DOE OSTI2017
This project successfully demonstrated novel wireless microwave acoustic temperature and pressure sensors that can be embedded into equipment and structures located in fossil fuel power plant environments to monitor the condition of components such as steam headers, re-heat lines, water walls, burner tubes, and power turbines. The wireless microwave acoustic sensor technology researched and developed through a collaborative partnership between the University of Maine and Environetix Technologies Corporation can provide a revolutionary impact in the power industry since it is anticipated that the wireless sensors will deliver reliable real-time sensing information in harsh power plant conditions that involve temperatures up to 1100oC and pressures up to 750 psi. The work involved the research and development of novel high temperature harsh environment thin film electrodes, piezoelectric smart microwave acoustic sensing elements, sensor encapsulation materials that were engineered to function over long times up to 1100oC, and a radio-frequency (RF) wireless interrogation electronics unit that are located both inside and outside the high temperature harsh environment. The UMaine / Environetix team have interacted with diverse power plant facilities, and identified as a testbed a local power generation facility, which burns municipal solid waste (MSW), the Penobscot Energy Recovery Company (PERC), Orrington, Maine. In this facility Environetix / UMaine successfully implemented and tested multiple wireless temperature sensor systems within the harsh-environment of the economizer chamber and at the boiler tubes, transferring the developed technology to the power plant environment to perform real-time sensor monitoring experiments under typical operating conditions, as initially targeted in the project. The wireless microwave acoustic sensor technology developed under this project for power plant applications offers several significant advantages including wireless, battery-free, maintenance-free operation, and operation in the harsh-environment of power plant equipment up to about 1100 oC. Their small size and configuration allows flexible sensor placement and embedding of multiple sensor arrays into a variety of components within power systems that can be interrogated by a single RF unit. The outcomes of this project and technological transfer respond to a DOE analysis need, which indicated that if one percent efficiency in coal burning is achieved, an additional 2 gigawatt-hours of energy per year is generated and the resulting coal cost savings is $300 million per year, also accompanied by a reduction of more than 10 million metric tons of CO2 per year emitted into the atmosphere. Therefore, the developed harsh environment wireless microwave acoustic sensor technology and the technological transfer achievements that resulted from the execution of this project have significant impact for power plant equipment and systems and are well-positioned to contribute to the cost reduction in power generation, the increase in power plant efficiency, the improvement in maintenance, the reduction in down-time, and the decrease in environmental pollution. The technology is also in a position to be extended to address other types of high-temperature harsh-environment power plant and energy sector sensing needs.
20 FOSSIL-FUELED POWER PLANTS↗