crelonweb.eec.wustl.educrelonweb.eec.wustl.edu/files/crelmeetings/2007/yi.pdf · science &...
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Yi Jiang, Research ManagerScience & Technology Division, New York
Oct 17, 2007 at CREL Annual Meeting, Washington University in St. Louis, Missouri
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2Science & Technology
Outline
• Introduction
• Emerging Technologies & CRE roles– Environmental Technology– Alternative Energies –Fuel Cells– Micro- & Nano-Technologies
• CRE Challenges– Critical Scale Down– Multiscale Integration– Interdisciplinary Efforts
• Concluding Remarks
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3Science & Technology
Corning Incorporated
Founded:1851
Headquarters:Corning, New York
Employees:Approximately 26,000 worldwide
2006 Revenues:$5.17 Billion
Fortune 500 Rank: 456
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4Science & Technology
1879
A Strategic Look Back
Glass Envelope For Light Bulb
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5Science & Technology
1879
A Strategic Look Back
1915
Heat-resistantPyrex Glass
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6Science & Technology
1879
A Strategic Look Back
1915
Panels & Funnels for CRTs
1947
Silicones
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7Science & Technology
1947
1879
A Strategic Look Back
1915
1957
Glass Ceramics Photo-Chromic Glasses
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8Science & Technology
1947
1879
A Strategic Look Back
1915
Low-Loss Optical Fiber
Low-Loss Optical Fiber
1970
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9Science & Technology
1947
1879
A Strategic Look Back
1915
1970
1972
Ceramic Substrates
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10Science & Technology
1947
1879
A Strategic Look Back
1915
LCD Glass
1970
1972
1984
Alkali Free Glass
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11Science & Technology
Recognition: National Medal of Technology
2000 Optical Fiber
1986 Glass Ceramics and Photochromics
1994 The Company
2003 Ceramic Substrates
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12Science & Technology
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Processes for mass producing the television bulb
Processes for mass producing the television bulb
19471947
First low-loss optical fiberFirst low-loss optical fiber
1970197019151915
Heat-resistant Pyrex®glass
Heat-resistant Pyrex®glass
19841984
LCD glass for computers and flat panel TVs
LCD glass for computers and flat panel TVs
18791879
Glass envelope for Thomas Edison’s light bulb
Glass envelope for Thomas Edison’s light bulb
19721972
Ceramic substrates for automotive catalytic converters
Ceramic substrates for automotive catalytic converters
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13Science & Technology
Growth Through Innovation
• Our Culture of Innovation is built on the foundation of Research and Development
• Our commitment to innovation distinguishes Corning as a true technology leader
• Our near term growth has been fueled by three distinctly different market opportunities
– LCD glass used in flat panel displays for computers, communications and entertainment
– Diesel emissions-control technology for light-, medium- and heavy-duty vehicles
– Optical fiber, cable and hardware for Fiber-to-the X applications
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14Science & Technology
Core of CRE
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15Science & Technology
Where Are CRE
CRECRE
Apply CRE core principles Apply CRE core principles to new problems in to new problems in emerging technologiesemerging technologies
Apply new techniques to the more Apply new techniques to the more effective solution of traditional effective solution of traditional problemsproblems
Integrate the widely varied CRE Integrate the widely varied CRE activities into broad, powerful systems activities into broad, powerful systems descriptionsdescriptions
A. V. Sapre & J. R. Katzer, IEC Res. (1995)
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16Science & Technology
Outline
• Introduction
• Emerging Technologies & CRE roles– Environmental Technology– Alternative Energies –Fuel Cells– Micro- & Nano-Technologies
• CRE Challenges– Critical Scale Down– Multiscale Integration
– Interdisciplinary Efforts
• Concluding remarks
