Fossil Energy R&D at the Department of Energy

Marvin SingerSenior Advisor & Director of Advanced Research

Presentation at

Basic Energy Sciences Advisory Committee Meeting

August 3, 2001

August 3, 2001 2

The Fossil Energy ProgramEnhancing U.S. Energy and Economic Security

Mission Goals

R&D Encourage innovative technology and sound regulations to maximize clean, efficient, and affordable development of fossil fuel resources

A virtually pollution free energy plant – “Vision 21”

Low cost carbon sequestration Power plant improvement Clean Coal Power Stabilize/increase production

of domestic oil and natural gas

Petroleum Reserves

Maintain readiness of the nation’s emergency crude oil stockpile; and

Northeast heating oil reserve

An emergency oil inventory An emergency heating oil

reserve

August 3, 2001 3

Fossil Energy R&D

Oil Technology

• Stop the decline in domestic oil production.

• Resolve environmental issues associated with oil production and processing.

Natural Gas Technologies• Ensure long-term availability and reliability of natural gas at

reasonable prices

Fuels & Power Systems• Develop progressively higher efficiency and cleaner

power generation systems

• Develop super-clean emission control system

• Develop economically competitive technologies for the production of alternative transportation fuels and chemicals

• Evaluate economically viable approaches to carbon sequestration

• Vision 21 encompasses these goals.

• Fossil Fuels supplies about 90% of U.S. energy needs. This reliance of these fuels is expected to continue for the foreseeable future.

Overview

Mission

• Enhance U.S. energy and economic security while meeting environmental objectives.

August 3, 2001 4

Fossil Energy R&D Budget(Million $)

FY 2001: $441.142

Gas10%

Petroleum15%

Advanced Metallurgical

Research1%

Fuels & Power Systems

69%

FY 2002: $366.500

Petroleum8%

Clean Coal Power

Initiative41%

Gas6%

Advanced Metallurgical

Research1%

Fuels & Power

Systems44%

324.025

- 5.214

66.874

45.029

159.801

21.00030.499

5.200 -

150.000

Enacted

Request

August 3, 2001 5

Fossil Energy R&D Performers(FY2000 Dollars in Millions)

Universities15%

In-House10%

Industry61%

National Lab14%

Total FE R&D $294 million

($29)

($40)

($179)

($45)

August 3, 2001 6

The Fossil Energy R&D Budget$ in millions

Program FY 2001

Adj. B/A

FY2002

Request

FY2002

House Mark

FY2002 Senate Mark

Clean Coal Power Initiative

$0.000 $150.000 $150.000 $150.000

Fuels & Power Systems

324.025 159.801 220.301 244.251

Gas 45.029 21.000 40.250 43.050

Petroleum 66.874 30.499 55.999 44.999

Adv. Met. Res. 5.214 5.200 5.200 5.200

Fossil Energy R&D $441.142 $366.500 $471.750 $487.500

August 3, 2001 7

The Fossil Energy R&D Budget

Program

Clean Coal Power Initiative

Fuels & Power Systems

Gas

Petroleum

Advanced Metellurgical

Research

Program Element

Materials

V-21 Plant of the Future

Sequestration

Turbines

Fuel Cells

Power Plant Improvement

Fuels

Oil & Gas Exploration & Production

Gas Hydrates

Delivery Infrastructure

Cleaner Fuels

August 3, 2001 8

The Fossil Energy R&D Budget

*includes several budget categories

$ in millions

Fuels & Power Systems

Program Element FY 2001 FY 2002

FY 2002 House Mark

FY 2002 Senate Mark

Materials 7.0 7.0 7.0 8.0

V-21 Plant of the Future* 51.5 37.5 44.0 53.0

Sequestration 18.7 20.7 32.1 32.1

Turbines 30.9 0.0 18.5 20.5

Fuel Cells 52.6 45.1 48.1 52.1

Power Plant Improvement 94.8 0.0 0.0 0.0

Fuels 23.4 7.0 25.0 33.95

August 3, 2001 9

Vision 21 Program

Fossil Fuels• Coal• Gas• Oil

Opportunity Feedstocks• Biomass• Municipal Waste• Petcoke

Electricity

Chemicals

TransportationFuels

Syngas

Hydrogen

Steam

OUTPUT

GasSeparation

Mo

du

les

Combustion/Gasification

Systems IntegrationSystems Integration

Mo

du

les

Power

High-Temp.Heat Exch.

