Project No: SC0010175
Performer: Mikro Systems Inc.


Contacts

Duration
Award Date:  06/10/2013
Project Date:  07/27/2016

Cost
DOE Share: $1,149,415.00
Performer Share: $0.00
Total Award Value: $1,149,415.00

Performer website: Mikro Systems Inc. - http://www.mikrosystems.com/

Advanced Energy Systems - Hydrogen Turbines

Rapid Manufacturing Method for High-Temperature Turbine Components

Project Description
This project addresses the need for rapid, low cost manufacturing for prototype and proof-of-concept gas turbine components. This process is expected to reduce the cost of component development, compress prototyping cycle times, and increase the number of design iterations possible during the component design phase.

Tooling cost and production times

Tooling cost and production times


Program Background and Project Benefits

Turbines convert heat energy to mechanical energy by expanding a hot, compressed working fluid through a series of airfoils. Combustion turbines compress air, mix and combust it with a fuel (natural gas, coal-derived synthesis gas [syngas], or hydrogen), and then expand the combustion gases through the airfoils. Expansion turbines expand a working fluid like steam or supercritical carbon dioxide (CO2) that has been heated in a heat exchanger by an external heat source. These two types of turbines are used in conjunction to form a combined cycle— with heat from the combustion gases used as the heat source for the working fluid— improving efficiency and reducing emissions. If oxygen is used for combustion in place of air, then the combustion gases consist mostly of carbon dioxide (CO2) and water, and the CO2 can be easily separated and sent to storage or used for Enhanced Oil Recovery (EOR). Alternatively, the CO2/steam combustion gases can be expanded directly in an oxy-fuel turbine. Turbines are the backbone of power generation in the US, and the diverse power cycles containing turbines provide a variety of electricity generation options for fossil derived fuels. The efficiency of combustion turbines has steadily increased as advanced technologies have provided manufacturers with the ability to produce highly advanced turbines that operate at very high temperatures. The Advanced Turbines program is developing technologies in four key areas that will accelerate turbine performance, efficiency, and cost effectiveness beyond current state-of-the-art and provide tangible benefits to the public in the form of lower cost of electricity (COE), reduced emissions of criteria pollutants, and carbon capture options. The Key Technology areas for the Advanced Hydrogen Turbines Program are: (1) Hydrogen Turbines, (2) Supercritical CO2 Power Cycles, (3) Oxy-Fueled Turbines, and (4) Advanced Steam Turbines.

Hydrogen turbine technology research is being conducted with the goal of producing reliable, affordable, and environmentally friendly electric power in response to the Nation's increasing energy challenges. NETL is leading the research, development, and demonstration of technologies to achieve power production from high hydrogen content (HHC) fuels derived from coal that is clean, efficient, and cost-effective; minimize carbon dioxide (CO2) emissions; and help maintain the Nation's leadership in the export of gas turbine equipment. These goals are being met by developing the most advanced technology in the areas of materials, cooling, heat transfer, manufacturing, aerodynamics, and machine design. Success in these areas will allow machines to be designed that have higher efficiencies and power output with lower emissions and lower cost.

Mikro Systems, Inc. is addressing the need for rapid, low cost manufacturing for prototype and proof-of-concept gas turbine components. This process is expected to reduce the cost of component development, compress prototyping cycle times, and increase the number of design iterations possible during the component design phase. These improvements have the potential to allow turbine OEMs to incorporate design enhancements more rapidly, leading to a reduction in cost for new products and ultimately lowering plant and electricity costs.


Accomplishments

Mikro has produced test bar molds and the first test bars. They are now moving to produce powered metal bars and will have them sintered for testing once they become available.