A novel method is described for monitoring coating performance in the thin liquid films found in condensing environments, such as in the corrosive condensate found in flue gas desulfurization (FGD) systems. The method involves exposing coated metal panels to controlled environments, created by atomizing solutions of appropriate composition, in fog chambers. The fog deposits on the coated surface as a thin film that simulates the condensate formed in actual service. The performance of the coatings is monitored in situ by electrochemical impedance spectroscopy (EIS) during periods when the exposed coated surfaces are temporarily flooded with bulk solution having the same composition as the condensate. The method has been used to evaluate the effects of sixteen environmental factors on the performance of eight coatings currently used in FGD outlet ducts.
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