1. DOE Perspective on Advanced Energy Materials
Robert Romanosky, Technology Manager
National Energy Technology Laboratory
January 6, 2009

2. Materials Program Goals
Development of a technology base in the synthesis, processing, life-cycle analysis, and performance characterization of advanced materials.
Development of new materials that have the potential to improve the performance and/or reduce the cost of existing power and non-power technologies.
Development of materials for new systems and capabilities.
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3. Fossil Energy Key Material Research Areas
USC Boilers/Turbines
Gasifier
Advanced
Turbines
Sensors
Oxy-Firing
Fuel Cells
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4. Ultra-Clean Energy Plant
Systems Integration
System modeling
Virtual Simulation
Instrumentation Sensors & Controls
Advanced
Materials
UltraSuperCritical Materials
Advanced Alloys
Gasification &
Combustion
Seals & Electrodes for
Fuel Cells
Thermal Barrier Coating for Turbines
Improved Refractories for Gasifiers
ODS Coatings
Gas Stream Cleanup Devices
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5. Breakthrough Concepts Supercritical Materials
Program Roadmap
Policy Goal
Technologies
Gasification
Combustion
Seques-
tration
Environ-
mental
Fuel Cells
Turbines &
Engines
Coal
Technology
Platforms
Heat
Exchangers
Air/Gas
Heaters
Gas
Separation
Particulate
Control
Vessel
Liners
Component
Technology
Turbine
Blades/
Rotors/Pipes
Castings
Membranes
Hot-Gas
Filters
Refractory
Castables/
Bricks
Adsorbents
Materials
Technology
Coatings/
Protection Materials
New Alloys
Breakthrough Concepts
Ultra
Supercritical Materials
Functional
Materials
R&D
Elements
Joining
Design
Modeling
Mechanical
Properties
Charac-
terization
Synthesis &
Processing/
Fabrication
Corrosion/
Erosion
Studies
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6. A Dash of Wolfram, A Pinch of Nickel
Creation of New Materials
A Dash of Wolfram, A Pinch of Nickel
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7. Advanced Research Materials Program HIGH TEMPERATURE APPLICATIONS
New Alloys - To increase the temperature capability of alloys for use in specific components required for advanced power plants by understanding the relationships among composition, microstructure, and properties.
Functional Materials - To understand the special requirements of materials intended to function in specific conditions such as those encountered in hot gas filtration, gas separation, and fuel cell systems.
Breakthrough Materials - To explore routes for the development of materials with temperature/strength capabilities beyond those currently available.
Coatings & Protection of Materials - To develop the design, application, and performance criteria for coatings intended to protect materials from the high-temperature corrosive environments encountered in advanced fossil energy plants.
Ultra Supercritical Materials – To evaluate and develop materials technologies that allow the use of advanced steam cycles in coal-based power plants to operate at steam conditions of up to 760°C (1400°F) and 5,000 psi
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8. Coatings Clusters Advanced Combustion/Gasification Conditions
Extended alloy lifetimes through improved coating performance and composition optimization
Microstructure and properties of HVOF-sprayed Ni-50Cr coatings
High-temperature corrosion resistance of candidate FeAlCr coatings in low-NOx
environments
Aluminide coatings for power generation applications
Development
Metallic Coatings for
Structural Alloys
Includes rig testing
Includes field testing
Evaluation
Coatings Clusters
Development
YSZ thermal barrier coatings by MOCVD
Modeling of CVD processing
Development of non-destructive evaluation methods for ceramic coatings
Materials issues for syngas turbines
Ceramic/ Composite Coatings
Evaluation
Includes field testing
Gasifier Refractory Linings
Gas Turbine Components

9. New Alloy Clusters Advanced Steam Conditions
Advanced pressure-boundary materials
High creep-strength alloys (Special Metals
Effects of off-normal metallurgical conditions on performance of advanced ferritic steels
