New Environmental/Thermal Barrier Coatings Suitable for Hydrogen Doped Gas Turbines

doi:10.12096/j.2096-4528.pgt.24120

Abstract

Abstract:

Objectives With the implementation of the national “Dual Carbon Strategy” (carbon peak and carbon neutrality), it is anticipated that the existing coating structures may not meet the requirements of future gas turbine thermal protection coatings. The concept of a new type of environmental/thermal barrier coating (E/TBC) structure with high temperature corrosion resistance has been proposed to meet the demand for thermal protection coatings in hybrid hydrogen combustion engines. Methods The development history and research status of thermal barrier coating (TBC), environmental barrier coating (EBC), thermal/environmental barrier coating (T/EBC) and thermal and environmental barrier coating (TEBC) were reviewed and analyzed from the perspective of thermal protection coating materials and coating structures. Moreover, the gap between the above coating structures and the requirementsof thermal protection coating for mixed hydrogen gas turbines was investigated. Results It is reasonable to superimpose the function of EBC onto the thermal protection coating of current mixed hydrogen gas turbines, thereby forming a new type of E/TBC structure with high temperature corrosion resistance on the high-temperature alloy substrate. Conclusions Through the preliminary test, it is proved that the new E/TBC structure is suitable for the thermal protection coating requirements of mixed hydrogen gas turbine against high temperature water oxygen corrosion, and it is pointed out that the theory and application research of this new E/TBC thermal protection coating should be vigorously carried out.

Key words: gas turbine, hydrogen fuel, hydrogen doped gas turbines, thermal barrier coatings (TBC), corrosion prevention, structural design of coatings

CLC Number:

TK 47

You WANG, Xiaodong ZHANG, Pei HAO, Xu HAN, Luwei DENG, Guoqiang LI, Fushuang WEI, Xiang JI. New Environmental/Thermal Barrier Coatings Suitable for Hydrogen Doped Gas Turbines[J]. Power Generation Technology, 2024, 45(5): 868-877.

Figures/Tables 9

Fig. 1 A typical YSZ thermal barrier coating structure

Fig. 2 Cross-sectional morphology of double ceramic layer LCZ/8YSZ coatings

Fig. 3 A typical EBC structure

Fig. 4 Schematic diagram of two thermal protective coatings

Fig. 5 Schematic diagram of the relationship between water oxygen corrosion rate and thermal expansion coefficient of several ceramic materials at 1450 ℃

Fig. 6 Macroscopic photos of several ceramic materials before and after water oxygen corrosion

Fig. 7 Design diagram of novel E/TBC structure

Tab. 1 Thermophysical properties of several potential E/TBC coating materials

材料	热导率/[W/(m⋅K)]	热膨胀系数/(×10^-6⋅K^-1)
Ni基高温合金^[34]	—	14~16
8YSZ^[34]	2.12(1 000 ℃)	9~11
Gd₂Zr₂O₇^[9]	1.91	7.91~9.18
5RE₂Zr₂O₇^[35]	0.7~1.5(300~1 300 ℃)	10~11(500~1 400 ℃)
Yb₂SiO₅涂层^[36]	0.68~1.13(200~1 400 ℃)	6.9~7.6(200~1 400 ℃)
Yb₂Si₂O₇涂层^[36]	0.78~1.37(200~1 400 ℃)	3.3~5.2(200~1 400 ℃)
(5RE_0.2)₂Si₂O₇^[37]	1.146(1 100 ℃)	1.96~3.95(300~1 300 ℃)

Fig. 8 Cross-sectional morphology and energy spectrum composition distribution of a novel E/TBC

