the ENERGY lab

Embedded Optical Sensors for Extreme Temperatures and Harsh Environments

For more information, contact techtransfer@netl.doe.gov

Harsh environment sensing in energy applications such as gas composition in gasification, natural gas processing, fuel cells, gas turbines, and other energy conversion systems can help improve efficiency and reduce emissions.

The Need

• These systems are becoming increasingly complex and are subject to harsher environments (higher temperatures and pressures) as energy efficiency is improved and emissions and safety regulations are implemented.

• However, there are no commercial solutions available for embedded sensors capable of both chemical and temperature sensing above 500oC.

The Problem

Solid Oxide Fuel Cell internal gas and temperature distribution

The Problem

Solid Oxide Fuel Cell internal gas and temperature distribution

Embedded Sensing Capability and the Ability to Monitor Spatial Gradients in Key

Parameters Will Be Critical For Maximizing Efficiency and Reliability as Well as New

Technology Adoption

Example Market Driver : Solid Oxide Fuel Cells

: www.environmental-expert.com

Early Solid Oxide Fuel Cell Market Feedback (Power Generation)

$1000 / 20kW Stack for Temp. Monitoring Capability

(~$5M total for 10MW, ~$50M total for 100MW)

$10000 / 20kW Stack for Distributed Temp. Monitoring Capability

(~$50M total for 10MW, ~$500M total for 100MW)

Total Market for Solid Oxide Fuel Cells:

2011 - $380 million

Projected for 2016 - $530 million

(6.9% compounded annual growth rate)

Traditional Thermocouples are Not Suitable

Embedded H2 Sensors Do Not Exist, New Market

In 2012 10MW New SOFC Power Capacity

100MW New Overall Fuel Cell Capacity

Membranes for clean and renewable energy applications, , Woodhead Publishing 2014

Dr. Paul R. Ohodnicki, Jr., Project PI

- Bachelor’s, Engineering Physics and Economics, U. Pitt. (2005)

- M.S. and PhD in Materials Science and Engineering, Carnegie Mellon (2008)

- Research Engineer, PPG Industries (2008-2010) - Project Manager, Material Scientist, Team Lead,

DOE NETL (Current) - Adjunct Faculty, Materials Science and Eng.,

Carnegie Mellon (Current)

In-House Sensor Project Team 7 MS or PhD-level Engineers / Scientists (Materials, Electrical, Mechanical, Chemists)

NETL University Collaborator

Research and Development Team

A Team of World-Renowned Experts in Materials and Sensor Devices!

Prof. Kevin Chen, Optical Sensor Devices, Univ. of Pittsburgh

Optical sensors enabled by advanced sensing materials for the embedded sensing of temperature and gas composition in extreme, high temperature environments:

NETL’s Technology Solution

• Potentially capable of operation in temperatures approaching 900oC

• Minimize or eliminate wires and electrical contacts at sensing location

• Stable, reliable, safe, and cost-effective

• Multi-function capability (gas and temperature)

• No comparable commercial sensor on the market!

Example Prototype Sensor Device

Single Sensor Element Capable of Temperature and Chemical

Sensing Depending Upon the Interrogation Wavelength.

NETL’s Technology Solution

Unique Functionality Along with Advantages of the Optical Based Approach Yields Opportunity for New Market Creation.

Early Stage Sensor Device Proof of Concept

Commercial Opportunity Summary

Demonstrates Feasibility of Embedded

Temperature and H2 Sensing in an Operational Solid Oxide Fuel Cell

The Applications

• Fossil and Nuclear Power Generation

• Oil & Gas

• Fuel Cells

• Industrial Manufacturing

• Aviation

• Aerospace

• Automotive

• Military

These sensors would enable unprecedented access to new information in real time

Temperature Sensors:

• Asia-Pacific represents the fastest growing region with a CAGR > 9%.

• Estimated Global Market for Temperature Sensors is projected to reach $4.5 billion by 2018.

The Market

Temperature Sensor Market

Asia-Pacific Represents Fastest

Growing Region with Compound Annual

Growth Rates >9% Estimated

Global Market for Temperature

Sensors is Projected to Reach

$4.5 Billion by 2018

Magnetic Field Sensor Market

Compound Annual Growth Rates of

8-10% Predicted by Frost & Sullivan

Global Revenues Estimated

at $1.5 Billion in 2012

No Identified Commercial Sensor

Rated at T > 175oC

Frost & Sullivanwww.sensormag.com

World Market (Magnetic Sensors)

Traditional Electrical Sensors:

• prohibitively costly and intrusive

• require stable wiring, insulation, electronic components

Complex Optical Sensors

• expensive

• inherent temperature instability issues

Electrically Insulating Fiber Optic Cables

The Competing Technologies

Traditional Sensors: Thermocouples, RTDs, Chemi-resistive Sensors, Fluxgate Magnetometers Employing Conventional Magnetics

Thermocouples Chemi-resistive Sensors RTDs

Commercially Available Sensors

0

50

100

150

200

250

300

0 5 10 15

Fiber Optic vs. Thermocouple Cost Comparison

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Length of Wiring / Fiber in Harsh Zone (m)

Technology Positioning Map

Price

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Thermocouples

NETL Patented Optical Sensors

RTDs

Catalytic Detectors

Fiber Optic Distributed

Strain Temperature

Sensor

Infrared Gas Detectors

MICS

Spectroscopy-based Detectors

$100 $2000 $800

1000°C

200°C

600°C

Embedded Gas and Temperature Sensors for High Temperatures and Harsh Environments

Unique IP Position • Focus on novel sensor materials • 5 Nonprovisional Patent Applications Submitted • 1 Provisional Patent Application, pending a full application

Markets are Significant and Growing

These technologies are available for licensing and/or further collaborative research from the U.S. Department of Energy’s

National Energy Technology Laboratory.

The Opportunity

Come Talk to Me About How You Can Work With our World Class Team to Make New Sensor Technologies a Commercial Reality!