Fossil Energy R D at the Department of Energy

Fossil Energy R&D at the Department of Energy Presentation at Basic Energy Sciences Advisory Committee Meeting August 3, 2001 Marvin Singer Senior Advisor & Director of Advanced Research

The Fossil Energy Program Enhancing U. S. Energy and Economic Security Mission R&D Petroleum Reserves Goals Encourage innovative technology and sound regulations to maximize clean, efficient, and affordable development of fossil fuel resources · A virtually pollution free energy Maintain readiness of the nation’s emergency crude oil stockpile; and Northeast heating oil reserve · An emergency oil inventory · · plant – “Vision 21” Low cost carbon sequestration Power plant improvement Clean Coal Power Stabilize/increase production of domestic oil and natural gas · An emergency heating oil reserve August 3, 2001 2

Fossil Energy R&D Fuels & Power Systems Overview • Fossil Fuels supplies about 90% of U. S. energy needs. This reliance of these fuels is expected to continue for the foreseeable future. • 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. Mission • Enhance U. S. energy and economic security while meeting environmental objectives. Natural Gas Technologies • Ensure long-term availability and reliability of natural gas at reasonable prices Oil Technology • Stop the decline in domestic oil production. • Resolve environmental issues associated with oil production and processing. August 3, 2001 3

Fossil Energy R&D Budget (Million $) Enacted - 5. 214 66. 874 45. 029 324. 025 Request 150. 000 159. 801 30. 499 21. 000 5. 200 August 3, 2001 4

Fossil Energy R&D Performers (FY 2000 Dollars in Millions) ($40) ($45) ($29) ($179) Total FE R&D $294 million August 3, 2001 5

The Fossil Energy R&D Budget $ in millions Program Clean Coal Power Initiative Fuels & Power Systems FY 2001 Adj. B/A $0. 000 FY 2002 Request FY 2002 House Mark FY 2002 Senate Mark $150. 000 324. 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 5. 214 5. 200 Adv. Met. Res. Fossil Energy R&D $441. 142 $366. 500 $471. 750 $487. 500 August 3, 2001 6

The Fossil Energy R&D Budget Program Element Program Clean Coal Power Initiative Fuels & Power Systems Gas Petroleum Advanced Metellurgical Research 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 7

The Fossil Energy R&D Budget $ in millions Fuels & Power Systems Program Element FY 2001 Materials FY 2002 House Mark FY 2002 Senate Mark 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 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 Fuels 23. 4 7. 0 25. 0 33. 95 *includes several budget categories August 3, 2001 8

Vision 21 Program Modular Technology Systems Integration High-Temp. Heat Exch. Gas Separati on Modules Power Gas Cleanup Modules • Biomass • Municipal Waste • Petcoke Modules Opportunity Feedstocks Combustion/ Gasification Modules • Coal • Gas • Oil Modules Fossil Fuels Modules INPUT Fuels/ Chemicals OUTPUT Electricity Chemicals Transportation Fuels Syngas Hydrogen Steam August 3, 2001 9

Vision 21 Program Objectives · Capital & Operating Costs/RAM Vision 21 must be competitive with other energy systems with comparable environmental performance Schedule of Benefits · Technology spinoffs by 2005 · Designs for modules by 2012 · Commercial plant designs by 2015 · · Emissions < 0. 01 lb/106 Btu SO 2 and NOx < 0. 005 lb/106 Btu PM <1/2 organic compounds in Utility HAPS Report <1 lb/109 Btu Hg Efficiency • Electricity generation coal based 60% (HHV) gas based 75% (LHV) • Fuels only plants 75% August 3, 2001 10

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 11

Technology Roadmapping Available at: http: //www. netl. doe. gov August 3, 2001 12

VISION 21 Technology Roadmap Enabling Technologies Low-Cost Gas Separation/Purification High-Temperature Heat Exchange Fuel-Flexible Gasification High-Performance Combustion Fuel Cells Fuel-Flexible Turbines Synthesis Gas Conversion to Fuels & Chemicals Supporting Technologies Materials Environmental Control Technology Controls and Sensors Computational Modeling/Virtual Simulation Systems Analysis/ Integration Technical/Economic/Market Analyses Systems Engineering Industrial Ecology Dynamic Response/Control August 3, 2001 13

