Overall Scope of Proposed Marine Gas Turbine S

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Overall Scope of Proposed Marine Gas Turbine ST
Program

• David A. Shifler
• Office of Naval Research
• 875 N. Randolph Street
• Arlington, VA 22203-1995
• shifled_at_onr.navy.mil
• 703-696-0285

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Outline

• Status of current Navy ST Program0
• Why gas turbines? Alternatives to gas turbines
• Fuels cells, batteries
• Nuclear power
• Futures issues
• Future fuels
• Future needs, capabilities
• Electric ship
• Operating conditions
• Leveraging from aircraft
• Defining current capabilities
• Technology gaps
• Defining a program
• Pathway to transition paramount
• Capabilities-based improvements (define degree of
  improvement)
• Prioritize ST needs and estimate costs, timeline
  for each step (6.1?6.2?6.3 (TRL6)
• Consider alternative funding paths

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Alternatives to Gas Turbine Engines

• Alternative energy sources debated LAWMAKERS,
  NAVY OFFICIALS VOICE CONCERNS ON NAVY ENERGY
  PRACTICES Date April 17, 2006 Lawmakers and
  Navy officials are voicing concerns that the
  service is taking insufficient measures to limit
  its dependency on oil, which may be an unreliable
  source of energy in the future. During a House
  Armed Services projection forces subcommittee
  hearing on alternative propulsion for ships April
  6, Chairman Roscoe Bartlett (R-MD) said the Navy
  must more actively seek alternative sources of
  energy. He cited President Bushs 2006 State of
  the Union address, during which Bush called on
  the nation to break its addiction to oil.
  Bartlett said the Navy should consider
  employing nuclear power on more vessels. We
  must look for ways to break ourselves free from
  dependency on foreign oil, and I would like to
  know why we are not moving towards an all-nuclear
  Navy, he said during his opening statement.
  Ranking Member Gene Taylor (D-MS) echoed
  Bartletts concerns that Navy must move away from
  oil as an energy source.

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Alternative to Gas Turbines Fuel Cells

• Fuel Cells advantages for surface ships
• High efficiency vs. gas turbine and diesel
  powered naval vessels (40 vs. 16-12)
• Reduced emissions of all types
• Low vibration and sound levels
• Improved thermal efficiencies
• Reduced cost for fuel (30 less for Navy)
• Ship design flexibility (modular units) (Can be
  placed throughout ship)
• Permits the use of alternative fuels

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Fuel cell advantages for submarines

• High efficiency vs. diesel powered submarines
  (40 vs. 16-12)
• Low thermal profile compared to SSNs
• Low vibration and sound levels
• Reduced radar cross section
• Does not require air breathing like diesel subs
• Only has to come up every several weeks

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Developers and Researchers

• Germany Working prototypes and service models
  of fuel cell submarines
• Canada Prototype for fuel cell submarine
• United States Prototypes and plans for both
  subs and surface ships
• United Kingdom Prototypes and plans for subs
  and surface ships

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Practical Applications

• Submarines
• Fuel Cells Silence Increased Stealth
• Fuel Cells No air required Longer dive times
• Surface Ships
• Fuel Cells Increased efficiencies Longer time
  out to sea
• Fuel Cells Reduced emissions Reduced Profile
  (Harder to detect)
• Operational Ships Germanys HDW U214 Submarine

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Power Plan Efficiencies
Courtesy of Edward House Office of Navy Research
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Challenges to Fuel Cell Development

• Fuel Type (Logistics and Fuel Reforming)
• Cost and System Efficiency for Units
• Reliability and Maintainability
• Duty Cycle and Transient Response
• Fuel Cell Life and Contamination
• Fuel Cell Sensitivity to shocks and motion

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Challenges fro Gas Turbines

• Need to acknowledge alternative power sources
• Need to accentuate its advantages over these
  power sources.
• Strategize for hybrid use?

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Future Fuels for Gas Turbines

• The U.S. in general is becoming more dependent on
  foreign sources for petroleum.
• Costs for fuels is escalating gt the surface fleet
  uses almost 1B gallons per year ? 2-3B/year now.
• Need to reduce costs push for efficiencies
  increasing.
• Need to reduce petroleum dependency.

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Energy Density of Fuels
Uranium X 1000

Liquid Hydrocarbons
Alcohols
Hydrogen
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AIRCRAFT ENGINES
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The Marine Environment

• Air intake requires filtering.

Major Seawater Constituents at 35 parts per
Thousand Salinity and 25oC.
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The Marine Environment

• Naval Fuels
• JP-5 sulfur max. 0.4 wt. (air and shipboard)
• F-76 sulfur max, 1.0 wt. (shipboard only)
• Future low-sulfur fuels proposed by Navy fuels
  group
• Materials life dependent on contaminant levels
• Dyed or undyed fuel
• Residue carbon
• Vanadium
• Salt deposits are largely unique to shipboard gas
  turbines
• Other impurities from fuel, air, or other
  sources.
• Temperatures lead to corrosion by sulfidation/hot
  corrosion rather than oxidation.

