Development of novel and cost effective corrosion resistant coatings for high temperature geothermal applications

Project Information

Geo-Coat

Grant agreement ID: 764086

DOI

10.3030/764086

Project closed

EC signature date 13 April 2018

Start date 1 February 2018

End date 31 May 2021

Funded under

• SOCIETAL CHALLENGES - Secure, clean and efficient energy

Total cost

€ 4 722 722,50

EU contribution

€ 4 722 722,50

Coordinated by

TWI LIMITED
United Kingdom

Periodic Reporting for period 2 - Geo-Coat (Development of novel and cost effective corrosion resistant coatings for high temperature geothermal applications)

Reporting period: 2019-08-01 to 2021-05-31

Summary of the context and overall objectives of the project

Geo-Coat is an EU-funded collaborative project that has investigated newly developed coatings and Metal Matrix Composite bulk materials for use in high erosion and corrosion environments. Specifically, the project has focused on improving the lifetime of materials used in plants for geothermal energy production by the use of specialized coatings. The Geo-Coat project has worked towards the following main objectives:

a) to capture, rationalise and model the design requirements for a range of geothermal components and environments spanning the European arena, based on the common degradation mechanisms experienced (i.e. corrosion, erosion and scaling);
b) to develop specialised corrosion- and erosion- resistant coatings, based on selected High Entropy Alloys (HEAs) and Ceramic/Metal mixtures (Cermets), to be applied through thermal powder deposition techniques (primarily high velocity oxy-fuel spray HVOF and Laser cladding) specifically tuned to provide the required bond strength, hardness and density for the challenging environments experienced in geothermal applications;
c) to develop improved models for efficient identification of optimal design requirements, modelling the chemistry and physics of corrosive and erosive forces at points along the process flow;
d) to develop a design Decision Support System (DSS) tool to produce reliable lifecycle estimates for performance, operational costs, environmental impact and risk. This tool will be developed with data from models and experimental database.

Following the conclusion of project activities towards the above mentioned objectives, it can be demonstrated that:
1) Geo-Coat has developed coating materials (based on High Entropy Alloys) and methodology combination for each of six types of substrates for application (pipes and casing, valves, turbines, pump impellers and heat exchangers) based on the performance in corrosion and mechanical tests.
2) A Knowledge Based Engineering (KBE) tool as part of implementation of a knowledge-based materials design system and a multi-phase, multi-component and dynamic flow assurance simulator for geothermal energy.
3) Identification of two key flagship projects, commercially viable coatings based on HEAs with exploitation potential.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

A summary of the key results:
• Identification of best coating material (based on High Entropy alloys) and methodology combination for each of six types of substrates for application (pipes and casing, valves, turbines, pump impellers and heat exchangers) based on the performance in corrosion and mechanical tests. See table Geo-Coat coatings (KBE tool, accessed via https://www.geo-coat.eu )
• Development and improvement of multi-phase, multi-component and dynamic flow assurance simulator for geothermal energy. Models for calculation of corrosion, erosion and scaling rates have been developed and implemented. These can be accessed via http://www.flowphys.com/software.html.
• Development and implementation of a knowledge-based materials design system, a Knowledge Based Engineering (KBE) tool. The tool has been designed and populated with the experimental and numerical data generated as part of the project activities. The KBE functionalities can be accessed via ‘KBE tool’ tab on https://www.geo-coat.eu/
• Demonstration of sustainability and lower environmental impact, of laser cladded High Entropy Alloys (HEA2) Geo-Coat coating system for geothermal application via Life Cycle Analysis (LCA). The graphical user interface (GUI) for the LCA tool can be accessed via project website.
• Demonstration of cost and performance optimisation of Geo-Coat materials through Levelised Cost Of Energy(LCOE)models. These studies reveal that the best ranked Geo-Coat system for most applications, LC-HEA2, has potential to reduce costs for geothermal plants.
• The environmental and economic sustainability models (LCA and LCOE) demonstrate the impact of the Geo-Coat technology on the sustainability of geothermal power plants in the European and global scenario. The analysis shows that the innovation brought in by the Geo-Coat technology can make geothermal power more sustainable and affordable.
• Identification of two key flagship projects, commercially viable coatings based on HEAs with exploitation potential:
1) Geo-Coat developed coated carbon steel-LC_HEA with capability to address corrosion issues in surface pipes
2) Geo-Coat developed coated stainless steel –LC_HEA with capability to address erosion and corrosion issues in steam turbines components.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The progress made beyond the state-of-the-art by the project can be summarised in the main following points:
• Development of innovative materials to address materials challenges in geothermal industry. The Geo-Coat project has identified best coating material (based on High Entropy alloys and methodology combination for each of six types of substrates for application (pipes and casing, valves, turbines, pump impellers and heat exchangers) based on the performance in corrosion and mechanical tests. See table on Geo-Coat coatings (KBE tool, accessed via https://www.geo-coat.eu )
• Maintenance and improvement of competitiveness and sustainability of the European geothermal industry. LCA analysis calculations reveals sustainability with lower environmental impact for Geo-Coat developed coatings. See report on Impact of Geo-Coat application on environmental footprint on geothermal power (https://www.geo-coat.eu/outreach)
• Demonstration of reduction in costs via LCOE models for Geo-Coat coatings. See report on Impact of Geo-Coat application on LCOE (https://www.geo-coat.eu/outreach)

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