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Embedded Gas and Temperature Sensors for Extreme Environments

National Energy Technology Laboratory

Contact NETL About This Technology

Technology Marketing Summary

Research is active on optical sensors integrated with advanced sensing materials for high temperature embedded gas sensing applications. A portfolio of patented and patent pending technologies are available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory (NETL). Organizations or individuals with capabilities in optical sensor packaging for harsh environment and high temperature applications are encouraged to contact NETL to explore potential collaborative opportunities.

Description

Innovative process control systems for improved efficiency and lower emissions in current and future fossil fuel-based power systems and related applications requires the development of durable embedded sensor technology that can operate at higher temperatures and in harsh conditions. Currently available sensor technologies have limitations including functional temperature ranges, durability, and cost. There is a clear need for remote gas sensors that are capable of operating at temperatures approaching 1,000° C.

NETL has developed a portfolio of advanced optical sensor materials that address process monitoring in harsh environments and at temperatures approaching 1,000° C. These inventions integrate metal oxide-based functional sensor layers with optical waveguide-based platforms for gas composition analysis and other process variables. The novel materials and simplified fabrication processes are anticipated to provide for embedded sensors demonstrating long-term durability and functionality.

 

 

Benefits
  • A broad portfolio of technologies for high temperature optical gas sensing involving metal oxide-based nanoparticles and films
  • Nanocomposite materials demonstrating stability and durability in corrosive environments at temperatures approaching 900?1,000 °C
  • Materials provide sensing responses across a broad range of wavelengths, which can potentially be used to construct multisensory arrays with enhanced sensing capabilities
  • Technologies allow for embedded optical sensors with remote monitoring capabilities
  • Novel materials that reduce fabrication complexity and cost of sensor devices
Applications and Industries
  • High temperature gas sensing for process monitoring and control in coal gasification, solid oxide fuel cells, gas turbines, boilers, and oxy-fuel combustion systems
  • Other areas where high temperature gas sensing is required, including nuclear power generation, aerospace, and industrial manufacturing process control 
More Information

U.S. Patent No. 8,411,275, issued April 2, 2013, titled "Nanocomposite Thin Films for High Temperature Optical Gas Sensing of Hydrogen."

Inventors: Paul R. Ohodnicki, Jr. and Thomas D. Brown

U.S. Patent No. 8,638,440, issued January 24, 2014, titled "Plasmonic Transparent Conducting Metal Oxide Nanoparticles and Nanoparticle Films for Optical Sensing Applications."

Inventors: Paul R. Ohodnicki, Jr., Congjun Wang, and Mark Andio

U.S. Patent No. 8,741,657, issued June 3, 2014, titled "Nanocomposite Thin Films for Optical Gas Sensing."

Inventors: Paul R. Ohodnicki, Jr. and Thomas D. Brown

U.S. Patent No. 8,836,945, issued September 16, 2014, titled "Electrically Conducting Metal Oxide Nanoparticles and Films for Optical Sensing Applications." 

Inventors: Paul R. Ohodnicki, Jr., Congjun Wang, and Mark Andio

U.S. Patent No. 9,568,377 issued February 14, 2017, titled "Nanocomposite Thin Films for Optical Temperature Sensing."

Inventors: Paul R. Ohodnicki, Jr., Thomas D. Brown, Christopher Matranga, and Michael P. Buric

U.S. Non-Provisional Patent Application 14/335,149 filed July 18, 2014, titled "Electronically Conductive Perovskite-Based Nanoparticles and Films for Optical Sensing Applications."

Inventors: Paul R. Ohodnicki and Andrew Shultz

U.S. Provisional Patent Application No. 62/065,964 filed October 20, 2014, titled “Nobel and Precious Metal Nanoparticle-Based Sensor Layers for Selective H2 Sensing.”

Inventors: Paul Ohodnicki Jr., John P. Baltrus, and Thomas Brown

U.S. Non-Provisional Patent No. 14/695,078 filed April 24, 2015, titled “Plasmonic-Based pH Sensors in Aqueous Environments.”

