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1 | Energy Efficiency and Renewable Energy eere.energy.gov
Materials for Harsh Service Conditions Workshop
November 19th, 2015
Mark JohnsonDirectorAdvanced Manufacturing Officewww.manufacturing.energy.gov
2
Motivation and Goals
1) MotivationThere are a number of key energy applications (systems) that operate in extreme
(temperature, pressure, corrosive, etc.) environments that rely on robust materials.
Advanced materials able to withstand these conditions will enable new and more
energy efficient technologies and processes.
2) ChallengeTo accelerate the applied research, development and diffusion of such materials. DOE is focused
not on just solving individual / specific technical problems, but on identifying strategic
horizontal or platform investments in technologies, capabilities, infrastructure or other resources
that will broadly benefit a number of sectors operating in harsh service conditions.
3) Goal
Bring together diverse set of stake holders to identify common barriers, technical pathways to
addressing these barriers, and where DOE / EERE / AMO can play a facilitating and enabling role
through strategic investments.
3
Example Results from Workshop
1) What are ambitions but feasible metrics for success? 1) Materials last twice as long in operation at same cost of production
2) Materials can operate at significantly higher temperature, pressure, etc. at a
competitive price point (for system)
3) Discovery-to-market time scale cut in half
2) What are the technical pathways needed to achieve this? 1) Shared facilities to address manufacturing challenges of novel materials
2) Targeted R&D investments in novel material systems
3) Techniques (e.g. HPC, modeling) for rapid testing and certification
3) Where are the gaps? 1) Industry won’t invest in shared infrastructure
2) Novel materials have high technical uncertainty limiting investment in scale-up
3) Lack of confidence in modeling or predictive simulation approaches: data into action
4
Overview of the Advanced Manufacturing Office at the U.S. Department of Energy
5
Clean Energy Solutions
Environment
Security
• Competitiveness in clean energy
• Domestic jobs• Clean air• Climate change• Health
• Energy self-reliance• Stable, diverse
energy supply
Economy
Clean Energy and Manufacturing: Nexus of Opportunities
Clean Energy ManufacturingMaking Products which Reduce Impact on Environment
Advanced ManufacturingMaking Products with Technology as Competitive Difference
6
Clean Energy Manufacturing Initiative – Across DOE
Fossil Energy- O&G- CCS
Nuclear Energy
ARPA-E
Science
EPSA
EM
NNSA
7
Advanced Manufacturing – Strategic Inputs
Climate Action Plan (EOP / CEQ / OSTP 2014)
Advanced ManufacturingPartnership (AMP2.0)(NEC / PCAST / OSTP 2014)
Quadrennial Energy Review(DOE / EPSA 2015)
Quadrennial Technology Review(DOE / Science and Technology 2015)
1) Broadly Applicable Efficiency Technologies for Energy Intensive and Energy Dependent Manufacturing
2) Platform Materials & Processes Technologies for Manufacturing Clean Energy Technologies
8
DOE QTR: Manufacturing Technology
Materials DevelopmentAdvanced Manufacturing Processes
Energy & Resource Management
Flow of Material thru Industry (Sustainable Manufacturing)
Critical Materials
Direct Energy Conversion Materials(Magnetocaloric, Thermoelectric, etc)
Wide Bandgap Power Electronics
Materials for Harsh Service Conditions
Advanced Materials & their Manufacture
Additive Manufacturing
Composite MaterialsRoll-to-Roll
Processing
Process Intensification
Process Heating
Advanced Sensors, Controls, Modeling
& Platforms
Waste Heat Recovery
Combined Heat and Power
EfficiencyTechnologies
(1)
(2)
(2)
(3)
(3)
(4)
Enabling PlatformTechnologies
(6)(5)
(5)
(5)
(7)
(8)
(9)
(10, 11)
Information & Data Processes Materials
9
Advanced Manufacturing Topical PrioritiesEfficiency Technologies for Manufacturing Processes (Energy, CO2)
(1) Advanced Sensors, Controls, Modeling and Platforms (HPC, Smart Manf.)(2) Advanced Process Intensification(3) Grid Integration of Manufacturing (CHP and DR)(4) Sustainable Manufacturing (Water-Energy, New Fuels & Feedstocks)