Vision 21 Program New Projects Contribute to the Ultra-Clean Energy Plant Virtual Simulation Systems Integration Gasification & Combustion Advanced Materials Modeling Combustion Turbines & Fuel Cells Oxygen Membrane Modeling Gas/Particle Flow Hydrogen Membrane August 3, 2001 14

FE Materials Programs Coatings New Functional Ultra-High &Protection Alloys Materials Performance Gasification Systems Fuel Cells Heat Engines Advanced Steam Generators Gas Separation Advanced Combustion Systems August 3, 2001 15

FE Materials Program Gasification Systems Coatings & Protection of Materials Heat Engines Evaluation/Development • ORNL-4 C: Reliable coatings for hightemperature environmental resistance • UNDEERC-4: Environmental testing in gasifier-related environments Evaluation/Development • ORNL-2 B/1: CVD metallic coatings for high-temperature environmental protection • TTU-2: Metallic coatings for power generation applications • INEEL-2: Advanced Steam Generators • LU-2: Processing Influence of processing on coating microstructures and properties Iron aluminide weld overlays and coatings Evaluation/Development • NETL-4: High-temperature materials testing in coal combustion environments • ORNL-2 B/2: Extended lifetime metallic coatings for high-temperature environmental protection August 3, 2001 16

FE Materials Program • ANL-4: Advanced Steam Generators • CSM-2: • MTI-2: • ORNL-2 C: • ORNL-5 L: New Alloys Heat Engines Advanced Combustion Systems Evaluation Corrosion and mechanical properties of alloys and ceramics in combustion and mixed-gas environments Weldability issues Boiler test of advanced austenitic alloys (Mc. Dermott) Development Modified austenitic alloys High creep-strength alloys (Special Metals CRADA) Evaluation & Development • ORNL-2 E/2: Oxidation-controlled lifetime modeling of ODS alloy sheet/foil • ORNL-5 J: Improved metallic recuperator materials (Solar Turbines CRADA) Development of MA 956 HX tubes • HA-2: (joint with Special Metals) • ORNL-2 E/1: ODS alloy development • TWI-2: Friction welding of ODS alloys • UCSD-2: Optimization of materials properties Reduction of defects in ODS • UL-2: processing • FW-5: Evaluation In-plant corrosion probe tests of ODS alloys (Foster Wheeler) August 3, 2001 17

FE Materials Program Processing • BU-3: Fuel Cells Low-cost processing for fuel cell fabrication • ORNL-2 F: Fabrication technology for fuel cell applications • ORNL-3 G: Efficient SOFC electrolyte fabrication • ORNL-3 H: Improved fuel cell materials, and economical fabrication Development & Modeling • PNNL-3: • UOL-3: Functional Materials Gas Separation Gasification Systems Solid state electrolyte systems for fuel cells and gas separation Modeling of CVD for solid state electrolytes Development • ELT-3: Proton exchange membranes for hydrogen separation • ETTP-3 B: Development of ceramic membranes for hydrogen separation • LANL-3: Pd-Ag membranes for hydrogen separation • ORNL-3 A: Materials for gas separation devices (joint with PNNL) • ORNL-5 D: Technology transfer—CFC molecular sieves (WESTVACO) • PNNL-3 A: 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-3 E: Development of novel activated carbon composites August 3, 2001 18

FE Materials Program Evaluation • ARC-1: Advanced Combustion Systems Ultrahigh Performance Materials Heat Engines Refractory material issues Processing & Development • ANL-1: Development of NDE methods • ORNL-1 A: Fiber-reinforced composites • ORNL-1 B: Corrosion-resistant composite structures/slurry-based mullite coatings • REMAXCO-5: Commercial process for producing Si. C fibrils Development • AMES-2: Mo-Si alloy development (joint with ORNL) • ORNL-2 D: Intermetallic-reinforced Cr alloys • ORNL-2 I: Mo-Si alloy development (joint with Ames) • ORNL-4 A: Corrosion protection of ultrahigh-temperature intermetallic alloys • UT-2 A: • WVU-2: Evaluation Fatigue and fracture behavior of Cr-X and intermetallic alloys Intrinsic and extrinsic fracture behavior of intermetallic compounds August 3, 2001 19

Power Reliability - Outage Costs Average Cost of Downtime Industry Cellular Communications $41, 000 per hour Telephone Ticket Sale $72, 000 per hour Airline Reservations $90, 000 per hour Credit Card Operations $2, 580, 000 per hour Brokerage Operations Source $6, 480, 000 per hour Teleconnect Magazine Contingency Planning Research 1996 August 3, 2001 20