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Government-Industry Advisory Group (MEL/DTNSRDC
1964)

• U.S. Navy Marine Gas Turbine Alloy Development
  Program
• Comprehensive Mechanism Study of Hot Corrosion
  in Marine Gas Turbine
• Comprehensive Alloy Development Program for Ni
  and Co-base Superalloys
• Mechanical properties equivalent to
• IN 713C for Ni-base alloys
• IN WI-52 for Co-base alloys
• Capable of operating at 927oC (17000F) for ?
  5000 hrs.
• Standardize Acceptance Criteria For Candidate
  Materials
• Other Approaches to Solve Hot Corrosion Problem
• Fuels additives
• self-healing coatings
• Standardize Hot Corrosion Test Equipment

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Type I, HTHC Burner Rig Exposure _at_ 1650oF (899oC)
97 hours
1000 hours
585 hours
Several efforts with OEMS have lead to repeated
failures with TBCs
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• INCREASING CAPABILITIES
• LEADING TO MATERIALS CHALLENGES

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Matt Driscoll, NAVSEA/NSWC Philadelphia
2006 IGTI Conference Barcelona
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Specific Power and Energy
Specific Power (W/kg)
36 s
1 hr
10000
Model Airplane
1000
Mobility
100
100 hr
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Batteries
Fuel Cells

• 10

100
1000
10000
Specific Energy (Whr/kg)
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(857C)
(937C)
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Hot Corrosion Temperature Ranges
Type I 850-950 oC (1562-1742 oF) Basic fluxing
alloy reaction with Na2SO4 leading to sulfide,
broad
Type II 600-750oC (1112-1382 oF) Acidic
fluxing SO2 or SO3 gases react with NiO or CoO
pitting
Increased engine temperatures will impact
materials thermal cycling between salt
deposition/corrosion and oxidation regimes
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Increased ship engine temperatures impact of
components
FT Synthetic fuel
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Task for Improving Ship Turbine Capabilities
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Shipboard Gas Turbines?

• Future Navy Needs
• Define baseline Capabilities
• Range, fuel efficiency, power capabilities, mean
  maintenance/readiness
• What can be achieved through materials in
  improving capabilities?
• Spiral development
• 2, 5, 10, 15, 20, 30 years?
• Improved capabilities/cost savings per spiral
• What type of research?
• Leveraging
• Transition path clearly defined
• 6.1 ?6.2 ? 6.3

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Basic Research

• What is known?
• What can be leveraged from prior work?
• What are the ST gaps?
• Mechanistic understanding
• Corrosion/oxidation and combination
• Thermomechanical
• Major and minor chemistries performance impact
• Materials
• Design

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Basic Research

• Identify needs
• Prioritize needs and estimate cost on
  accomplishing research goals, establish timeline.
• Core funding
• Alternative funding lines
• MURIs
• SBIRs
• DARPA for transition??????
• Capabilities possible from research (need
  industry input)
• Ex. Corrosion/oxidation resistant TBC that is
  resistant to spallation. Increased engines
  temperatures of xxxC could potentially improve
  YYY (range) capabilities by zz. This could save
  ____ per year.

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6.1 Basic Research

• Research areas
• Future fuels, lubricity, and fuel contaminants
• Hot corrosion
• Sulfate/vanadium or combination
• Creep, Fatigue
• Equiaxed, DS, and SX.
• Thermal cycling
• Corrosion-influenced interdiffusion
• Thermomechanical
• Spallation
• Coatings
• Overlay, diffusion, TBCs
• Alloys and CMCs, ceramics, and other materials
• Modeling, prediction, and prognostication
• Performance prediction of coating/alloys
  combinations
• Alternative TBCs
• Alloy/coating stabilities
• Long-term (10-30 years) materials

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6.2 Applied Research

• After benchtop research, steps and follow-up
  research needed to reach TRL3.
• Depends on product
• University/laboratory research
• Fabrication/casting/processing/application
  techniques
• Chemistry control
• Microstructural control
• Rig testing
• Navy/Industry co-funding
• Cost and timelime, spirals

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6.3 Demonstration

• Testing and associated work need to achieve
  TRL6. (requires industry/Navy interaction and
  agreement)
• Shipboard Engine Testing
• Land-based engine testing
• Simulated engine testing
• Component manufacturing
• Estimate cost and time needed to achieve TRL goal
  by coating/alloy or material

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End of Day

• Overall outline of ST pathway from 61 to 6.3
• Preliminary prioritizations, costs, and
  timelines.
• Need final plan by NLT September, 30 2006

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