Platform Materials & Technologies for Clean Energy Applications(5) Advanced Materials Manufacturing
(incl: Extreme Mat’l., Conversion Mat’l, etc.)(6) Critical Materials(7) Advanced Composites & Lightweight Materials(8) 3D Printing / Additive Manufacturing (9) 2D Manufacturing / Roll-to-Roll Processes(10) Wide Bandgap Power Electronics(11) Next Generation Electric Machines (NGEM)
QTR Manufacturing Focus Areas Mapped to Advanced ManufacturingTopical Areas for Technology Development
10
Materials for Harsh Service Conditions
Flow of Materials through Industry (Sustainable
Manufacturing)
Critical Materials
Materials for Harsh Service Conditions
Advanced Materials Manufacturing
Additive Manufacturing
Composite Materials
Roll-to-Roll Processing
Process Intensification
Process Heating
Advanced Sensors, Controls, Platforms
and Modeling
Waste Heat Recovery
Combined Heat and Power
74
FuelsBuildingsElectric Power
Grid
Connections to other QTR Chapters and Technology Assessments
53
• Fuels: corrosion in offshore drilling equipment; ash fouling in biomass conversion equipment; hydrogen embrittlement in H2 pipelines
• Electric Power: radiation-resistant fuel cladding; high-temperature alloys for nuclear reactors and gas and steam turbines
• Transportation: corrosion-resistant lightweight materials
Key Extra-Chapter Connections
Scope• Materials for extreme environments including high
temperatures, high pressures, corrosive chemicals, heavy mechanical wear, nuclear radiation, and hydrogen exposure
Ch. 6 - Materials for Harsh Service Conditions Technology Assessment
Application Area
Materials Challenges
Estimated Annual Energy
Savings Opportunity
Estimated Annual GHG
Emissions Savings
Opportunity H
igh
pres
sure
st
abili
ty
Hig
h te
mpe
ratu
re
stab
ility
Cor
rosi
on o
r fo
ulin
g re
sist
ance
Wea
r or
ero
sion
re
sist
ance
Res
ista
nt to
neu
tron
em
britt
lem
ent
Res
ista
nt to
hy
drog
en
embr
ittle
men
t
Advanced Ultra-Supercritical Steam Turbines1
X X X X 859 TBtu 88.2 million tons CO2-eq.
Waste Heat Recuperators for Harsh Environments2
X X X 247 TBtu 14.5 million tons CO2-eq.
Corrosion-Resistant Gas Pipelines3
X X X 67 TBtu 28.6 million tons CO2-eq.
Irradiation-Resistant Nuclear Fuel Cladding4
X X X n/a 34.7 million tons CO2-eq.
Total for Energy and Emissions Savings Opportunities 1,173 TBtu 166 million
tons CO2-eq.
1 Opportunity based on a 10% increase in efficiency for new power plants added by 2040, measured from a baseline efficiency of 60% (the current state of art) 2 Opportunity based on recovery of heat from currently unrecoverable waste heat sources in the steel, glass, aluminum, and cement/lime industries 3 Opportunity based on elimination of methane gas leaks and energy content lost to gas leaks 4 Energy opportunity not applicable because increased nuclear generation would displace other electricity generation. Emissions opportunity is based on emissions from displaced fossil fuel generation, assuming nuclear reactor refueling shutdowns at 36 months instead of 18 months
Materials challenges and energy savings opportunities for selected harsh service condition application areas*
*Source: internal analyses (see Technology Assessment for assumptions)
8
Transportation
Thermoelectric Materials, Devices and Systems
Wide Bandgap Power Electronics
CFOOMB
Advanced Materials DOE-Wide Challenges
11
Mission: Material challenges are at the core of many DOE imperatives - advances in energy generation and use as well as our national nuclear security
Drivers: The past decade has seen tremendous progress in tools development for materials research along with need for accelerated pace of materials advancement
– The confluence of new theories, novel synthesis and characterization capabilities, and new computer platforms that extend capabilities to the atomic and nano-scale with the urgent demand for new and improved energy technologies
– 2015 Quadrennial Technology Review, National Lab Summit, Materials Genome Initiative, AMP 2.0, Stockpile Stewardship and Management Plan