References 38

1	马勤勇，钱白云，董利江，等．掺氢比例对氢混天然气燃气轮机运行特性影响的研究[J]．热能动力工程，2022，37(9)：41-49．
	MA Q Y， QIAN B Y， DONG L J，et al ．Research on the influence of hydrogen blending ratio on the operation characteristics of hydrogen blended fuel gas turbine[J]．Journal of Engineering for Thermal Energy and Power，2022，37(9)：41-49．
2	赵昊，楼国锋，刘少鹏，等．掺氢对天然气燃烧室燃烧及排放特性影响[J]．科学技术与工程，2024，24(1)：223-229．
	ZHAO H， LOU G F， LIU S P，et al ．Effect of hydrogen mixing on the combustion and emission characteristics of natural gas combustion chamber[J]．Science Technology and Engineering，2024，24(1)：223-229．
3	杨盼．铈锆酸镧基高温热障涂层的制备与性能研究[D]．兰州：兰州大学，2022．
	YANG P ．Study on preparation and properties of La₂(Zr_0.75Ce₀ .₂₅ )2O7-based high-temperature thermal barrier coatings[D]．Lanzhou：Lanzhou University，2022．
4	PEREPEZKO J H ．The hotter the engine，the better[J]．Science，2009，326(5956)：1068-1069． doi:10.1126/science.1179327
5	JAMALI H， MOZAFARINIA R， SHOJA-RAZAVI R，et al ．Comparison of hot corrosion behaviors of plasma-sprayed nanostructured and conventional YSZ thermal barrier coatings exposure to molten vanadium pentoxide and sodium sulfate[J]．Journal of the European Ceramic Society，2014，34(2)：485-492． doi:10.1016/j.jeurceramsoc.2013.08.006
6	SAEEDI B， SABOUR A， KHODDAMI A M ．Study of microstructure and thermal shock behavior of two types of thermal barrier coatings[J]．Materials and Corrosion，2009，60(9)：695-703． doi:10.1002/maco.200905111
7	LEONI M， JONES R L， SCARDI P ．Phase stability of scandia-yttria-stabilized zirconia TBCs[J]．Surface and Coatings Technology，1998，108：107-113． doi:10.1016/s0257-8972(98)00617-3
8	PADTURE N P， GELL M， JORDAN E H ．Thermal barrier coatings for gas-turbine engine applications[J]．Science，2002，296(5566)：280-284． doi:10.1126/science.1068609
9	WEI Z Y， MENG G H， CHEN L，et al ．Progress in ceramic materials and structure design toward advanced thermal barrier coatings[J]．Journal of Advanced Ceramics，2022，11(7)：985-1068． doi:10.1007/s40145-022-0581-7
10	BAI Y， HAN Z H， LI H Q，et al ．High performance nanostructured ZrO₂ based thermal barrier coatings deposited by high efficiency supersonic plasma spraying[J]．Applied Surface Science，2011，257(16)：7210-7216． doi:10.1016/j.apsusc.2011.03.092
11	魏秋利，郭洪波，宫声凯．电子束物理气相沉积Nd₂O₃和Yb₂O₃共掺杂的YSZ热障涂层研究[J]．航空学报，2007，28(S1)：163-167．
	WEI Q L， GUO H B， GONG S K，et al ．Study on YSZ thermal barrier coatings co-doped with Nd₂O₃ and Yb₂O₃ by electron beam physical vapor deposition[J]．Acta Aeronautica ET Astronautica Sinica，2007，28(S1)：163-167．
12	王铀，刘勇，周飞飞，等．热喷涂纳米结构热障涂层的高温长效服役性能研究进展[J]．航空制造技术，2019，62(21)：14-21．
	WANG Y， LIU Y， ZHOU F F，et al ．Research progress on high temperature and long service performance of thermal sprayed nanostructured thermal barrier coatings[J]．Aeronautical Manufacturing Technology，2019，62(21)：14-21．
13	周飞飞，刘敏，邓春明，等．等离子喷涂用纳米结构T′ 相8YSZ球形喂料及应用展望[J]．表面技术，2019，48(1)：37-42． doi:10.3390/nano10010038
