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