Inventors: Paul Ohodnicki, Jr., Barbara Kutchko, Congjun Wang, and Thomas Brown

U.S. Non-Provisional Patent No. 15/160,389 filed May 20, 2016, titled "Thermally Emissive Materials for Chemical Spectroscopy Analysis."

Inventors: Paul Ohodnicki, Jr. and Zsolt Poole

Patents and Patent Applications
ID Number
Title and Abstract
Primary Lab
Date
Patent 9,568,377
Patent
9,568,377
Nanocomposite thin films for optical temperature sensing
The disclosure relates to an optical method for temperature sensing utilizing a temperature sensing material. In an embodiment the gas stream, liquid, or solid has a temperature greater than about 500.degree. C. The temperature sensing material is comprised of metallic nanoparticles dispersed in a dielectric matrix. The metallic nanoparticles have an electronic conductivity greater than approximately 10.sup.-1 S/cm at the temperature of the temperature sensing material. The dielectric matrix has an electronic conductivity at least two orders of magnitude less than the dispersed metallic nanoparticles at the temperature of the temperature sensing material. In some embodiments, the chemical composition of a gas stream or liquid is simultaneously monitored by optical signal shifts through multiple or broadband wavelength interrogation approaches. In some embodiments, the dielectric matrix provides additional functionality due to a temperature dependent band-edge, an optimized chemical sensing response, or an optimized refractive index of the temperature sensing material for integration with optical waveguides.
U.S. Department of Energy 02/14/2017
Issued
Patent 9,019,502
Patent
9,019,502
Electronically conductive perovskite-based oxide nanoparticles and films for optical sensing applications
The disclosure relates to a method of detecting a change in a chemical composition by contacting a electronically conducting perovskite-based metal oxide material with a monitored stream, illuminating the electronically conducting perovskite-based metal oxide with incident light, collecting exiting light, monitoring an optical signal based on a comparison of the incident light and the exiting light, and detecting a shift in the optical signal. The electronically conducting perovskite-based metal oxide has a perovskite-based crystal structure and an electronic conductivity of at least 10.sup.-1 S/cm, where parameters are specified at the gas stream temperature. The electronically conducting perovskite-based metal oxide has an empirical formula A.sub.xB.sub.yO.sub.3-.delta., where A is at least a first element at the A-site, B is at least a second element at the B-site, and where 0.8<x<1.2, 0.8<y<1.2. Exemplary electronically conducting perovskite-based oxides include but are not limited to La.sub.1-xSr.sub.xCoO.sub.3, La.sub.1-xSr.sub.xMnO.sub.3, LaCrO.sub.3, LaNiO.sub.3, La.sub.1-xSr.sub.xMn.sub.1-yCr.sub.yO.sub.3, SrFeO.sub.3, SrVO.sub.3, La-doped SrTiO.sub.3, Nb-doped SrTiO.sub.3, and SrTiO.sub.3-.delta..
U.S. Department of Energy 04/28/2015
Issued
Patent 8,638,440
Patent
8,638,440
Plasmonic transparent conducting metal oxide nanoparticles and films for optical sensing applications
The disclosure relates to a method of detecting a change in a chemical composition by contacting a doped oxide material with a monitored stream, illuminating the doped oxide material with incident light, collecting exiting light, monitoring an optical signal based on a comparison of the incident light and the exiting light, and detecting a shift in the optical signal. The doped metal oxide has a carrier concentration of at least 10.sup.18/cm.sup.3, a bandgap of at least 2 eV, and an electronic conductivity of at least 10.sup.1 S/cm, where parameters are specified at a temperature of 25.degree. C. The optical response of the doped oxide materials results from the high carrier concentration of the doped metal oxide, and the resulting impact of changing gas atmospheres on that relatively high carrier concentration. These changes in effective carrier densities of conducting metal oxide nanoparticles are postulated to be responsible for the change in measured optical absorption associated with free carriers. Exemplary doped metal oxides include but are not limited to Al-doped ZnO, Sn-doped In.sub.2O.sub.3, Nb-doped TiO.sub.2, and F-doped SnO.sub.2.