	ZHOU F F， LIU M， DENG C M，et al ．Nanostructured T' phase 8YSZ spherical feedstocks for plasma spraying and application prospects[J]．Surface Technology，2019，48(1)：37-42． doi:10.3390/nano10010038
14	王铀，王亮，刘赛月，等．热喷涂纳米结构La₂Zr₂O₇(LZ)/8YSZ双陶瓷热障涂层[J]．中国表面工程，2016，29(1)：16-24．
	WANG Y， WANG L， LIU S Y，et al ．Nanostructured La₂Zr₂O₇(LZ)/8YSZ double ceramic layer thermal barrier coatings fabricated by thermal spraying[J]．China Surface Engineering，2016，29(1)：16-24．
15	ZHOU F， WANG Y， CHEN W，et al ．Fabrication and characterization of novel powder reconstitution derived nanostructured spherical La₂(Zr_0.75Ce_0.25)₂O₇ feedstock for plasma spraying[J]．Applied Surface Science，2018，459：468-476． doi:10.1016/j.apsusc.2018.08.040
16	ROST C M， SACHET E， BORMAN T，et al ．Entropy-stabilized oxides[J]．Nature Communications，2015，6：8485． doi:10.1038/ncomms9485
17	CHEN K， PEI X， TANG L，et al ．A five-component entropy-stabilized fluorite oxide[J]．Journal of the European Ceramic Society，2018，38(11)：4161-4164． doi:10.1016/j.jeurceramsoc.2018.04.063
18	顾俊峰，邹冀，张帆，等．高熵陶瓷材料研究进展[J]．中国材料进展，2019，38(9)：855-865．
	GU J F， ZOU J， ZHANG F，et al ．Recent progress in high-entropy ceramic materials[J]．Materials China，2019，38(9)：855-865．
19	颜邓伊，许文举，吉利，等．高熵陶瓷材料的研究进展[J]．材料保护，2023，56(8)：35-49．
	YAN D Y， XU W J， JI L，et al ．Research progress of high-entropy ceramic materials[J]．Materials Protection，2023，56(8)：35-49．
20	VAN ROODE M ．Ceramic gas turbine development：need for a 10 year plan[J]．Journal of Engineering for Gas Turbines and Power，2010，132(1)：011301． doi:10.1115/1.3124669
21	PADTURE N P ．Advanced structural ceramics in aerospace propulsion[J]．Nature Materials，2016，15：804-809． doi:10.1038/nmat4687
22	NASIRI N AL， PATRA N， NI N，et al ．Oxidation behaviour of SiC/SiC ceramic matrix composites in air[J]．Journal of the European Ceramic Society，2016，36(14)：3293-3302． doi:10.1016/j.jeurceramsoc.2016.05.051
23	TEJERO-MARTIN D， BENNETT C， HUSSAIN T ．A review on environmental barrier coatings：history，current state of the art and future developments[J]．Journal of the European Ceramic Society，2021，41(3)：1747-1768． doi:10.1016/j.jeurceramsoc.2020.10.057
24	POERSCHKE D L， HASS D D， EUSTIS S，et al ．Stability and CMAS resistance of ytterbium-silicate/hafnate EBCs/TBC for SiC composites[J]．Journal of the American Ceramic Society，2015，98(1)：278-286． doi:10.1111/jace.13262
25	XU J， SARIN V K， DIXIT S，et al ．Stability of interfaces in hybrid EBC/TBC coatings for Si-based ceramics in corrosive environments[J]．International Journal of Refractory Metals and Hard Materials，2015，49：339-349． doi:10.1016/j.ijrmhm.2014.08.013
26	TURCER L R， PADTURE N P ．Towards multifunctional thermal environmental barrier coatings (TEBCs) based on rare-earth pyrosilicate solid-solution ceramics[J]．Scripta Materialia，2018，154：111-117． doi:10.1016/j.scriptamat.2018.05.032