Challenge Focus: Materials RDD&D that involves close coordination between Office of Science, Technology Offices, and National Security Offices to form a cohesive network of capabilities:
Unprecedented opportunity to impact the materials development cycle from scientific discovery to technological innovation and deployment
(1) Materials Design & Synthesis
(2) Functional (Applied)
Design
11
12
Energy Consumption by Sector
13
Energy Use in the Manufacturing Sector
Separations and Reactions
14
Deeper Look at Energy in Manufacturing
15
Bandwidth Studies: Energy Savings Potentials
AMO: September 2015
Current opportunities represent energy savings that could be achieved by deploying the most energy-efficient commercial technologies available worldwide. R&D opportunities represent potential savings that could be attained through successful deployment of applied R&D technologies under development worldwide
16
Energy Intensive Industries
Primary Metals1608 TBTU
Petroleum Refining6137 TBTU
Chemicals 4995 TBTU
Wood Pulp & Paper2109 TBTU
Glass & Cement 716 TBTU
Food Processing1162 TBTU
17
Processes for Clean Energy Materials & TechnologiesEnergy Dependence: Energy Cost Considered in Competitive Manufacturing
Solar PV Cell
Carbon Fibers
Light Emitting Diodes
Electro-Chromic Coatings
Membranes
EV Batteries
Multi-Material Joining
18
Possible Impact Areas of Cross-Cutting Technology for Energy Intensive Industry Sectors
Chemicals & Bio-chemicals
PetroleumRefining
Primary Metals
Forest &Food Products
Clean Water
SMART ManufacturingProcess IntensificationCHP & Grid IntegrationSustainable Manufacturing
19
Water and Energy in Sustainable Manufacturing
Energy for Water
Water for Energy Water Energy Uses
20
Bridging the Gap to Manufacturing
AMO: Advanced Manufacturing Office
Technology Maturity (TRL; MRL; etc.)
R&D
Inve
stm
ent L
evel
Governments and Universities Private sector
GapDOE Energy
Innovation Hubs
NSF Engineering Research Centers
NSF IUCR Centers
SBIR/STTR
NIST Manufacturing Extension Partnership
AMO
R&D Facilities
R&D Projects
Concept Proof of Concept Lab scale development Demonstration and scale-up Product Commercialization
Technical Assistance
21
Modalities of Support
Technology Assistance: (Dissemination of Knowledge)Better Plants, ISO-50001 / SEP, Industrial Assessment Centers, Combined Heat and Power Tech Assistance Centers, Energy Management Tools & Training
Technology Development Facilities: (Innovation Consortia)Critical Materials Hub, Manufacturing Demonstration Facility (Additive), Power America NNMI, IACMI NNMI, CyclotronRoad, HPC4Manufacturing
Technology Development Projects: (Individual R&D Projects)Individual Projects Spanning AMO R&D Space -
University, Small Business, Large Business and National Labs. Each a Project Partnership (Cooperative Agreement).
22
1. Technical Assistance – driving a corporate culture of continuous improvement and wide scale adoption of proven technologies, such as CHP, to reduce energy use in the industrial sector
2. Research and Development Projects 3. Shared R&D Facilities
Three partnership-based approaches to engage industry, academia, national labs, and state & local government:
AMO Elements
23
Industrial Technical Assistance
Student Training &
Energy AssessmentsUniversity-based Industrial
Assessment Centers
Efficient On-Site EnergyClean Energy Application Centers
(to be called Technical Assistance Partnerships
since in FY14) Energy-Saving Partnership
Better Buildings, Better Plants,
Industrial Strategic Energy Management
24
1. Technical Assistance
2. Research and Development Projects - to support innovative manufacturing processes and next-generation materials
3. Shared R&D Facilities
AMO Elements
Three partnership-based approaches to engage industry, academia, national labs, and state & local government:
25
R&D Projects: Manufacturing Processes
Ultrafast, femtosecond pulse lasers (right) will eliminate machining defects in fuel injectors. Image courtesy of Raydiance.
Energy-efficient large thin-walled magnesium die casting, for 60% lighter car doors.Graphic image provided by General Motors.