Steam turbine materials and corrosion
Materials for USC steam turbines (consortium)
Development
Fireside and steamside corrosion of alloys for USC plants
USC materials plant trials (B&W)
Improved metallic recuperator materials (Solar Turbines CRADA)
USC steam tubing consortium
Evaluation
High-temperature ‘Conventional’
Wrought Alloys
New Alloy Clusters
Development
Enabling the practical application of ODS-ferritic steels
Optimization of ODS-Fe3Al and MA956 alloy heat exchanger tubes
Control of defects and microstructure in ODS alloys
Cross-rolling/flow-forming of ODS alloy HX tubes
Evaluation
In-plant corrosion probe tests of
Corrosion and joining of ODS FeCrAl alloys for very high -temperature heat exchangers
MA956 heat exchanger tubes
ODS Alloys
Advanced Heat Exchangers/
Engines

10. Functional Materials Clusters
Gas Filtration/Separation/
Clean-up
Development of inorganic membranes for hydrogen separation
Activated carbon composites for air separation
Metal membranes for hydrogen separation
Development
Processing
Gas sensors for fossil energy applications
Brazing technology for gas separation membranes: advances in air brazing
Ceramic Membranes/
Structures
Functional Materials Clusters
Development
Low-chrome/chrome-free refractories for slagging gasifiers
Protection systems: corrosion-resistant coatings
Refractories
Evaluation
field testing
Gasifier Refractory Linings

11. Breakthrough Concepts
Concept Development
ORNL-2D: Multiphase HT Alloys: Exploration of Laves-strengthened steels
ORNL-4A: Novel structures through controlled oxidation
ORNL-4C: Concepts for smart, protective high-temperature coatings
AMES-2: Optimizing processing of Mo-Si-B intermetallics through thermodynamic assessment of Mo-Si-B and related systems
UT-2A: Effects of W on the microstructures of TiAl-based intermetallics
WVU-2: Influence of impurities on ductility of Cr-based alloys and in-situ mechanical property measurement
ORNL-2I: Development of ultra-high temperature molybdenum borosilicides-See below
Multiphase HT Alloys: Exploration of Laves-strengthened steels
Novel structures through controlled oxidation
Concepts for smart, protective high-temperature coatings
Optimizing processing of Mo-Si-B intermetallics through thermodynamic assessment of Mo-Si-B and related systems
Effects of W on the microstructures of TiAl-based intermetallics
Influence of impurities on ductility of Cr-based alloys and in-situ mechanical property measurement
Development of ultra-high temperature molybdenum borosilicides-See below
Enabling Technologies
AMES-3: New Processing Developments in Metallic Powders for Fossil Energy Applications
REMAXCO-5: Pilot facility for the production of
New Processing Developments in Metallic Powders for Fossil Energy Applications
Pilot facility for the production of silicon carbide fibrils
Strength/Env Resistance at T > Current Alloys
Breakthrough Concepts
Increased HT capability for ‘Conventional’
Wrought Alloys
Concept Development
ORNL-2I: Strengthening phases with increased stability
Strengthening phases with increased stability
Enabling Technologies
Interaction with ORNL-2C
Interaction with ORNL
Advanced Combustion/Gasification Conditions

12. Materials Evaluation for Biomass and Black Liquor Gasifiers
Gasification of black liquor and biomass involves high-pressure, high-temperature, and sometimes caustic conditions.
Materials used in gasifier equipment must be robust and
able to withstand the chemical and thermal conditions as well as the cycling aspects of gasifier operation
Critical materials issues such as fatigue, corrosion, stability, and longevity of materials will be the primary focus of research
Corrosion and corrosion fatigue studies will be conducted with the intent of identifying possible degradation mechanisms for metallic and refractory materials.
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13. Hydrogen Membranes
Hydrogen can be produced from coal, natural gas, biomass, and biomass derivatives through the use of gasification, pyrolysis, reforming and shift technologies.
The use of membranes holds the promise of reducing cost by combining the separation and purification with the shift reaction in a reactive separation operation.