27	MAIER N， RIXECKER G， NICKEL K G ．Formation and stability of Gd，Y，Yb and Lu disilicates and their solid solutions[J]．Journal of Solid State Chemistry，2006，179(6)：1630-1635． doi:10.1016/j.jssc.2006.02.019
28	林俐，郑馨姚，周龙文．基于燃氢燃气轮机的风光火储多能互补优化调度[J]．电网技术，2022，46(8)：3007-3022．
	LIN L， ZHENG X Y， ZHOU L W ．Wind-PV-thermal-storage multi-energy complementary optimal dispatching based on hydrogen gas turbine[J]．Power System Technology，2022，46(8)：3007-3022．
29	李祥晟，郭菡，郁鸿飞，等．掺氢对燃气轮机燃烧室燃烧和排放性能的影响研究[J]．西安交通大学学报，2022，56(6)：9-16．
	LI X S， GUO H， YU H F，et al ．Study on combustion and emission performance of hydrogen fuel gas turbine combustor[J]．Journal of Xi’an Jiaotong University，2022，56(6)：9-16．
30	秦锋，秦亚迪，单彤文．碳中和背景下氢燃料燃气轮机技术现状及发展前景[J]．广东电力，2021，34(10)：10-17．
	QIN F， QIN Y D， SHAN T W ．Technology status and development prospects of hydrogen fuel gas turbine under the background of carbon neutral[J]．Guangdong Electric Power，2021，34(10)：10-17．
31	KANG N L， ZHU D， LIMA R S ．Perspectives on environmental barrier coatings (EBCs) manufactured via air plasma spray (APS) on ceramic matrix composites (CMCs)：a tutorial paper[J]．Journal of Thermal Spray Technology，2021，30(1)：40-58． doi:10.1007/s11666-021-01168-0
32	WANG Y， LIU J ．First-principles investigation on the corrosion resistance of rare earth disilicates in water vapor[J]．Journal of the European Ceramic Society，2009，29(11)：2163-2167． doi:10.1016/j.jeurceramsoc.2009.02.005
33	路明辉，冯志海，周延春．硅基非氧化物陶瓷表面环境障涂层的研究进展[J]．陶瓷学报，2015，36(2)：107-118．
	LU M H， FENG Z H， ZHOU Y C ．Recent research progress on environmental barrier coatings for non-oxide ceramics[J]．Journal of Ceramics，2015，36(2)：107-118．
34	张博，李广荣，徐彤，等．长寿命热障涂层的剥落机理及抗剥落结构设计[J]．航空材料学报，2022，42(1)：1-14．
	ZHANG B， LI G R， XU T，et al ．Failure mechanism and cracking-resistant design of thermal barrier coatings with long life span[J]．Journal of Aeronautical Materials，2022，42(1)：1-14．
35	REN K， WANG Q， SHAO G，et al ．Multicomponent high-entropy zirconates with comprehensive properties for advanced thermal barrier coating[J]．Scripta Materialia，2020，178：382-386． doi:10.1016/j.scriptamat.2019.12.006
36	ZHONG X， NIU Y， LI H，et al ．Comparative study on high-temperature performance and thermal shock behavior of plasma-sprayed Yb₂SiO₅ and Yb₂Si₂O₇ coatings[J]．Surface and Coatings Technology，2018，349：636-646． doi:10.1016/j.surfcoat.2018.06.056
37	WEI F， ZHANG D， GONG X，et al ．A systematic analysis of the calcium-magnesium-aluminosilicate corrosion behavior of high-entropy (5Re_0.2)₂Si₂O₇ materials[J]．Corrosion Science，2023，219：111221． doi:10.1016/j.corsci.2023.111221
38	王铀，张晓东，郝佩，等．一种氢燃料燃气轮机用纳米结构热防护涂层及其制备方法：CN118326307A[P]．2024-07-12．
	WANG Y， ZHANG X D， HAO P，et al ．A nanostructured thermal protection coating and preparation method for hydrogen fuel gas turbine[P]．2024-07-12．