Protective coating materials for high-performance membranes, for pulp and paper industry.Image courtesy of Teledyne
A water-stable protected lithium
electrode. Courtesy of PolyPlus
26
AMO Elements
Three partnership-based approaches to engage industry, academia, national labs, and state & local government:
1. Technical Assistance2. Research and Development Projects
3. Shared R&D Facilities - affordable access to physical and virtual tools, and expertise, to foster innovation and adoption of promising technologies
27
Address market disaggregation to rebuild the industrial commons
How could we get innovation into manufacturing today?- RD&D Consortia based Eco-Systems- Public-private partnership to scale
Shared R&D Facilities & Consortia
Ford River Rouge Complex, 1920sPhoto: Library of Congress, Prints & Photographs Division, Detroit Publishing Company Collection, det 4a25915.
Then Now
OEM
Tier 1
Tier 2
Tier 3
Tier 2
Tier 3
Tier 1
Tier 2
Tier 3
28
Manufacturing Technology Maturation
TRL 6/7: System Testing in Production Relevant EnvironmentMRL 6/7: System Components made in Pilot Environment
TRL 5/6: Hardware-in-Loop System Testing in LaboratoryMRL 5/6: Investigate Pilot Environment to Make Systems
TRL 4/5: System Technology Tested in Laboratory MRL 4/5: Investigate Pilot Environment to Make Components
TRL 3/4: Enabling Technology Tested in Laboratory MRL 3/4: Enabling Components Made in Laboratory
FoundationalScience
Dep
loym
ent
Dem
onst
ratio
nD
evel
opm
ent
App
lied
Res
earc
hB
asic
Res
earc
h
TRL 1-3:MRL 1-3:
End-Use Adoption
Tech
nolo
gy N
eeds
and
Req
uire
men
ts
Tech
nolo
gy C
apab
ilitie
s an
d O
ppor
tuni
ties
IndustryPartnerships
LabFacilities
29
• Consortium of 7 companies, 6 universities, and 4 national laboratories
• Led by Ames National Laboratory
Critical Materials - as defined by U.S. Department of Energy, Critical Materials Strategy, 2011.
A DOE Energy Innovation Hub
Lighting
Vehicles
Solar PV
Wind
Dy Eu Nd Tb Y Li Te
30
Program goal is to accelerate the manufacturing capability of a multitude of AM technologies utilizing various materials from metals to polymers to composites.
Arcam electron beam processing AM equipment
POM laser processing AM equipment
Additive Manufacturing
Manufacturing Demonstration Facility
Spallation Neutron Source
Supercomputing Capabilities
31
PowerAmerica:Next Generation Power Electronics Manufacturing Institute
Higher temps, voltages, frequency, and power loads (compared to Silicon)
Smaller, lighter, faster, and more reliable power electronic components
1 Lux Research, 2012.
Institute Mission: Develop advanced manufacturing processes that will enable large-scale production of wide bandgap semiconductors
$3.3 B market opportunity by 2020.1
Opportunity to maintain U.S. technological lead in WBG
Poised to revolutionize the energy efficiency of electric power control and conversion
32
50% Lower Cost
Using 75% Less Energy
And reuse or recycle >95% of
the material
ObjectiveDevelop and demonstrate innovative technologies that will, within 10 years, make advanced fiber-reinforced polymer composites at…
Institute for Advanced Composite Materials Innovation (IACMI)
33
SMART Manufacturing: Advanced Controls, Sensors, Models & Platforms for Energy Applications
• Encompass machine-to-plant-to-enterprise real time sensing, instrumentation, monitoring, control, and optimization of energy (>50% improvement in energy productivity)
• Enable hardware, protocols and models for advanced industrial automation: requires a holistic view of data, information and models in manufacturing at Cost Parity (>50% reduction in installation cost)
• Significantly reduce energy consumption and GHG emissions & improve operating efficiency – (15% Improvement in Energy Efficiency)
• Increase productivity and competitiveness across all manufacturing sectors:
Special Focus on Energy Intensive &Energy Dependent Manufacturing Processes
Leverage AMP 2.0 and QTR
Focus on Real-TimeFor Energy Management
34
Materials in Extreme Conditions
Sustainable Materials in Manufacturing
Process Intensification (Chemical)
Process Intensification (Thermal)
Functional Membrane Structures
Smart Manufacturing
Topical Engagment with Industry
Advanced Materials
Process Intensification
Roll-to-Roll Processing
Advanced Sensors, Controls, Models, Platforms
Application 2Application 1
Technical Challenge HierarchyMulti-Disciplinary Technology Translation
Demo Demo A Demo B
KnowledgeGaps
Technical Needs
Scientific Foundation
Enabling Technologies
System Test-Beds
ApplicationDomain
Qualified NewTechnologies
Technical Insight &Understanding
UnderlyingKnowledge A
Technical Capability I
Lab Test Bed 1
TRL
3/4
TRL
4/5
TRL
5/6
System Requirements
Validated SystemCapabilities
TRL
6/7
Lab Test Bed 2 Lab Test
Bed 3
UnderlyingKnowledge B Underlying
Knowledge C
Technical Capability II Technical
Capability III
Technical Capability IV
LIKE QUANTIFICATION OF POSSIBLE REQUIREMENTS, NEEDS & GAPS
36
What does Success Look Like?