Emissions from Fossil Fuel Power Generation 25 24. 89 (Pounds of emissions per 1000 k. Wh NOx, CO, SOx, Hydrocarbon, Particulates) 20 1. 5 1. 2 1. 0 0. 6 0. 5 0 0. 04 Average U. S. fossil fuel plant Microturbine Combined cycle gas turbine Fuel cell (Pounds of CO 2 per 1000 k. Wh) 2700 1862 2000 1164 911 1000 610 Average US fossil fuel plant Combined cycle gas turbine Microturbine Fuel cell (with co-generation) August 3, 2001 21

Siemens Westinghouse SOFC Demonstration EDB-ELSAM 100 k. We CHP System August 3, 2001 22

Fuel Cells for the 21 st Century Goals · Approaching $400/k. W Installed Costs · 80% (LHV) Electric Efficiency · Applications in Distributed Power, Central Station Power and Transportation · Fuel Flexibility August 3, 2001 23

Core Technology Program The Technology Base University National Lab Industry Small Business Fuel Processing Manufacturing Controls & Diagnostics Power Electronics Fuel Cell Core Technology Modeling & Simulation Materials August 3, 2001 24

Fuel Cell Observatory Electrochemical Phenomena Electrochemic al Modeling Cell/stack test Fuel Cell Observatory In-situ Diagnostics Sensors, dat a analysis Thermomechanical Phenomena Surface Science Issues Cell and System Optimization August 3, 2001 25

Selected 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 26

The Fossil Energy R&D Budget $ in millions Gas & Petroleum Program Element Oil and Gas Exploration & Production FY 2001 Adj B/A FY 2002 Request FY 2002 House Mark FY 2002 Senate Mark $71, 137 $36, 149 $78, 149 $64, 949 Gas Hydrates 9, 938 4, 750 9, 800 Delivery Infrastructure 8, 110 5, 050 8, 050 10, 050 22, 718 250 3, 250 102, 903 51, 499 96, 249 88, 049 Cleaner Fuels TOTAL August 3, 2001 27

Natural Gas & Oil Program Research and Development Oil, Gas Exploration & Production Imaging & Diagnostics Advanced Drilling Systems Enhanced Recovery Technologies Environmental Compliance Natural Gas, Crude Oil Delivery Infrastructure Pipeline Integrity & Metering Leak Detection Gas Storage Natural Gas, Crude Oil Cleaner Fuels Gas-to-Liquids Oil Refining & Upgrading Coal-to-Liquids August 3, 2001 28

Office of Fossil Energy Acting Assistant Secretary Robert S. Kripowicz Effective as of January 22, 2001 Office of Environment, Security, Safety, and Health Office of Human Resources and Program Support Craig Zamuda Office of Coal & Power Systems Strategic Planning - Raymond J. Braitsch International Issues - Sun W. Chun Acting Principal Deputy Rick Furiga Ed Kilroy Office of Communications Office of Budget & Financial Management Robert Porter Charles Roy Office of Petroleum Reserves Office of Natural Gas & Petr. Tech. George Rudins Product Line Director for Power Systems Victor Der Product Line Director for Environmental Systems David Beecy Product Line Director for Coal Fuels & Ind. Sys. Lowell Miller Advanced Research Marvin Singer Rick Furiga Guido De. Horatiis (Acting) Associate Deputy Assistant Secretary Guido De. Horatiis (Acting) Research and Development Guido De. Horatiis Natural Gas & Petroleum Import & Export Activities Don Juckett Management & Administration Vacant Finance & Policy John Shages Planning & Engineering David Johnson Project Management Office William Gibson Operations & Readiness Lynette Le. Mat Office of Naval Petr. & Oil Shale Res. Tony Dammer Planning & Environmental Analysis Nancy Johnson Albany Research Center Coal & Power Import/Export Activities Barbara Mc. Kee Planning & Environmental Analysis Doug Carter George Dooley - Director NPOSR - CO, UT, WY Clark Turner National Energy Technology Laboratory (NETL) Rita Bajura - Director Morgantown, WV http: //www. fe. gov NPR - CA James Killen Pittsburgh, PA National Petroleum Technology Office (NPTO) Bill Lawson - Director August 3, 2001 29