Building the IoT Platform for the Energy Industry · Building the IoT Platform for the Energy...

Building the IoT Platform for the Energy Industry

Larry Berardinis, ASM International

Efforts and opportunities in government-

funded research on sensors, controls, and

materials for power generation applications

Copyright 2016 ASM International

World’s largest association of metals-

focused materials scientists and engineers.

About ASM International

Founded in 191330,000 members

84 Professional Chapters

90 Student Chapters

Affiliate Societies Electronic Device

Failure Analysis SocietyShape Memory &

Superelastic Society

Heat Treating SocietyInternational

Metallographic Society Thermal Spray Society


Sensors in focus

Key trends

• Growth of the IoT is fueling the

demand for sensors of all types

and grades.

• Industrial applications account

for 37% of the IoT sensor market.

• Automotive applications account

for 21% followed by consumer

(19%), medical (12%), and

aerospace (6%).

Eyes and ears of the IoT


The sky’s the limit

• GE’s PGT25 aeroderivative gas turbine engines

incorporate nearly 200 sensors of various types.

• In flight, the sensors generate 300 data

points/sec, monitoring and controlling engine

performance.

Flying higher

• Pratt & Whitney jet engines currently capture around

100 parameters in multiple snapshots during flight.

• Its new geared turbofan engines will collect more

than 5,000 parameters continuously and generate

roughly 12 petabytes of data over the life of the design.

IoT in the air

https://www.youtube.com/watch?v=FUkquhcPGBI

https://www.youtube.com/watch?v=FUkquhcPGBI


The energy connection

The Internet of Things will help save energy,

but it will also increase energy demand,

particularly for standby power.

Standby power consumption is expected

to increase at a rate of 20% annually,

reaching 46 TWh by 2025.


Batteries not included

www.iea-4e.org/document/384/energy-efficiency-of-the-internet-of-things

The IoT is also expected to increase

worldwide demand for batteries to

supply standby power. According to

the recent EDNA report, more than

23 billion battery powered IoT

devices will be in operation by 2025.

The energy

required to

manufacture a

battery is

usually 40 to

500 times

more than the

battery’s rated

capacity.

For a typical AAA alkaline battery with a capacity of 1.8

Wh, and a conservative estimate of 100 for the energy

factor, it will take 2 TWh of energy by 2025 just to

produce standby batteries for IoT devices. Where will

the additional energy – nearly 50 TWh – come from?


IoT on the supply side

National interests in clean energy

are fueling the development of

advanced technology for the

power generation industry.

Near term – Refurbishing the U.S. coal-fired fleet

with advanced sensors and controls can:

• Reduce CO2 emissions by 14 million metric tons each year

for every 1% heat rate improvement

• Save $300 million per year in coal costs

• Reduce forced outages by 10%, resulting in 2 GW of

additional power

Long term – Next-generation turbines made from

high-performance materials can:

• Boost power plant efficiencies to over 45%

• Reduce CO2 emissions by over 20%, in some cases,

achieving 100% carbon capture

IoT-relevant research funded by the

National Energy Technology Laboratory

(NETL) includes work on sensors, controls,

and high-performance materials.

Anticipated benefits

Target technologies


Formidable challenges

High

pressure

Harsh chemicals

and solvents

Shock and

vibration

Stress and

strain

Corrosion

Turbulent

gas flows

EMI/RFI

Electrical

transients

Boiler

(furnace)

Coal

TurbineWorking

fluidTransmission

lines

Erosive

particles

High

temperature


Track record of success

1,400 employees, more than 60% of

which are scientists and engineers

Founded as the U.S.

Bureau of Mines in

1910 to focus on

safety and the

responsible use of

natural resources

NETL Research Directorates

Computational Science and Engineering

Energy Conversion Engineering

Materials Engineering and Manufacturing

Systems Engineering and Analysis

Geological and Environmental Systems

Focused on applied research with

high commercial potential

Operates under the

Department of Energy,

and is the only national

lab fully owned by DOE

1,400 research projects Total award value: $15 billion

Private sector cost-sharing: $10B

NETL’s mission is to discover, integrate, and mature

technology solutions to enhance the nation’s energy

foundation and protect the environment for future generations.


Advanced modeling and simulation

Simulation of the interdiffusion of atomic

species between the LSM cathode and YSZ

electrode after 1,000 hours at 1,000oC. The

change in interfacial composition changes the

catalytic and transport properties around the

interface.

SEM image of a solid oxide

fuel cell cathode modified

with nano-electrocatalysts.

Electron charge density distributions in different

planes of a high entropy alloy, a class of materials

than can withstand severe environments.

Joule, one of the world’s largest

computers, is driven by 24,192

cores, giving NETL research teams

access to 503 TFLOPS of compute

power for modeling and visualization.

