Project No: FWP-2012.03.02
Performer: NETL On-Site Research


Richard A. Dennis
Technology Manager, Turbines
National Energy Technology Laboratory
3610 Collins Ferry Road
P.O. Box 880
Morgantown, WV 26507-0880

Patcharin Burke
Technical Monitor
National Energy Technology Laboratory
626 Cochrans Mill Road
P.O. Box 10940
Pittsburgh, PA 15236-0940

Mary Anne Alvin
Technical Coordinator
National Energy Technology Laboratory
626 Cochrans Mill Road
P.O. Box 10940
Pittsburgh, PA 15236-0940

Award Date:  10/01/2011
Project Date:  09/30/2014

DOE Share: $3,498,000.00
Performer Share: $0.00
Total Award Value: $3,498,000.00

Performer website: NETL On-Site Research - /research/on-site-research

Advanced Energy Systems - Hydrogen Turbines

Turbine Thermal Management

Project Description

The Turbine Thermal Management project is focused on basic and applied technology development in the areas of heat transfer, materials development, and secondary flow control. Specific objectives are as follows:

Aerothermal and Heat Transfer: Identify internal and external airfoil cooling concepts that provide composite benefit for reduced cooling flow and heat management, and which can be commercially manufactured. At least one new turbine cooling technology concept will be developed and demonstrated under realistic engine operating conditions. Concepts include National Energy Technology Laboratory (NETL)-Regional University Alliance (RUA's) near-surface embedded micro-channel concept, porous media thermal barrier coatings (TBCs), and/or tripod-hole film cooling configurations.

Coatings and Materials Development: Develop bond coat, diffusion barrier, and extreme temperature TBCs as an integrated composite-architecture for utilization in next generation land-based engines. Expand NETL-RUA's programmatic direction and focus through initiation of research on ceramic matrix composites and oxide dispersion strengthened material systems for use at temperatures exceeding 1400 ºC. The performance and extended durability of these materials systems are being assessed through bench-scale isothermal and thermal cycling/flux testing.

Design Integration and Testing: Utilizing enhanced heat transfer internal and film cooling designs, commercially cast coupon test articles for heat transfer assessment at near room temperature and at high temperature under pressurized combustion gas conditions generated in NETL's aerothermal test facility in Morgantown, WV.

Secondary Flow Rotating Rig: Design and construct a world-class test facility for testing new cooling improvement strategies for the turbine rotating blade platform, and develop performance data relevant to initial concept designs and/or platform modifications. The primary focus of the turbine test facility is to increase turbine efficiencies by using disruptive new designs in sealing the interfaces between stationary and rotating airfoil components. The main driver of this effort is development of new designs that will lead to reduction in fuel usage by an order of magnitude or more. The facility will include a section of a turbine including a vane/blade/vane (i.e., 1.5-stage turbine), which will be operated at conditions replicating those in a modern gas turbine engine.

In 2014, the Turbine Thermal Management project will begin to explore pressure gain combustion and advanced supercritical CO2 cycles as a possible means to contribute to overall improved plant operating efficiency.

Program Background and Project Benefits

This project will identify the combination of internal and external cooling concepts that provide composite benefit for reduced cooling flow, heat management, and which can be commercially manufactured. Turbine aerodynamics and heat transfer research will develop advanced cooling technology that will allow for higher firing temperatures which translate into increased cycle efficiency. Specifically, this project will additionally investigate NETL-RUA’s near-surface embedded micro-channel (NSEMC) concept and/or tripod-hole, as well as internal cooling and film cooling configurations for cooling effectiveness and manufacturability.



Aerothermal and Heat Transfer:

Figure 1. Results from Heat Transfer Enhancement Studies Conducted at the University of Pittsburgh for Advanced Internal Airfoil Cooling Concepts.

Coatings and Materials Development:

Figure 2. Virginia Tech’s Tripod Hole Film Cooling Configuration, Laboratory Test Equipment and Recent Experimental Results Demonstrating Enhanced Cooling Effectiveness over Current State-of-the-Art Film Cooling Configurations.

Figure 3. Microstructure of the Ames University HVOF Ni-ODS Overlay Coating on MarM-247 in the (a) Heat-Treated and (b) As-Sprayed Condition along with Corresponding X-Ray Spectra Indicating the Oxygen-Exchange Reaction and Precipitation of Oxide Dispersion Phase (Y4 Al2O9).

Figure 4. Ames Laboratory Grit Blasted Near Surface Embedded Micro-Channel Concept after Impregnation with Fugitive Thermoset Filler along the External Channels.

Design Integration and Testing:

Figure 5. Commercial Production of NETL-RUA’s Advanced Cooling Concepts at Mikro Systems Inc. (a) First Cast CM247 Fully Bridged Pin Fin Coupons; (b) CT Scan of Cast CM247 Fully Bridged Pin Fin Coupon Illustrating Absence of Blockage within the Pin Fin Array; (c) CT Scan of Trailing Edge Zig-Zag Cooling Configuration; (d) Tripod Hole Film
Cooling Hole Core.

Figure 6. Area-Average Overall Effectiveness Illustrated as a Function of Blowing Ratio during Testing of Haynes 230 Coupons Containing Fan-Shaped Film Cooling Holes in NETL’s High Temperature, Pressurized Aerothermal Test Facility.

Figure 7. The New Secondary Flow Rotating Rig Design at Penn State has been Completed and Is Currently Being Manufactured and Assembled.

Secondary Flow Rotating Rig: