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

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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.

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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

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Overview of the Advanced Manufacturing Office at the U.S. Department of Energy

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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

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Clean Energy Manufacturing Initiative – Across DOE

Fossil Energy- O&G- CCS

Nuclear Energy

ARPA-E

Science

EPSA

EM

NNSA

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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

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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

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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

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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

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FuelsBuildingsElectric Power

Grid

Connections to other QTR Chapters and Technology Assessments

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• 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)

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Transportation

Thermoelectric Materials, Devices and Systems

Wide Bandgap Power Electronics

CFOOMB

Advanced Materials DOE-Wide Challenges

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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

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Energy Consumption by Sector

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Energy Use in the Manufacturing Sector

Separations and Reactions

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Deeper Look at Energy in Manufacturing

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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

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Energy Intensive Industries

Primary Metals1608 TBTU

Petroleum Refining6137 TBTU

Chemicals 4995 TBTU

Wood Pulp & Paper2109 TBTU

Glass & Cement 716 TBTU

Food Processing1162 TBTU

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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

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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

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Water and Energy in Sustainable Manufacturing

Energy for Water

Water for Energy Water Energy Uses

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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

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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).

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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

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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

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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:

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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

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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

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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

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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

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• 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

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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

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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

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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)

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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

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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

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What does Success Look Like?

…And Competitively Made Here!

Energy Products Invented Here…

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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

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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:

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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

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Thank You