Mo

du

les

Gas Cleanup

Mo

du

les

Mo

du

les

Mo

du

les

Fuels/Chemicals

INPUT

Modular Technology

August 3, 2001 10

Vision 21Program Objectives

Capital & Operating Costs/RAM Vision 21 must be competitive

with other energy systems with comparable environmental performance

Emissions < 0.01 lb/106 Btu SO2 and NOx

< 0.005 lb/106 Btu PM <1/2 organic compounds in

Utility HAPS Report <1 lb/109 Btu Hg

Schedule of Benefits Technology spinoffs by 2005 Designs for modules by 2012 Commercial plant designs by

2015

Efficiency• Electricity generation coal based 60% (HHV) gas based 75% (LHV)• Fuels only plants 75%

August 3, 2001 11

Drivers for Vision 21 Recognition that fossil energy will be part of

future energy mix

Concern about environment, including global climate change

Restructuring of energy industry

Decreasing reserve margins and grid reliability issues

Uncertain natural gas prices

Recognition of value of “future options”

August 3, 2001 12

Technology Roadmapping

Available at:

http://www.netl.doe.gov

August 3, 2001 13

EnablingTechnologies

SupportingTechnologies

Systems Analysis/

Integration

Low-Cost Gas Separation/PurificationHigh-Temperature Heat Exchange

Fuel-Flexible GasificationHigh-Performance Combustion

Fuel CellsFuel-Flexible Turbines

Synthesis Gas Conversion to Fuels & Chemicals

MaterialsEnvironmental Control Technology

Controls and SensorsComputational Modeling/Virtual Simulation

Technical/Economic/Market AnalysesSystems Engineering

Industrial EcologyDynamic Response/Control

VISION 21 Technology Roadmap

August 3, 2001 14

Modeling -Gas/Particle Flow

V E21 P

CO2 Sequestration

ISION NERGY LEXV E21 P

CO2 Sequestration

Oxygen Membrane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenSeparation

ISION NERGY LEXV E21 P

CO2 Sequestration

Oxygen Membrane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenSeparation

Gasification

ISION NERGY LEXV E21 P

CO2 Sequestration

Oxygen Membrane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenSeparation

Gasification

ISION NERGY LEXV E21 P

CO2 Sequestration

Oxygen Membrane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenSeparation

Gasification

ISION NERGY LEXV E21 P

CO2 Sequestration

Oxygen Membrane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenSeparation

Gasification

GasStream

Cleanup

Fuels/Chemicals

ISION NERGY LEXV E21 P

CO2 Sequestration

Oxygen Membrane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenSeparation

Gasification

GasStream

Cleanup

Fuels/Chemicals

Fue l Ce llF uel Cell

L iquids Convers ionLiquids Convers ion

High Effi ciency TurbineH igh Effi ciency Turbine

ISION NERGY LEXV E21 P

CO2 Sequestration

Oxygen Membrane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenSeparation

Gasification

GasStream

Cleanup

Fuels/Chemicals

Fue l Ce llF uel Cell

L iquids Convers ionLiquids Convers ion

High Effi ciency TurbineH igh Effi ciency Turbine

ISION NERGY LEXV E21 P

CO2 Sequestration

Oxygen Membrane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenSeparation

Gasification

GasStream

Cleanup

Fuels/Chemicals

Fue l Ce llF uel Cell

L iquids Convers ionLiquids Convers ion

High Effi ciency TurbineH igh Effi ciency Turbine

ISION NERGY LEXV E21 P

Coal

OtherFuels

Vision 21 Program New Projects Contribute to the Ultra-Clean Energy Plant

Systems Integration

Advanced MaterialsModeling - Combustion

Turbines & Fuel Cells

Hydrogen Membrane

Virtual Simulation

Gasification &Combustion

OxygenMembrane

August 3, 2001 15

FE Materials Programs

HeatEngines

Coatings

&Protection

New

Alloys

Functional

Materials

Ultra-High

Performance

Gasification Systems Fuel Cells

AdvancedCombustion

Systems

AdvancedSteam

GeneratorsGas

Separation

August 3, 2001 16

FE Materials Program

• NETL-4: High-temperature materials testingin coal combustion environments

• ORNL-2B/2: Extended lifetime metallic coatingsfor high-temperature environmentalprotection

