professor, Shrikant Joshi. “Our coatings achieved both durability and efficiency, which are essential for real-world bioenergy systems. When we started, we weren’t sure if these industrial coatings would even work with microbes. But the results exceeded our expectations and open a new direction for using engineered materials in green energy technologies,” said BITS Pilani PhD scholar Yuvraj Mao. The coatings also demonstrated high stability and repeatability across multiple cycles, confirming their potential for long-term and scalable applications such as wastewater treatment plants and off-grid renewable energy setups. This innovative crossover between materials science and bioenergy highlights how technologies designed for extreme environments can contribute to a more sustainable and resilient energy future. Other contributors to this recently published collaborative work include Khairunnisa Amreen from BITS Pilani Hyderabad and Vasanth Gopal from University West, the release added.
