carbon fiber technology facility - eteba
TRANSCRIPT
Carbon Fiber
Technology Facility
Lee McGetrick
Director, CFTF
Oak Ridge National Laboratory
This briefing does not contain any proprietary,
confidential, or otherwise restricted information
February 23, 2012
Presentation to ETEBA
2 Managed by UT-Battelle for the U.S. Department of Energy
Why Low-cost Carbon Fiber?
Energy
Independence
Jobs
Growth
U.S.
Manufacturing
Large Scale
Commercialization
of Low Cost
Carbon Fibers
• Lightweight
vehicles
• Larger wind
turbines
• Infrastructure
• Power distribution
• Precursors
• Carbon Fiber
• Composites
design, testing,
manufacturing
• Construction
• Manufacturing
• Engineering
• Management
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Potential markets and needs (sample)
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Industry Benefit Applications Drivers ObstaclesCurrent
Market
Potential
Market
Automotive
Mass Reduction:
10% Mass
Savings translates
to 6-7% Fuel
Reduction
Throughout Body
and Chassis
Tensile Modulus;
Tensile Strength
Cost: Need $5-7/lb;
Fiber Format;
Compatibility with
automotive resins,
Processing
Technologies
< 1M lbs/yr> 1B
lbs/year
Wind Energy
Enables Longer
Blade Designs
and More Efficient
Blade Designs
Blades and
Turbine
Components that
must be mounted
on top of the
towers
Tensile Modulus;
Tensile Strength to
reduce blade
deflection
Cost and Fiber
Availability;
Compression
Strength; Fiber
Format &
Manufacturing
Methods
1-10 M
lbs/yr
100M - 1B
lbs/yr
Oil & Gas
Deep Water
Production
Enabler
Pipes, Drill Shafts,
Off-Shore
Structures
Low Mass, High
Strength, High
Stiffness, Corrosion
Resistant
Cost and Fiber
Availability;
Manufacturing
Methods
< 1M lbs/yr10 - 100M
lbs/yr
Electrical Storage
and Transmission
Reliability &
Energy Storage
Low Mass, Zero
CTE transmission
cables; Flywheels
for Energy
Storage
Zero Coeficient of
Thermal Expansion;
Low Mass; High
Strength
Cost; Cable Designs;
High Volume
Manufacturing
Processes; Resin
Compatibility
< 1M lbs/yr10-100M
lbs/yr
Pressure VesselsAffordable Storage
Vessels
Hydrogen Storage,
Natural Gas
Storage
High Strength; Light
Weight
Cost; Consistent
Mechanical Properties< 1M lbs/yr 1-10B lbs/yr
Potential Markets and NeedsMaterials
250+ KSI, 25 MSI Fiber 550 - 750 KSI, 35 - 40 MSI Fiber
20 Managed by UT-Battellefor the U.S. Department of Energy Presentation_name
Industry Benefit Applications Drivers ObstaclesCurrent
Market
Potential
Market
Automotive
Mass Reduction:
10% Mass
Savings translates
to 6-7% Fuel
Reduction
Throughout Body
and Chassis
Tensile Modulus;
Tensile Strength
Cost: Need $5-7/lb;
Fiber Format;
Compatibility with
automotive resins,
Processing
Technologies
< 1M lbs/yr> 1B
lbs/year
Wind Energy
Enables Longer
Blade Designs
and More Efficient
Blade Designs
Blades and
Turbine
Components that
must be mounted
on top of the
towers
Tensile Modulus;
Tensile Strength to
reduce blade
deflection
Cost and Fiber
Availability;
Compression
Strength; Fiber
Format &
Manufacturing
Methods
1-10 M
lbs/yr
100M - 1B
lbs/yr
Oil & Gas
Deep Water
Production
Enabler
Pipes, Drill Shafts,
Off-Shore
Structures
Low Mass, High
Strength, High
Stiffness, Corrosion
Resistant
Cost and Fiber
Availability;
Manufacturing
Methods
< 1M lbs/yr10 - 100M
lbs/yr
Electrical Storage
and Transmission
Reliability &
Energy Storage
Low Mass, Zero
CTE transmission
cables; Flywheels
for Energy
Storage
Zero Coeficient of
Thermal Expansion;
Low Mass; High
Strength
Cost; Cable Designs;
High Volume
Manufacturing
Processes; Resin
Compatibility
< 1M lbs/yr10-100M
lbs/yr
Pressure VesselsAffordable Storage
Vessels
Hydrogen Storage,
Natural Gas
Storage
High Strength; Light
Weight
Cost; Consistent
Mechanical Properties< 1M lbs/yr 1-10B lbs/yr
Potential Markets and NeedsMaterials
250+ KSI, 25 MSI Fiber 550 - 750 KSI, 35 - 40 MSI Fiber
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Carbon Fiber Composites Program “Pillars”
Develop and demonstrate new
carbon fiber precursors
Develop and demonstrate
advanced technologies for
converting conventional and
alternative precursors to carbon
fiber
Advance high-volume composite
design and manufacturing
capabilities
Transition technology to industry
partners Fully-carbonized fiber exiting the
microwave assisted plasma
carbonization unit
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ORNL Carbon Fiber Unique Capabilities
Precursor
evaluation system Pilot CF conversion line Melt spinning
Microwave-assisted plasma carbonization
Mesh Belt Furnace
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Building a bridge from R&D to
deployment and commercialization
Carbon Fiber Technology Facility (CFTF)
roles
Demonstrate low-cost carbon fiber
(LCCF) technology scalability with the last scaling step before full-scale
commercial production
Produce quantities of LCCF needed for large-scale material
and process evaluations and
prototyping
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CFTF is located in the Horizon Center
Oak Ridge National Laboratory
Horizon Center
Leased facility – 10 year lease
42,500 sq. ft.
