Phase IIA - DOE12-14c: Advanced Ceramic Materials and Packaging Technologies for Realizing Sensors Operable up to 1800 Celsius in Advanced Energy Generation Systems
- Sporian Microsystems, Inc., Lafayette, CO (United States)
There is a need for condition monitoring-sensors capable of functioning in the harshest environments associated with advanced power systems. These sensors will: directly contribute to improving system control, protect capital equipment investment, and promote safety through prevention of catastrophic equipment failure. These harsh environments include extreme temperatures (800-1800°C), high pressures (500-1000 psi), and highly corrosive/erosive media. Sporian Microsystems has developed a high-temperature sensor technology for power system applications based on the combination of high-temperature packaging and polymer-derived ceramics (PDCs), which possess excellent mechanical and electric properties at high temperatures up to 1600°C. The Phase IIA objective was to further mature the innovative ultra-high temperature (UHT) sensor technology beyond current limitations with the ultimate goal of creating sensors and packaging capable of operating in temperatures up to 1800°C (3270 °F). Specifically, the purpose of the research was to develop two advanced ceramic sensor-based application implementations of high OEM interest: 1800°C temperature sensors, and 1600°C temperature/pressure sensor suites, which can endure the UHT harsh combustion environments. Research carried out in Phase IIA: During the Phase IIA, the polymer synthesis and sensor element fabrication process improvement were carried out to achieve PDC sensor elements of advanced design, high-temperature functionality, and structural robustness. The key aspects of the Phase II packaging including material, processes, and designs were advanced with an emphasis on installation compatibility and long term reliability. To promote post Phase IIA transition oriented activities, rigorous testing and reliability assessment of full prototype systems (hardware and electronics) were carried out for technology demonstration within OEM/relevant environment test systems. Research findings and results: Sporian worked with energy system OEMs to identify and guide applications/implementations for the UHT sensing technology. Sporian optimized ceramic sensor material formulations and extended the key materials’ thermal stability limit to 1600°C. Advanced ceramic sensor designs and innovative fabrication processes resulted in ceramic UHT sensor elements with high sensitivity and reliable electrical interconnections. The performance and reliability of 1800°C-capable temperature sensors and 1600°C-capable pressure/temperature sensor suites and associated packaging and conditioning electronics were demonstrated through rigorous lab testing up to 1800°C and 500 psi. Sporian prototype sensors and packaging hardware were successfully demonstrated in a High Temperature Pressurized Flow Facility (HTPFF) at the Southwest Research Institute (SwRI). The recorded combustor’s hot section gas path temperatures were between 1100 and 1500°C. The sensor probe exhibited excellent survivability and durability in the harsh environment, which represents a TRL-5 demonstration. Other OEM engine tests conducted in Phase IIA included Solar Turbine ST-T60 and ST-T130 tests. Another test under the Engine Life Extension and Health Monitoring (ELEHM) Program will be completed and reported as data becomes available. Potential applications of the research: Advanced sensing systems will be essential to achieving the cost and performance targets in advanced energy and power generation systems as well as aerospace propulsion systems. There is a significant market opportunity, as the sensor technology could benefit coal gasifiers, gas turbines, advanced coal combustion systems, oxy-fuel combustion systems, and other critical or high maintenance equipment. Generating asset OEMs, utilities, and end users will all stand to benefit from these high-efficiency, low emissions power systems.
- Research Organization:
- Sporian Microsystems, Inc., Lafayette, CO (United States)
- Sponsoring Organization:
- US DOE Office of Science (SBIR)
- DOE Contract Number:
- SC0008269
- OSTI ID:
- 1470679
- Type / Phase:
- SBIR (Phase IIA)
- Report Number(s):
- DOE-Sporian-SC8269
- Country of Publication:
- United States
- Language:
- English
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