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17Science & Technology
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• Leading global supplier of cellular ceramic technologies and solutions for mobile and stationary emissions control
• New generation of thin-wall and ultra-thin wall substrates provide extremely high geometric surface area for improved conversion efficiency
• Tighter diesel emission standards worldwide drive dramatic market growth for filters and substrates
• Expanding our state-of-the-art manufacturing facility in Erwin, NY further demonstrates our commitment to meeting the demands of the burgeoningdiesel market
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18Science & Technology
Three-Way Catalyst (TWC)
PollutantsPollutants
CCmmHHnn CO CO NONOx x
STOICHIOMETRIC
Gasoline Engine
Diesel Oxidation CatalystLNT CatalystSCR Catalyst
Diesel Particulate Filter (DPF)
FUEL LEAN
Diesel Engine
NONOx x SootSoot
Engine Pollutants & Substrate Products
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19Science & Technology
Diesel Aftertreatment Challenges
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20Science & Technology
CRE in Cellular Catalytic Converters
S. Tischer, Y. Jiang, K. W. Hughes, M. D. Patil, M. Murtagh, SAE 2007-01-1071
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21Science & Technology
Toyota DPNR (Diesel Particulate-NOx Reduction System)
- Akira Shoji, Aug 13-16, 2007, 13th DEER Conference, Detroit
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22Science & Technology
NOx Storage Reduction Catalyst
- Akira Shoji, Aug 13-16, 2007, 13th DEER Conference, Detroit
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23Science & Technology
Solid Oxide Fuel Cell (SOFC) R&D: CRE Roles
• Novel catalysts for fossil fuels, biomass-derived fuels
• Comprehensive models for integrated system design (heat exchanger-catalytic burner)
• Electrochemical characterization of fuel cell behaviors,
• Fundamental electrochemical kinetic studies of solid oxide cathode reactions
System description for energy balance
Single cell and fuel cell stack
A. M. Al-Qattan et al., CES, 59 (2004) 131-137
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24Science & Technology
SOFC Using H2 FuelSOFC Using H2 Fuel
Cathode reaction: 1/2 O2 + 2e- => O2-
Anode reaction: H2 + O2- => H2O + 2e-
Electrolyte O2- ions
O2
Load
e-
e-
H2 H2O
Cathode
Anode
O2+N2
H2
YSZ
Net Reaction @ 650-900 C:
H2 + 1/2 O2 => H2O + kWe + QY. Jiang, S. C. Pollard, AIChE Annual Meeting, Cincinnati, OH, USA, November 1, 2005
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25Science & Technology
2O2- + X � Y + 4e-
O2 + 4e- � 2O2-
X Y
O2
V
e-
CH4+H2O ���� 3H2+CO -QCO2+CH4 ���� 2H2 + 2CO -QCO+H2O ���� H2+CO2 +Q2H2+O2 ���� 2H2O+Q; CO+O2 ���� CO2 +Q
Anode
Cathode e-
SOFC Using ReformateSOFC Using Reformate
External AND/OR Internal Coupling
Fuel Processing & SOFC
O2+N2O2+N2
CH4, H2, COCO2, H2O
CH4, H2, COCO2, H2O
2O2- ions YSZElectrolyte
Y. Jiang, S. C. Pollard, AIChE Annual Meeting, Cincinnati, OH, USA, November 1, 2005
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26Science & Technology
SOFC System & IntegrationSOFC System & Integration
Hydrocarbon � Fuel Reformer (Endothermic) �H2 Rich-Gas � SOFC Stack (Exothermic) �DC Power � AC Power
Hydrocarbon Hydrocarbon �� Fuel Reformer Fuel Reformer ((Endothermic) ) ��H2 RichH2 Rich--Gas Gas �� SOFC Stack (SOFC Stack (Exothermic) ) ��DC Power DC Power �� AC PowerAC Power
FUEL
H2 RICHGASHC Fuel
AIR
SOFCStack
PowerConditioner
FuelReformer DC
PowerH2 Rich
Gas
Heat Exhaust
ACPower
Multiscale, Multispecies, Multi-physics System
- Thermodynamics, Transport, Kinetics Database -Y. Jiang, S. C. Pollard, AIChE Annual Meeting, Cincinnati, OH, USA, November 1, 2005
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27Science & Technology
Component Models & System IntegrationComponent Models & System Integration
ElectrochemicalPhenomena
ElectrochemicalElectrochemicalPhenomenaPhenomena
ThermochemicalPhenomena
ThermochemicalThermochemicalPhenomenaPhenomena
ThermomechanicalPhenomena
ThermomechanicalThermomechanicalPhenomenaPhenomena
Material ScienceIssues
Material ScienceMaterial ScienceIssuesIssues
System Design &Optimization
System Design &System Design &OptimizationOptimization
System Efficiency& Operation
System EfficiencySystem Efficiency& Operation& Operation
Dynamic ControlModels
Dynamic ControlModels
