Rapid SiC: Room Temperature Roll-to-Roll Production of Polymer-Derived SiC Fibers

Natural gas turbines typically function at temperatures below 1100°C resulting in fuel-to-energy conversion efficiencies between 30 - 40%, however, if they are operated at temperatures exceeding 1400°C, efficiencies can be as high as 50-60%. The operating temperature of current natural gas turbines is limited by the turbine materials of construction. To enable turbines to operate at higher temperatures, ceramic matrix composites (CMCs) have emerged as promising advanced materials. Unfortunately, current CMCs are prohibitively expensive for applications in natural gas turbine applications. When considering the cost of CMCs, the reinforcing fibers are a main component that contributes to the high total cost. Current commercial silicon carbide (SiC) fibers cost between $9,000 - $15,000 per kilogram, primarily because of costly production methods. Current fiber production methods are slow (days of production), produce single fibers, have high capital equipment costs, and high operating costs due to operating temperatures over 1000°C. These high production costs are a major factor contributing to the extremely high price point of SiC fiber. Luna Labs will work with the University of Massachusetts – Amherst and Ballydel Technologies, Inc. to develop a SiC fiber production process (Rapid SiC) that will reduce SiC fiber price by decreasing the maximum operating temperature to room temperature, leveraging a roll-to-roll manufacturing process to produce 100’s of fibers simultaneously, and converting pre-ceramic polymer precursors to SiC at the millisecond time scale. During the Phase I, the Luna Labs team will demonstrate the Rapid SiC fiber production process at lab scale, characterize the chemical and mechanical properties of the produced fibers, perform an initial cost analysis of the production process, and prepare a preliminary techno-economic analysis of the Rapid SiC fiber technology. Furthermore, a roll-to-roll technology transition plan will be developed in the Phase I. The production method developed during the project is anticipated to be highly disruptive to the SiC fiber and non-oxide ceramic fiber industries. The novel Rapid SiC manufacturing costs are expected to allow SiC fibers to be sold at a fraction of the current market price and, in turn, decrease the overall cost of CMCs. By reducing CMC costs and maintaining the high-temperature performance criteria, the integration of CMCs reinforced by Luna Labs’ Rapid SiC fiber will enable the next generation of high-temperature natural gas turbines that can operate at fuel-to-energy efficiencies of 50 – 60%. Thus, reducing energy costs by up to 57% and the overall emissions from natural gas power plants. The Rapid SiC fiber technology will allow for new technologies in aerospace applications, advanced refractory systems, chemical refinement processes, and the defense industry. These advanced technologies will benefit the public by reducing energy costs, decreasing manufacturing costs, improving national defense capabilities, exploring harsh space environments, and reducing emissions of various industrial processes.