U.S. Department of Energy 01/28/2014
Issued
Patent 8,836,945
Patent
8,836,945
Electronically conducting metal oxide nanoparticles and films for optical sensing applications
The disclosure relates to a method of detecting a change in a chemical composition by contacting a conducting oxide material with a monitored stream, illuminating the conducting oxide material with incident light, collecting exiting light, monitoring an optical signal based on a comparison of the incident light and the exiting light, and detecting a shift in the optical signal. The conducting metal oxide has a carrier concentration of at least 10.sup.17/cm.sup.3, a bandgap of at least 2 eV, and an electronic conductivity of at least 10.sup.-1 S/cm, where parameters are specified at the gas stream temperature. The optical response of the conducting oxide materials is proposed to result from the high carrier concentration and electronic conductivity of the conducting metal oxide, and the resulting impact of changing gas atmospheres on that relatively high carrier concentration and electronic conductivity. These changes in effective carrier densities and electronic conductivity of conducting metal oxide films and nanoparticles are postulated to be responsible for the change in measured optical absorption associated with free carriers. Exemplary conducting metal oxides include but are not limited to Al-doped ZnO, Sn-doped In.sub.2O.sub.3, Nb-doped TiO.sub.2, and F-doped SnO.sub.2.
U.S. Department of Energy 09/16/2014
Issued
Patent 8,411,275
Patent
8,411,275
Nanocomposite thin films for high temperature optical gas sensing of hydrogen
The disclosure relates to a plasmon resonance-based method for H.sub.2 sensing in a gas stream at temperatures greater than about 500.degree. C. utilizing a hydrogen sensing material. The hydrogen sensing material is comprised of gold nanoparticles having an average nanoparticle diameter of less than about 100 nanometers dispersed in an inert matrix having a bandgap greater than or equal to 5 eV, and an oxygen ion conductivity less than approximately 10.sup.-7 S/cm at a temperature of 700.degree. C. Exemplary inert matrix materials include SiO.sub.2, Al.sub.2O.sub.3, and Si.sub.3N.sub.4 as well as modifications to modify the effective refractive indices through combinations and/or doping of such materials. At high temperatures, blue shift of the plasmon resonance optical absorption peak indicates the presence of H.sub.2. The method disclosed offers significant advantage over active and reducible matrix materials typically utilized, such as yttria-stabilized zirconia (YSZ) or TiO.sub.2.
U.S. Department of Energy 04/02/2013
Issued
Patent 8,741,657
Patent
8,741,657
Nanocomposite thin films for optical gas sensing
The disclosure relates to a plasmon resonance-based method for gas sensing in a gas stream utilizing a gas sensing material. In an embodiment the gas stream has a temperature greater than about 500.degree. C. The gas sensing material is comprised of gold nanoparticles having an average nanoparticle diameter of less than about 100 nanometers dispersed in an inert matrix having a bandgap greater than or equal to 5 eV, and an oxygen ion conductivity less than approximately 10.sup.-7 S/cm at a temperature of 700.degree. C. Exemplary inert matrix materials include SiO.sub.2, Al.sub.2O.sub.3, and Si.sub.3N.sub.4 as well as modifications to modify the effective refractive indices through combinations and/or doping of such materials. Changes in the chemical composition of the gas stream are detected by changes in the plasmon resonance peak. The method disclosed offers significant advantage over active and reducible matrix materials typically utilized, such as yttria-stabilized zirconia (YSZ) or TiO.sub.2.
U.S. Department of Energy 06/03/2014
Issued
Technology Status
Development StageAvailabilityPublishedLast Updated
DevelopmentAvailable05/18/201707/06/2017

Contact NETL About This Technology

To: Jessica Sosenko<jessica.sosenko@netl.doe.gov>