Evaluation/Development

• INEEL-2: Influence of processing on coatingmicrostructures and properties

• LU-2: Iron aluminide weld overlays andcoatings

Processing

• ORNL-4C: Reliable coatings for high-temperature environmentalresistance

• UNDEERC-4: Environmental testing ingasifier-related environments

Evaluation/Development

Evaluation/Development• ORNL-2B/1: CVD metallic coatings for

high-temperature environmentalprotection

• TTU-2: Metallic coatings for powergeneration applications

HeatEngines

Gasification Systems

Advanced Steam

Generators

Coatings & Protection

of Materials

August 3, 2001 17

• ANL-4: Corrosion and mechanical propertiesof alloys and ceramics in combustionand mixed-gas environments

• CSM-2: Weldability issues• MTI-2: Boiler test of advanced austenitic

alloys (McDermott)

Evaluation

• ORNL-2E/2: Oxidation-controlled lifetimemodeling of ODS alloy sheet/foil

• ORNL-5J: Improved metallic recuperatormaterials (Solar Turbines CRADA)

Evaluation & Development

Development

• TWI-2: Friction welding of ODS alloys

Reduction of defects in ODS

• HA-2: Development of MA956 HX tubes(joint with Special Metals)

• ORNL-2E/1: ODS alloy development

• UCSD-2: Optimization of materials properties• UL-2:

processing

HeatEngines

AdvancedSteam

Generators

Advanced Combustion

Systems

• ORNL-2C: Modified austenitic alloys• ORNL-5L: High creep-strength alloys (Special

Metals CRADA)

Development

Evaluation

• FW-5: In-plant corrosion probe tests ofODS alloys (Foster Wheeler)

New Alloys

FE Materials Program

August 3, 2001 18

Gasification Systems

Gas Separation • ELT-3: Proton exchange membranes for

hydrogen separation• ETTP-3B: Development of ceramic membranes

for hydrogen separation• LANL-3: Pd-Ag membranes for hydrogen

separation• ORNL-3A: Materials for gas separation devices

(joint with PNNL)• ORNL-5D: Technology transfer—CFC molecular

sieves (WESTVACO)• PNNL-3A: Materials for gas separation devices

(joint with ORNL)• SNL-3: Molecular sieves for hydrogen

separation

Development

• Ames-3: Metallic filters for hot gas cleaning• ORNL-3E: Development of novel activated

carbon composites

Development

Processing

• BU-3: Low-cost processing for fuel cellfabrication

• ORNL-2F: Fabrication technology for fuel cellapplications

• ORNL-3G: Efficient SOFC electrolyte fabrication• ORNL-3H: Improved fuel cell materials, and

economical fabrication

Fuel Cells

Development & Modeling

• PNNL-3: Solid state electrolyte systems for fuelcells and gas separation

• UOL-3: Modeling of CVD for solid stateelectrolytes

Functional Materials

FE Materials Program

August 3, 2001 19

• ARC-1: Refractory material issues

Evaluation

• AMES-2: Mo-Si alloy development (joint withORNL)

• ORNL-2D: Intermetallic-reinforced Cr alloys• ORNL-2I: Mo-Si alloy development (joint with

Ames)• ORNL-4A: Corrosion protection of

ultrahigh-temperature intermetallicalloys

Development

• ANL-1: Development of NDE methods• ORNL-1A: Fiber-reinforced composites• ORNL-1B: Corrosion-resistant composite

structures/slurry-based mullitecoatings

• REMAXCO-5: Commercial process forproducing SiC fibrils

Processing & DevelopmentAdvanced

CombustionSystems

Heat Engines

• UT-2A: Fatigue and fracture behavior of Cr-Xand intermetallic alloys

• WVU-2: Intrinsic and extrinsic fracturebehavior of intermetallic compounds

Evaluation

Ultrahigh Performance

Materials

FE Materials Program

August 3, 2001 20

Power Reliability - Outage Costs

IndustryAverage Cost of

DowntimeSource

Cellular Communications

$41,000 per hourTeleconnect Magazine

Telephone Ticket Sale

$72,000 per hour

Contingency Planning Research 1996  

Airline Reservations

$90,000 per hour 

Credit Card Operations

$2,580,000 per hour

Brokerage Operations

$6,480,000 per hour

August 3, 2001 21

Emissions from Fossil Fuel Power Generation

Average U.S.fossil fuel plant

Combined cyclegas turbine

Microturbine

(Pounds of emissions per 1000 kWh NOx, CO, SOx, Hydrocarbon, Particulates)

Fuel cell

0.5

1.0

0

1.5

20

25

0.04

Microturbine Fuel cell Fuel cell (with co-generation)

(Pounds of CO2 per 1000 kWh)