Joule computing center

Surface engineering

Interdiffusion simulation

Electron charge distributions


IoT relevant research

Advanced sCO2

turbines

High performance

materials

Fuel side: 1,600°C at 7 MPa

Steam side: 760°C at 35 MPa

Operating conditions

Advanced

control

Embedded

temperature,

pressure,

gas flow &

composition

measurement

Sensor technology

Nonlinear

dynamics and

multiphase flow


Examples of embedded sensing

United Technologies

Research Center

• Variable-reluctance rotary

angle sensor

• Self-powered at 500oC

• Employs additive

manufacturing techniques

Embedded sensor

Metal coating

deposited via

cold spray

Additional sensor

covered by thin

metal sheet

RFID sensors embedded in rotor

Structural lifetime sensing

Smart turbine

vane

http://www.netl.doe.gov/Image Library/Research/Coal/Crosscutting Research/fe0012299-image.jpg?code=d6df1da5-cf41-4064-85fe-20234e1981a8





Wireless communication

Washington State University

SensorsRF chip

Thin-film

baseAntenna

(temp and strain) Turbine

blade

RF link on board


Magnetically coupled sensing

Advanced sensor design

and packaging process

address stress cracking

and volatility at high

temperatures

Successfully tested to

process temperatures of

1,300oC

Currently working to

increase range to 1,500oC

Palo Alto Research Center (PARC)

Magnetic coupling concept

An example of a thermionic temperature

and pressure sensing element housed

in a hermetically sealed package.

Novel sensor design

The magnetic field

transmitter is an 8-in.

copper coil, 10 mil thick

and 200 mil wide, sitting

on a 1-in. substrate made

of alloy 800.

Magnetic coupling overcomes

eddy currents and opposing

fields generated within metal,

countering the attenuation

experienced with RF signals.


Smart refractory bricks

University of

West Virginia

Investigating ceramic

composites with embedded

sensor designs at

temperatures up to 1,450oC

Developing algorithms for

model-based estimation of

temperature profile, slag

penetration depth, spallation

thickness, and overall

system health

Sensors are

fabricated via tape

casting then

embedded in Cr2O3

brick and sintered in

an argon

atmosphere.

Accelerated corrosion testing

Sequence of steps for testing a smart refractory brick with

an embedded MoSi2-Al2O3 thermistor (2h @ 1,350oC).


Specific challenges

• Loss of electrical connection with bricks during testing

• Metal lead delamination due to wetting limitations

• Phase oxide formation in exposed areas causing drift in response

Materials-related issues and limitations


High-performance materials

• Fundamentally different from traditional

ceramics

• Stable up to 1,800-2,200oC with respect

to decomposition and crystallization

• Higher creep resistance than

polycrystalline SiC and Si3N4

• Ten times lower oxidation and corrosion

rates than silicon-based materials

• Excellent strength retention

• Electrical and mechanical properties

are well suited for temperature and

stress/strain-related sensing

University of Central Florida

Polymer-derived ceramics (PDC)


Amenable to microfabrication

A pressure sensor made from SiAlCN

amorphous ceramic uses a resonator

circuit to measure pressure variations.

Cap

Resonator

Diaphragm

Glass

substratePressure

signal

Pressure sensor design


ICME approach to materials design


Data driven version of Cohen’s reciprocity


Correlating microstructure with tensile strength

The relationships

or linkages

between

microstructure

and material

properties –

complex and

often unknown –

are contained

within the data.


Materials by design

ICME

supports

data driven

discovery and

development

of new

materials.


ICME for bandgap engineering

Goal: Identify the most

commercially promising

materials to make phosphor-

converted LEDs for illumination-

grade lighting applications.

Approach: Relate the electronic

structure of known narrow and

broad-band phosphors to the

optical, chemical, and thermal

properties of a nitride host.

Summary of work

4f bands

Lowest 5d

Narrow-band

emission

∆ES > 0.1 eV

Investigators: University of California, San Diego; Lawrence

Livermore National Laboratory

as appeared in…


ICME for bandgap engineering

• Narrow-band emission

bandwidths are characterized by

a large split (> 0.1 eV) between

the two highest Eu2+ 4f7 energy

bands

• This descriptor was used to

guide a high-throughput

screening of 2,259 nitride

compounds and nine well-known

phosphors

• Of the compounds considered,

five are predicted to be

chemically stable, resistant to

thermal quenching, and efficient

producers of desirable light

Key observations and results

Figure a) band structure and density of states (DOS) of a

narrow-band red-emitting phosphor, SrLiAl3N4:Eu2+; Fig. b) band

structure and DOS of a broad-band red-emitting phosphor,

CaAlSi3N4:Eu2+, Fig. c) average Eu2+ 4f band levels for five

narrow-band and four broad-band phosphors.

Electronic structures for selected (oxy)nitride phosphors


Thank you!

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