[1]	Chao ZHANG, Haichuan ZHANG, Jinglun FU, Zhiting TONG, Junqiang ZHU. Research Progress on Film Cooling Fed by Crossflow Ribbed Passage of Gas Turbine Blades [J]. Power Generation Technology, 2024, 45(5): 781-792.
[2]	Jing REN, Xueying LI. Research Status and Development Trend of Rotating Internal Cooling Channel in Gas Turbine Blade [J]. Power Generation Technology, 2024, 45(5): 793-801.
[3]	Qiuru ZUO, Yong LUAN, Yihui XIONG, Yu RAO. Review of Research on Swirl Cooling Technology of Gas Turbine Blades [J]. Power Generation Technology, 2024, 45(5): 802-813.
[4]	Ming CHENG, Yangyang XIANG, Guangwei YANG, Qiang ZHOU, Jun LI. Analysis of Application Status and Key Issues of Hydrogen Blending Power Generation Technology for H-class Gas Turbine [J]. Power Generation Technology, 2024, 45(5): 814-825.
[5]	Wenchang YU, Yang DING, Xuyang WANG, Yonggang CHEN, Ke BI, Zhigang LIU, Xingang SHANGGUAN, Daohuo HUANG, Feng XIAO, Guang LI, Guang WANG, Hanzhang KE, Yasong SUN, Xin WANG. Optimization and Evaluation of Cooling Structure of Stage 1 Blade of Heavy-Duty Gas Turbine [J]. Power Generation Technology, 2024, 45(5): 838-846.
[6]	Yuheng SHI, Runze LIU, Shilong LI, Dongxiang JIANG. SGT5-4000F Gas Turbine Improvement and Upgrade Measures Analysis [J]. Power Generation Technology, 2024, 45(5): 847-855.
[7]	Mingyang ZHAO, Linlin YIN, Wentao WEI, Yun CHEN, Richen LIU, Jun LI. Impact of Falling Blocks of High Pressure Turbine Rotor Blades With Squealer Tip on the Aerodynamic Performance and Vibration Characteristics [J]. Power Generation Technology, 2024, 45(5): 856-867.
[8]	Fuyuan FENG, Tongyu LI, Bo LI, Heng CHEN, Peiyuan PAN, Gang XU, Tong LIU. Performance Analysis of Combined Medical Waste-Waste Tire Resource Utilization System Based on Gasification and Pyrolysis [J]. Power Generation Technology, 2024, 45(4): 611-621.
[9]	Zeyang CUI, Xiangling KONG, Jinglun FU, Jiajun SHI. An Image-Based Turbine Blade Parameter Inspection Method [J]. Power Generation Technology, 2024, 45(1): 106-112.
[10]	Yang YANG, Yaoqiang LI, Jinqi ZHANG. Design of Dome Structure for A Lean Premixed Swirled Combustor of Gas Turbine Based on the Numerical Method [J]. Power Generation Technology, 2023, 44(5): 712-721.
[11]	Yang YANG, Desan GUO, Yaoqiang LI, Jinqi ZHANG. Design of Lean Premixed Multi-Swirl Combustor Dome Structure for Gas Turbine [J]. Power Generation Technology, 2023, 44(2): 183-192.
[12]	Hongyi ZHANG, Litao QU. Research and Application of Numerical Simulation for Selective Catalytic Reduction Denitration of 9F Gas Turbine [J]. Power Generation Technology, 2023, 44(1): 78-84.
[13]	Jiangang HAO, Wenming GONG, Yang DING, Danwei ZHENG, Yong LIU. Analysis on Combustion Instability Characteristics of Model Swirl Combustor With Gas Fuel [J]. Power Generation Technology, 2022, 43(6): 927-934.
[14]	Yunfeng JIN, Chao LIU, Gaofeng DENG, Yunlong GUAN, Jiangang HAO, Haizhou HUANG, Dongxiang JIANG. Cost Benefit Analysis for Maintenance Strategy of Gas Turbine Inlet Filtration System [J]. Power Generation Technology, 2022, 43(1): 119-125.
[15]	Mingliang BAI, Dongxue ZHANG, Jinfu LIU, Jiao LIU, Daren YU. Anomaly Detection of Gas Turbine Hot Components Based on Deep Autoencoder and Support Vector Data Description [J]. Power Generation Technology, 2021, 42(4): 422-430.