Tailorable Environmental Barrier Coatings for Super Alloy Turbine Components in Syngas

Award Information
Agency: Department of Energy
Branch: N/A
Contract: DE-FG02-03ER83620
Agency Tracking Number: 72505S03-I
Amount: $749,605.00
Phase: Phase II
Program: SBIR
Awards Year: 2004
Solicitation Year: 2003
Solicitation Topic Code: 28
Solicitation Number: DOE/SC-0059
Small Business Information
2425 South 900 West, Salt Lake City, UT, 84119
HUBZone Owned: Y
Woman Owned: N
Socially and Economically Disadvantaged: Y
Principal Investigator
 Shekar Balagopal
 (801) 978-2142
Business Contact
 Raymond Miller
Title: Mr.
Phone: (801) 978-2114
Email: rkm@ceramatec.com
Research Institution
72505-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.

* Information listed above is at the time of submission. *

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