Topic Area 3 - Materials Topics; Sub-Topic 3.1: Mechanisms of Degradation and Resistant Syngas Turbine Materials

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Public and State controlled institutions of higher education Private institutions of higher education

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Grant Description

NOTE: This descriptive area provides an overview of Technical Topic Area 3: Sub-Topic 3.1: Mechanisms of Degradation and Resistant Syngas Turbine Materials only. YOU MUST READ THE ENTIRE FUNDING OPPORTUNITY ANNOUNCEMENT DOCUMENT FOR ADDITIONAL INFORMATION, EVALUATION CRITERIA AND INSTRUCTIONS ON HOW TO PREPARE AN APPLICATION UNDER Technical Sub-Topic Areas. Please scroll to the bottom of this page to access the Funding Opportunity Announcement. Topic Area 3 - Materials Topics Even though limited IGCC plant data on measured syngas impurities indicate lower levels of critical ash constituents (e.g., Na, K, Ca) than limits from turbine fuel specifications, greater materials degradation (corrosion, erosion, and deposition) has occurred in at least some IGCC plant turbines to date than for the same model turbines operated with conventional fuels such as natural gas. For properly designed and operated syngas cleanup systems, no forced turbine outages resulting from hot section materials degradation associated with syngas appear to be reported at IGCC plants. However, at least in some cases, hot section coatings, vanes, and blades have needed replacement during routine maintenance shutdowns at more frequent intervals than for natural gas fired turbines. For example, analyses of IGCC turbine first rotor blades have shown that, at some locations, surface reactions were radically different in nature and more severe than typically observed in turbines operating with conventional fuels. These areas appeared to experience a combination of sulfidation and oxidation. However, the mechanisms leading to this attack are uncertain because partial pressures of sulfur containing gases in the syngas combustion products do not appear to be as high as required to produce materials sulfidation. Also, Thermal Barrier Coatings (TBC's) in IGCC turbines have experienced deposition and spallation and sometimes needed replacement at more frequent intervals than for natural gas fired turbines. Analyses have indicated that iron oxides (e.g., Fe2O3) have been primary constituents of deposits on the TBC's, which also penetrated into the TBC porosity. The presence of other ash elements (e.g., Si, Al, Ca, Mg, Na, K and sulfate ions) has also been detected. These deposits are different in composition than deposits consisting of calcium, magnesium, aluminum, and silicon (CMAS) that have caused past degradation of airborne turbine TBC's. The following sequence of materials research topics are directed to first understanding the nature of degradations to date in IGCC turbines, identifying approaches to alleviate these degradations, and then using these insights as a starting knowledge base for evaluations of materials for turbines using HHC fuels derived from coal gasification. Sub-Topic 3.1: Mechanisms of Degradation and Resistant Syngas Turbine Materials (DE-PS26-08NT00165-3A) Goals of this topic include identification of the specific mechanisms of degradation and development of an understanding of the critical aspects (e.g., critical impurities) of IGCC turbines flow-path environments that have contributed to and caused the atypical sulfidation/oxidation type degradation of alloys and environmental coatings experienced to date. Evaluation of materials and syngas impurity analyses described in the literature, interactions with materials experts at turbine OEM companies, and additional university analyses of IGCC turbine parts (if available), should be explored to understand the degradation processes. Based on this understanding, laboratory experiments should be designed to replicate critical aspects (e.g. critical impurities and mechanisms) of the materials degradation experienced to date in order to then test alternate environmental coatings and alloys and determine those most resistant to syngas turbine environments. The presence of water vapor can potentially affect the nature and growth rate of protective oxide scales. To evaluate conditions for future systems, additional experiments should explore the combined effects of impurities and water vapor at levels representative of the flow-path of higher temperature IGCC turbines (vicinity of 8.5%) and also higher water vapor levels for future turbines operating with HHC fuels (vicinity of 20%).

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