Advanced Ceramic Materials and Packaging Technologies for Realizing Sensors Operable up to 1800 Celsius in Advanced Energy Generation Systems

There is a need for condition monitoring sensors capable of functioning in the harshest environments associated with advanced power systems that will: directly contribute to improving system control, protect capital equipment investment, and promote safety through prevention of catastrophic equipment failure. These harsh environments include extreme temperatures (800-1800C), high pressures (500-1000 psi), and highly corrosive/erosive exposures. Consequently, it has been a challenge to develop sensors that can endure these harsh environments. Sporian Microsystems has previously developed a high-temperature sensor technology for power system applications based on the combination of high-temperature packaging and silicon carbide nitride (SiCN) based polymer derived ceramics (PDCs), which possess excellent mechanical and electric properties at high temperatures up to 1800C. Sporian proposes to develop alternative precursors, processes, packaging materials, and methods to extend the current operational capabilities of Sporians sensor technology beyond current limits to 1600-1800C. Sporian worked with energy system OEMs to identify and guide applications/implementations for the technology. Innovative materials synthesis, micro-fabrication approaches, and new packaging materials/methods were developed and evaluated. Sporian refined and optimized ceramic sensor material formulations and micro-fabrication processes, including extensive mechanical property characterization and thermal stability testing, and increased the key materials thermal stability limit to 1600C. Ultra-high-temperature packaging and sensor design were developed, implemented, and lab tested up to 1800C. Sporian prototype sensors and packaging hardware has been were successfully demonstrated in the DOE NETL Aerothermal Test Rig combustion environment (1100C, 30 hours), and additional testing (performance and reliability) for the remaining Phase II period is planned. Phase IIA will focus on further maturing the innovative ultra-high temperature sensor technology beyond current limitations through: improving polymer synthesis and handling processes to increase the stability limits from 1600oC to 1800oC; advancing key aspects of the Phase II packaging, emphasizing long term reliability; rigorous testing of full prototype systems (hardware and electronics), emphasizing reliability assessment/tests to promote post Phase IIA transition oriented activities; and full prototype system testing and demonstration within turbine OEM test systems. Advanced sensing systems will be essential to achieving the cost and performance targets in advanced energy and power generation systems as well as aerospace propulsion systems. There is a significant market opportunity and the sensor technology could benefit coal gasifiers, gas turbines, advanced coal combustion systems, oxy-fuel combustion systems, and other critical or high maintenance equipment. Generating asset OEMs, utilities, and end users will all stand to benefit from these high-efficiency, low emissions power systems.