…And Competitively Made Here!
Energy Products Invented Here…
37
Materials for Harsh Service Conditions
• Harsh Service Conditions include– High temperatures – High pressures– Corrosive chemicals
• Examples– Waste heat recovery can provide major efficiency gains at manufacturing sites, but
many sources of industrial waste heat are unrecoverable because existing heat exchanger alloys and power conversion materials are incompatible with corrosive, high-flow-rate, and/or high-temperature flue gases. New geometries.
– Gas and steam turbine power plants could achieve higher efficiencies if they operated at higher inlet temperatures, but operating temperatures are constrained by the thermal stability of existing turbine alloys at high temperatures and pressures.
– Conventional nuclear fuel cladding materials are unstable at very high temperatures and may contribute to nuclear core meltdowns in loss-of-coolant accidents.
– Mechanical wear– Neutron irradiation– Hydrogen attack
38
Workshop on Materials for Harsh Service Conditions
A. High Temperature and Corrosion Conditions– Phase-stable materials that are stable in ultra-high temperature (>1200°C) conditions– Advanced coatings and surface treatments that provide outstanding material properties at
surfaces in corrosive conditions.
B. Mechanical Wear in Gas Turbines, Rotary Machinery and Non-Rotating Machinery – Superalloy that are stable at extreme high temperatures, either steam-side (or other working
fluid) oxidation and erosion resistance high-temperature fireside corrosion resistance over component lifetime, while easy to fabricate and join.
– Advanced coatings and surface treatments that provide outstanding material properties at surfaces such as wear and corrosion resistance.
C. Radiation and Hydrogen Embrittlement Environments– Embrittlement-resistant materials are needed to resist material aging effects in certain
extreme environments, including exposure to hydrogen (which can cause hydrogen embrittlement) and radiation (which can cause neutron embrittlement and radiation-induced swelling).
Three cross-cutting materials challenges areas of interest:
39
Advanced Alloys, Advanced Surfaces Material Aging
High Temperature and Pressure Stability
Corrosion Resistance
Wear Resistance
Corrosion Resistance
Neutron Embrittlement
Hydrogen Embrittlement
FOCUS AREA
MATERIALS CHALLENGES
EXAMPLE APPLICATIONS
Industrial Waste Heat Recuperator
Ultra-Supercritical Steam Turbine
Oil & Gas, Mining, and Agriculture Equipment
Nuclear Fuel Cladding
Hydrogen Pipelines and Storage Tanks
Desalination Systems
Turbine & Rotary Eq, e.g., Geothermal Turbomchinery
Breakout Topics, Focus Areas, and Materials ChallengesBREAKOUT
TOPICMechanical Wear in
Turbines, Rotary Machinery & Non-
Rotating Machinery
Radiation & Hydrogen
Embrittlement Environments
High Temperature & Corrosion Conditions
Phase-Stable Materials,Advanced Surfaces
Low Friction Coatings & Surface Modifications for
Vehicles
New Materials will Enable Numerous Clean Energy Applications Provide Opportunities for Energy Savings & Emissions Reductions
40
Thank You