Offices, labs, mechanical, high bay
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Carbon Fiber Technology Center (CFTF)
Snapshot
Highly instrumented, highly
flexible conventional carbon fiber
line for “any precursor in any
format”
Melt-spun fiber line to produce
precursor fibers
Provisions for additional future
equipment
Produce up to 25 tonnes/year of
carbon fibers
Train and educate workers
Grow partnerships with US
industry
Facility and equipment perspective
Future
Advanced
Conversion
Line Melt Spinner
(in-line)
Conventional
Conversion Line
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Key Milestones
Milestone Status
CD-0 Issued Aug 2009
Equipment RFP’s Issued July 2010
Building lease Awarded Oct 2010
NEPA documentation Approved Jan 2011
CD-1/2/3 Approvals Issued Mar 2011
Groundbreaking Req’d Jun 2011, Actual April 2011
Equipment contracts Awarded Mar 2011
Building “dry-in” Required May-12, Actual Nov-11
Equipment fabricated Required Mar-13, forecast Aug-12
Equipment installed Required June-13, forecast Sept-12
Equipment operational Required Sept-13, forecast Jan-13
CD-4 Required Sept-13, forecast Feb-13
Approach
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Creel/pre-treatment
Melt spinning Oven stack 1 Oven stack 2
Low-temperature furnace
High-temperature furnace
Post-treatment Winding
Scale of operations
Production line length: ~390 ft
Equipment height: ~25 ft
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Dealing with demanding operating
conditions
Equipment requires round-the-clock operation
– 6–12 hours to start up carbon fiber line
– Large demand for electricity during start-up
Minimum practical operating schedule: 3 shifts (24 hours/5 days)
Overarching goals
• Safety and reliability (procedures, training, discipline)
• Strong start with well-planned commissioning
• Early technology demonstration leading to commercialization
• Workforce development encouraging local/regional commercial investment
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CFTF roles and responsibilities
CFTF Director (McGetrick)
Administrative Assistant (1 person)
Feb 2012
Operations Manager (Connie Jackson)
January 2012
Shift Supervisor (1 Person)
June 2012
CFTF Technicians (5 persons)
ORAU Interns
June 2012
CFTF Technicians (6 persons)
ORAU Interns
March 2012 and June 2012
Shift Supervisor (1 Person)
June 2012
CFTF Technicians (5 persons)
ORAU Interns
June 2012
Research Team Programs &
Partnerships Team
Shift Supervisor (1 Person)
June 2012
13 Managed by UT-Battelle for the U.S. Department of Energy
14 Managed by UT-Battelle for the U.S. Department of Energy
Collaboration in Workforce Training
LM003
CARBON FIBER
TECHNOLOGY FACILITY
DOL grant funded
Located at ORNL
Industry focused training
For qualified unemployed or under-employed
Pool of Candidates Technician Internship Program
High-quality STEM learning experience
Collaboration with researchers in field of interest
Growth of S&T talent
Hands-on experience on complex CF line
Learn S&T underpinning ORNL research
Develop skills directly transferrable to industry
Longer term Vision: Develop workforce
training system for future carbon fiber
manufacturing partners
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We Have Developed a Three-
Step Commercialization Strategy
1.Establish the Oak Ridge Carbon Fiber Composites Consortium
2. Identify and Secure Key Alliance Partners for Raw Materials and Fiber Production
3.Develop new CF composites applications with numerous partners
www.cfcomposites.org
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Textile PAN
Polyolefin
Lignin
RAW
MATERIALS
APPLICATIONS COMPOSITE
FORMULATION
PRECURSOR
FIBERS
Resin
Design
Matrix
Formulation
Pre-pregging
Weaving
Pre-forming
Molding
Filament
Winding
Curing
Etc.
End Users provide ORNL with cost & performance specs
Melt
Spinning
Ad
va
nce
d C
on
ve
rsio
n P
roce
sse
s
Plasma Surface
Treatment
Atmospheric Pressure Plasma
Microwave Assisted Plasma
CONVERSION
Highly Flexible Thermal Process
Solution
Spinning PAN
Testing
And
Prototyping
TESTING &
PROTOTYPING
STRUCTURAL
Vehicles
Wind
Defense
Aerospace
Oil & Gas
Infrastructure
NON STRUCTURAL
Flame Retardant
Energy Storage
Filtration
Thermal Mgmt.
Electrodes
Engaging the Composites Value Chain to
Develop/Validate Low-Cost CF Composites Matls
& Mfg Technologies & Grow the Supply Base
CFTF in dashed area
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Workforce
Development
Job Creation
Building a cluster around carbon fiber
ORNL
Research
CFTF
Pilot Plant
Carbon Fiber
Commercialization
Plan
Industry
Collaboration
Dept. of Labor
Grants:
Multiple companies are
considering locating CF
composites mfg facilities
in east TN
$2.86M for AMTEC
$1.6M DOL grant for
ACE Accelerator
$1.2M for STEM
certificate programs