improving economics of generation 3 csp system components ... summit20… · dan purdy, cara libby...
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© 2019 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m
John Shingledecker, Ph.D.Sr. Program Manger, EPRI Cross Sector TechnologiesDan Purdy, Cara Libby (EPRI)Jack deBarbadillo, Brian Baker (SMC)
Solar Energy Technologies Office (SETO) CSP Program Summit 2019: Oakland, CA – March 19, 2019
Improving Economics of Generation 3 CSP System Components Through Fabrication and Application of High Temperature Nickel-based AlloysDE-EE0008367 (DOE SETO: GEN3 CSP SYSTEMS)
© 2019 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m2
Unanticipated materials challenges in first-of-a-kind applications and demonstrations in power generation
Materials Selection &Environmental Effects
Fabrication challenges
Materials research during Design and continuing through Demonstration reduces overall project risk
Codes, Standards, and Specifications
New Environments New Materials
© 2019 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m3
40
60
80
100
300
500
550 600 650 700 750 800
1100 1200 1300 1400
6
8
10
30
50
70
Stre
ss (M
Pa)
Average Temperature for Rupture in 100,000 hours (oC)
9-12Cr Creep-Strength Enhanced Ferritic Steels (Gr. 91, 92, 122)
Nickel-BasedAlloys
Std. 617CCA617
Inconel 740
Haynes 230
Advanced Austenitic Alloys (Super 304H, 347HFG, NF709, etc.)
Haynes 282
Average Temperature for Rupture in 100,000 hours (oF)
Stre
ss (k
si)
Materials Selection for Gen 3 CSP Goal: >715oCHigh Temperature Strength, Corrosion Resistance, Ductility, Fatigue, etc. = Age-HardenableNickel-Based Alloys will be utilized
°
/740H
§ Current Gen 2 Materials (limited solid solution alloys) are not governed by creep§ Time dependent (creep) behavior must be considered for Gen 3
Increased creep strength
= Higher allowable
stress à
enables thinner walls =
lower cost, more cyclic flexibility
Relative Pipe Thickness at 700°C per ASME Allowable Stress
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Nickel-Based Materials will be needed for all pathways
R&D GAPS
§ Low-cost manufacture
§ Data for Codes and
Standards
§ Fabrication/Welding
Trials
§ Gen 3 Environments
§ Potential damage
interactions: Creep-
fatigue, TMF, etc.
Product Forms:
§ Thin-wall tubing
(receivers, HX)
§ Large diameter pipe
(piping, downcomers)
§ Thin sheets and plates
(HXs)
§ Forgings/castings
(valves)
§ Welded structures
(headers, HX, piping)
© 2019 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m5
Research Goals:
§ Enable reduced Nickel-based alloy cost through– Materials Selection
§ Use of higher-strength alloys to minimize overall material usage§ 740H up to 50% less expensive than 230 for pressure boundary components
– Innovative manufacturing§ Rolled & welded tubing up
to 30% less expensive compared to seamless
§ Challenges (some)– Processing of new alloy grade– Weld structure and performance– Code acceptance
© 2019 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m6
Project Organization & Team – Key Areas of Progress § Task 1: Project Management - EPRI§ Task 2: Collaboration with Gen 3 CSP Teams & Code Interactions – EPRI
– Materials for testing, test conditions, specific design and component requirements – Engage codes and standards to ensure testing will address current deficiencies
§ Task 3: Manufacturing – Special Metals (and partners)– Baseline materials– Welded tube (thin wall)– Welded pipe (Large diameter)– Subcomponent manufacture (bending, welding)– Techno-economics (enable cost estimates and savings for design teams)
§ Task 4: High-Temperature Mechanical Testing & Data Analysis – EPRI– Tensile/Fatigue (time independent)– Creep (time dependent): determination of weld strength reduction– Pressurized creep of welded tubing – Unique to CSP receivers to gain code acceptance
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Tube Processing
Primary Melt + Remelt(VIM + ESR)
Cold roll to sheet coil,
anneal, pickle, and
slit
Cut Multsand Extrude
Cold Draw or Pilger
Anneal, Age, & Pickle
Final Straighten & Test Final Product
Forge to Tube
Round
Hot roll slab ingot to hot
band
Weld Tube
In-line / Off-line Anneal
and Age (if
required)
Test Final Product
Redraw, Anneal,
and Age (if Required)
Test Final
Product
Seamless Tube Production
Welded Tube Production
x4-6
Multiple steps: High energy use, lower yield
Images Courtesy: RathGibson Welded Tube Production
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Successful Welded Tube Production: Inconel® Alloy 740H®
§ Two successful trials:– Passed flattening tests– Passed non-destructive
evaluation requirements (eddy current) – no cracks or discontinuities
Coil Weight kg (lbs) Coil Thickness mm(in) Coil Width mm(in) Produced Tube Diameter mm(in)
ASTM Grain Size
Trial 1 112 (247) 1.65 (0.065) 76.7 (3.02) 25.4 (1) 7.5Trial 2 230 (508) 1.65 (0.065) 157 (6.19) 50.8 (2) 7.5
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Tensile Test Results
§ Yield and Tensile Strength of Mill Annealed Tubes was equivalent to starting coil stock– After aging, all tubes met ASME minimum criteria
§ Tensile Ductility (Elongation)– Mill Annealed tube & aged tubes > Coil– All materials exceed ASME Min Requirement
§ Pressurized room temperature burst test à failures outside of weld
Coil-
MA,
47.0
Coil-
MA+
Age,
30.
3
T1-M
A, 55
.0
T1-M
A, 54
.0
T1-F
A, 5
0.0
T1-FA
, 60.
0
T1-F
A+Ag
e, 34
.0
T1-F
A+Ag
e, 37
.0
T2-M
A, 5
6.0
T2-M
A, 5
6.0
T2-F
A+Ag
e, 32
.5
T2-F
A+Ag
e, 44
.0
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
Elon
gatio
n (%
)
ASME Min. (Aged)
Weld Seam
© 2019 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m10
Key next steps for tubing§ Room temperature properties ≠ high-
temperature behavior§ How will these tubes perform at Gen 3 CSP
Conditions (~700oC)?– Creep Considerations:
§ Processing (heat-treatment)§ Grain Size§ Weldments
– Fatigue
10 100 1000 10000 100000 100000010
100
1000
10000
100000
1000000 Grain Size < 100µm Grain Size > 100µm
Pred
icte
d R
uptu
re L
ife (h
rs) -
eq.
1
Rupture Life (hrs)
Slope = 0.93
+/- factor of 2
Open Symbols = Ongoing Test
Research on alloy 740H shows grain-size effect on long-term creep in typical wrought product with lower-
scatter band (weaker) properties when grain size is finer than ASTM 3.5
After Shingledecker, et al. 2013
EPRI Facility for Pressurized Creep Testing of CSP Thin-walled tubes
© 2019 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m11
Summary
§ Age-hardenable nickel-based alloys
are key candidates for Gen 3 CSP Systems
§ Reduced alloy (product form) cost through advanced manufacturing is needed
to improve overall economics
§ Ongoing research to evaluate Inconel® Alloy 740H®
– Production of: Welded tube, welded pipe, CSP specific processes
– Long-term data: Creep of welds, pressurized creep, low cycle fatigue
– Validate economic assumptions
– Gain code acceptance for new processes
Research to date on welded tubing shows promising results
© 2019 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m12
Together…Shaping the Future of Electricity
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