Development is needed to improve hydrogen membrane separation and purification technology for use in the production of hydrogen
The focus of the research should be on low cost, high flux rate, durable membranes systems that can be integrated with the shift reaction.
Membranes of interest include ceramic ionic transport membranes, micro-porous membranes, and palladium based membranes.
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14. UltraSupercritical Boilers and Turbines
Current technology for USC Boilers
Typical subcritical = 540 °C
Typical supercritical = 593 °C
Most advanced supercritical = ~610 °C
USC Plant efficiency is improved to
45 to 47% HHV
Ultrasupercritical (USC) DOE goal for higher efficiency and much lower emissions, materials capable of:
760 °C (1400 °F)
5,000 psi
Oxygen firing
Meeting these targets requires:
The use of new materials
Novel uses of existing materials
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15. Technical Barriers
Long-term degradation of materials ( ,000 hours) are not well understood or characterized for this alloy class
Combination of creep strength, weldability (necessary component for boiler fabrication), oxidation, and corrosion resistance
Effects of heat-treatment, fabrication variables, welding is critical
Need new welding processes, fabrication processes, etc.
Ability to produce material is also an issue
Microhardness map of Thick Section USC weld showing “soft” weld metal – long-term testing is needed to understand the implication of this type of weld on material performance
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16. What and Why Oxy-fuel Combustion
Energy production (in particular, electricity) is expected to increase due to population increase and per capita increase in energy consumption
Oxy-fuel combustion is one option for providing increased capacity to satisfy the future energy consumption demand
Can be used for retrofitting or new plants
Global climate change - one of the sources for CO2 increase in the atmosphere is exhaust from fossil fuel combustion plants
Oxy-fuel combustion readily supports the capture and sequestration of CO2 from power plants
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17. Technological Barriers – Materials Needs
Better understanding of material performance in oxyfuel environments
Evaluate ash assisted hot-corrosion of boiler alloys
Develop computational models to predict fireside corrosion will aid in the development of all advanced combustion systems
Evaluate other plant components e.g., coal pulverizers (wear-corrosion interactions)
Future Capability: Combine Oxyfuel with USC.
Potential cleaner coal combustion technology
Oxyfuel: ease of flue gas clean-up and CO2 sequestration
USC: maximize efficiency
Need cost effective advanced alloys that can withstand the oxyfuel/USC environment
higher temperatures and higher pressures than current systems
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18. Advanced Sensor Materials
Harsh Environmental Conditions
Sensor Material Development
Rugged Sensor Designs
Sensor
Signal Wire 1”
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19. Driver for New Sensing Technology
Advanced Power Generation:
Harsh sensing conditions throughout plant
Monitoring needed with advanced instrumentation and sensor technology.
Existing instrumentation and sensing technology are inadequate
Coal Gasifiers and Combustions Turbines:
have the most extreme conditions
Gasifier temperatures may extend to 1600 °C and pressures above 800 psi. Slagging coal gasifiers are highly reducing, highly erosive and corrosive.
Combustion turbines have a highly oxidizing combustion atmosphere.
Targeting development of critical on line measurements
Sensor materials and designs are aimed at up to 1600 °C for temperature measurement and near 500 °C for micro gas sensors.
Goal is to enable the coordinated control of advanced power plants followed by improvement of a system’s reliability and availability and on line optimization of plant performance.