Thermo-mechanical Models
Thermo-mechanical Models
Electro-chemical Models
Electro-chemical Models
Thermo-chemical Models
Thermo-chemical Models
Heat/Electricity Management
Heat/Electricity Management
In-SituDiagnostics
In-SituDiagnostics
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 0.5 1 1.5 2
Current Density [A/cm 2]
Voltage[V]
650 C Data650 C 1D Model650 C 3D Model725 C Data725 C 1D Model725 C 3D Model
“Hybrid” platformY. Jiang, S. C. Pollard, AIChE Annual Meeting, Cincinnati, OH, USA, November 1, 2005
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28Science & Technology
Internal Reforming in Anode (SOFC)
H. Zhu, R.J. Kee, V.M. Janardhanan, O. Deutschmann, D.G. Goodwin, N.P.Sullivan, (2003)
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29Science & Technology
C. Guemeur. Ph. Caze, O. Lobet, P. Woehl (Corning Inc.)The 5th International Workshop on Micro Chemical PlantsJanuary, 29-30, 2007, KYOTO University
Micro- and Nano-Technologies
CorningGlass Microreactor
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30Science & Technology
Outline
• Introduction
• Emerging Technologies & CRE roles– Environmental Technology– Alternative Energies –Fuel Cells– Micro- & Nano-Technologies
• CRE Challenges– Critical Scale Down– Multiscale Integration– Interdisciplinary Efforts
• Concluding remarks
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31Science & Technology
Critical Scale Down
lKn
∂∂= ρ
ρλ
Photos: Courtesy of Sasol
• Where does the continuum concept break down?• Complex fluids in complex flow domain
Kn < 0.01 (in continuum), ~1.0 (slip flow), > 1.0 (Knudsen flow)
12
*1
*2
*
**
xxxJ x −
Φ−Φ=∂Φ∂∝
1 2 1 2
Microscopic space Macroscopic space
12
12
xxxJ x −
Φ−Φ=∂Φ∂∝
LLNL Microreactor fuel processors for generating H2, chemical synthesis, & bioreaction studies.
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32Science & Technology
Multiscale Transport/Reaction Fundamentals
Corning Celcor® substrates
A -nm -µm -cm
BaCO3
Particle-scaleDiffusion-Reaction
of NOx Storage
Ba(NO3)2
NOx
��
���
�
∂∂
∂∂=
∂∂
rC
Drrrt
C 21
Particle
Pt
NOO2 NO2 + O*
NOx Storage
Pt
HCCO
NO + O*
N2 H2OCO2
NOx Reduction
Washcoat
Substrate web
Channel Monolith
γ-Al2O3 (grey); CeO2 (white)
Washcoat
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33Science & Technology
Multiscale Modeling Integration
Technical Business needs
Quantum
Atomistic
Meso-scale
Obj
ectiv
es
Obj
ectiv
es
Obj
ectiv
es
Obj
ectiv
es
Delivery
Delivery
Delivery
Delivery
Experiment
Lite
ratu
re
CBA
Macro-scale
D. Chowdhury (2005)
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34Science & Technology
Interdisciplinary Efforts
• We don’t really understand all the physics and chemistry of many compact devices in emerging technologies
• Coupling of chemical/mechanical/electrical properties in compact devices gives rise to complex dynamics
CRE + Advanced Materials + Solid Mechanics
10 µmMicrostructure & simulated CO concentration:Gaussian porous medium, Lxy= 54 nm (dhM=220 nm), e M=15 %,CPt = 50 mol/m3, DCO = 6 x10-8 m2/s, T=300 °C.
Meso-Scale Modelling of Reactions and Transport in Digitally Reconstructed Porous Catalyst: CO Oxidation on Pt/Al2O3, Miloš Marek, Petr Ko�í, Milan Kubí�ek,
František Št�pánek (2005)
A. Ayyar & N. Chawla (2006)
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35Science & Technology
Concluding Remarks
• CRE has been expanding in scope and breadth, the strong core of CRE, however, still plays critical roles in emerging technology R&D.
• The ability to apply CRE tools and methodology to novel emerging technologies is essential.
• Emerging technologies require a greater integration of interdisciplinary skills, and it is extremely important for CRE being involved.
• Building interdisciplinary integrations in CRE curriculum and ingraduate research program are crucial for CRE playing leading roles in tomorrow’s emerging technology innovations.
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36Science & Technology
Acknowledgement
• Prof. Shantanu Roy (IIT, India) with Corning Inc ~ 2004
• Dr. Garima Bhatia (GM, India) with Corning Inc ~2004
• Dr. Peng Chen (Corning Inc.)
• Ms. Jenny Weng (Corning Inc.)
• Dr. Aravind Rammohan (Corning Inc.)
• Dr. Gautam Meda (Research Director, Corning Inc.)
• Dr. Dipak Chowdhury (Director, Corning European Technology Center, Paris, France)
• CREL, Washington University in St. Louis