2000

1000

2700

911

1862

1164610

Average USfossil fuel plant

Combined cyclegas turbine

0.6

1.2

24.89

August 3, 2001 22

Siemens Westinghouse SOFC Demonstration

EDB-ELSAM 100 kWe CHP System

August 3, 2001 23

Fuel Cells for the 21st Century

Goals

Approaching $400/kW Installed Costs

80% (LHV) Electric Efficiency

Applications in Distributed Power, Central Station Power and Transportation

Fuel Flexibility

August 3, 2001 24

Small BusinessUniversity

NationalLab Industry

Core Technology ProgramThe Technology Base

Fuel CellCore

Technology

FuelProcessing

Materials

Modeling &Simulation

PowerElectronics

Controls &Diagnostics

Manufacturing

Materials

August 3, 2001 25

Fuel Cell ObservatoryFuel Cell Observatory

Electrochemical Modeling

In-situ Diagnostics

Cell/stack test

Sensors,data analysis

Electrochemical Phenomena

Surface Science Issues

Thermo-mechanical Phenomena

Cell and System Optimization

Fuel CellObservatory

August 3, 2001 26

Selected Research TopicsSelected Research Topics• Quantitative microstructural characterization of electrodes

and correlation with measured electrochemical performance and modeling.

• Direct measurement of activation overpotentials on electrodes of known triple phase boundaries.

• Measurement of gas diffusion in porous electrodes; effect of pore size and pore fraction.

• Determination of charge transfer mechanisms on electrodes.

• Investigation of fuel reformation mechanisms and kinetics on different anodes.

August 3, 2001 27

The Fossil Energy R&D Budget

$ in millions

Gas & Petroleum

Program Element

FY 2001 Adj B/A

FY 2002 Request

FY 2002 House Mark

FY 2002 Senate Mark

Oil and Gas Exploration & Production

$71,137 $36,149 $78,149 $64,949

Gas Hydrates 9,938 4,750 9,800 9,800

Delivery Infrastructure 8,110 5,050 8,050 10,050

Cleaner Fuels 22,718 250 250 3,250

TOTAL 102,903 51,499 96,249 88,049

August 3, 2001 28

Research and Development

Oil, Gas Exploration & Production

Delivery Infrastructure

Cleaner Fuels

Imaging & DiagnosticsAdvanced Drilling SystemsEnhanced Recovery TechnologiesEnvironmental Compliance

Pipeline Integrity & MeteringLeak DetectionGas Storage

Gas-to-LiquidsOil Refining & UpgradingCoal-to-Liquids

Natural Gas, Crude Oil

Natural Gas, Crude Oil

Natural Gas & Oil Program

29August 3, 2001

Acting Assistant SecretaryRobert S. Kripowicz

Acting Principal DeputyRick Furiga

Office of Budget &Financial Management

Charles Roy

Strategic Planning - Raymond J. BraitschInternational Issues - Sun W. Chun

National Energy Technology Laboratory (NETL)

Rita Bajura - Director

Albany Research CenterGeorge Dooley - Director

Office of Petroleum Reserves

Rick Furiga

Finance & PolicyJohn Shages

Planning & EngineeringDavid Johnson

Operations & ReadinessLynette LeMat

Management & AdministrationVacant

Project ManagementOffice

William Gibson

Office of Naval Petr. & Oil Shale Res.

Tony Dammer

Office of Human Resources and Program Support

Ed Kilroy

Office ofNatural Gas & Petr. Tech.

Guido DeHoratiis (Acting)

Research and DevelopmentGuido DeHoratiis

Natural Gas & PetroleumImport & Export Activities

Don Juckett

Planning & EnvironmentalAnalysis

Nancy Johnson

National Petroleum Technology Office (NPTO)

Bill Lawson - Director

Office of Communications

Robert Porter

Office ofCoal & Power

SystemsGeorge Rudins

Product Line Director for Power Systems

Victor Der

Product Line Directorfor Environmental Systems

David Beecy

Product Line Directorfor Coal Fuels & Ind. Sys.

Lowell Miller

Advanced ResearchMarvin Singer

Coal & PowerImport/Export Activities

Barbara McKee

Planning &Environmental Analysis

Doug Carter

Office of Fossil EnergyEffective as of January 22, 2001

Office of Environment, Security, Safety, and Health

Craig Zamuda

Associate Deputy Assistant Secretary

Guido DeHoratiis (Acting)

Morgantown, WV Pittsburgh, PA

NPR - CAJames Killen

NPOSR - CO, UT, WYClark Turner

http://www.fe.gov