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20. Materials for Sensing in Harsh Environments (Optical and Micro Sensors)
Sapphire
Alumina
Silicon Carbide
Doped Silicon Carbide Nitride
Yttria stabilized zirconia
Fused/doped silica for certain conditions
Interest in
Active / doped coatings
3D porous or “mesh” nano-derived ceramics / metal oxides
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21. Turbines Technical Barriers Environmental Conditions Research Underway
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22. Gas Phase Conditions for Advanced Turbines
IGCC Based Syngas and H2 Fueled Turbines
 Parameter
ST 2010
HT 2015
Combustor exhaust temp
2700 °F
Turbine inlet temp
2500 °F
2600 °F
Turbine exhaust temp
1100 °F
Turbine inlet pressure
250 psig
300 psig
Combustor exhaust composition
CO2 (9.27), H2O (8.5), N2 (72.8), Ar (0.8), O2(8.6)
CO2 (1.4), H2O (17.3), N2 (72.2), Ar (0.9), O2(8.2)
IGCC Oxy-Fuel Turbine Cycle
 Turbine Parameters
OFT 2010
OFT 2015
Intermediate Pressure
Turbine inlet
1150 °F
3200 °F
Pressure
450 psig
625 psig
High Pressure -
1400 °F
1500 psig
Working Fluid Composition (%)
H2O (82), CO2 (17), O2 (0.1), N2 (1.1), Ar (1)
H2O (75-90), CO2 (25-10), balance (17) O2, N2, Ar
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23. Turbine Materials Technical Barriers
Mechanical / chemical stability of bond coating interface
Stresses developed as a result of CTE mismatch
Change in thermal conductivity across the thickness of the ceramic as a result of service exposure
Cleanup techniques with various levels of sulfur removal:
MDEA: 20 – 30 (+) ppm
Selexol: 2 – 11 ppm
Rectisol: 0.01 – 6 ppm
CO2 capture w/ deeper sulfur removal w/ less sulfur problems
Research needed on:
new materials & deposition procedures (techniques)
new TBC structures with corrosion resistance
environmental barrier coating (EBC)
ceramic matrix composite (CMC)
These number will tend towards the lower numbers
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24. What R&D is underway to address these issues?
TBC compositions for corrosion resistance with no increase in thermal conductivity and good CTE match.
TBC failure mechanisms with alternate fuels especially under high heat flux (HHF) conditions.
Understanding deposition (condensation) kinetics for critical vapor species on high temperature surfaces – water vapor activated recession of TBC materials
Effect of cooling strategy on TBC thermal gradient and degradation modes
Deposition, erosion, or corrosion (D-E-C) due to contaminants (Si, Al, Ca, Mg, Na K, sulfate ions, As, P, Se etc.) when firing syngas
Simulated lab tests
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25. Fuel Cells Technical Barriers Environmental Conditions
Research Underway
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26. Fuel Cell Materials Material improvements process
Faster kinetics for oxygen reduction to lower the irreversible losses for electrochemical charge transfer.
Stable surface chemistries are sought with active sites for dissociative adsorption of oxygen
Technical barriers
Cathode performance correlated with oxide surface chemistry in high partial pressures of oxygen
Cathode surface boundary is affected by cation dopant distributions
Local surface chemistry establishes adsorption sites with kinetic barriers to charge and mass transport
Dopants and defect segregation modify surface chemistry
Modified atomic arrangements can provide stable and fast reaction sites with improved electrochemical performance
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27. Fuel Cell Materials R&D Underway
Work to fully understand the surface chemistry of established cathode oxides
Epitaxial growth through pulsed laser deposition to prepare thin film model surfaces
Identify key correlations between surface structure, chemistry, and performance parameters
Theoretical modeling to interpret the underlying chemistry and guide modifications to the cathode surfaces.
Technology Future
Improve Cathode performance to extend functional operating temperature from the current lower range of 750 °C down to 650 °C.
Technology Benefit
Reduce SOFC cost through more efficient operational performance.
Increase efficiency in advanced power generation systems
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28. What Does the Future Look Like?
The USA and the world will face great energy challenges with ever increasing environmental constraints
Advanced fossil energy power systems will be needed
The Advanced Research Materials Program is poised to have even greater impacts on future energy systems
Novel materials for gas separation
Fuel cell materials
Next generation stainless steels with higher strength and better oxidation resistance
Advanced coatings
Prescriptive materials design and lifetime prediction for extreme environments
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29. Fossil Energy Key Material Research Areas
USC Boilers/Turbines
Gasifier
Advanced
Turbines
Sensors
Oxy-Firing
Fuel Cells
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