61
Tailorable
Environmental Barrier Coatings for Super Alloy Turbine Components in Syngas--Ceramatec,
Inc., 2425 South 900 West, Salt Lake City, UT
84119-1517; 801-978-2114, www.ceramatec.com
Dr.
Shekar Balagopal, Principal Investigator, shekar@ceramatec.com
Mr.
Raymond K. Miller, Business Official, rkm@ceramatec.com
DOE
Grant No. DE-FG02-03ER83620
Amount:
$749,605
Integrated gasification combined cycle (IGCC) coal
combustion has the potential for significantly improving the efficiency of
converting coal power and for reducing emissions.
However, corrosion in the syngas environment limits the lifetime of IGCC
components and increases cost. This
project will develop low-cost, dip-coated ceramic oxide coatings to prevent the
high temperature corrosion of super alloys used in turbine engines that operate
in syngas environments. The dense
ceramic oxide coating will function as environmental barrier coatings (EBC) on
super alloys, providing protection in the aggressive and corrosive conditions
found in high temperature turbine applications.
In Phase I, the feasibility of applying well bonded graded coatings of
oxide compositions was demonstrated. The
coatings were in the 2 to 60 micron thickness range, and were crack free and
dense. It was demonstrated that the
graded oxide coating have excellent corrosion stability in atmospheres composed
of syngas, coal and fly ash impurities, and sulfur gas.
In tests lasting one thousand hours, the coating showed good
thermo-mechanical stability while protecting the alloy from corrosion.
In Phase II, longer term exposure tests (10,000 hours) of the oxide
coating on super alloy will be demonstrated in corrosive and abrasive
environments. A fabrication process
for oxide coatings on complex alloy components for use in IGCC systems will be
developed. A partnership with a
commercial synthetic gas company, to test the coating in real IGCC gas streams,
will maximize the chances of developing a commercial viable oxide coating
technology.
Commercial
Applications and Other Benefits as
described by awardee: The new
coatings would protect the turbine components and process equipments exposed to
high temperature syngas environments in IGCC systems, and also would be
applicable to other chemical, aerospace, and military processes.
The coatings should also be suitable for other applications requiring
high temperature corrosion resistance for super alloys, for example Kraft
recovery boilers.