The goal of Process Development research at NETL is to generate information to help improve processes used in the production of materials that are being developed to improve efficiency and performance of power plant operation. Some of this research is helping to prove the feasibility of new fabrication processes used, for example, to produce economical, high-performance solid oxide fuel cells. In addition, process development research has a goal to protect the environment by developing effective, reliable, and affordable technologies for capturing and ameliorating the waste streams of fossil energy power production. By developing innovations that will form the basis of future power generation, process development is advancing the efficiency of the Nation's energy systems by evaluating and improving processes in existing power systems.

Process Development research specializes in the development of processes to:

• efficiently produce prototype parts, castings, and/or plate or sheet from ferrous, non-ferrous, and refractory alloys;
• formulate and develop alloys for use in high temperature applications;
• recover or recycle valuable materials from wastes;
• improve material production by melting or smelting;
• develop processes for efficient carbon management including the sequester of greenhouse gas emissions;
• improve efficiencies of high temperature melting or smelting systems; and
• improve power plant efficiency, and reduce power plant emissions.

NETL understands and respects the need for confidentiality and the value of intellectual property that is developed in the conduct of all research conducted with industrial partnerships such as these. NETL partnership agreements are designed to protect company-specific proprietary information and intellectual property developed during a cooperative research agreement. NETL continues to develop new partnerships to collaborate with industry, for example, to s upport the development of new combustion technologies by providing solutions to the complex interactions of high temperature combustion and energy processes with the materials and metals that will be employed in these service environments .

The Liquid Metal Processing (LMP) Laboratory provides capabilities to melt, alloy, cast, forge, roll, and heat treat materials from a few grams up to 100s of kilograms. In addition, the division has a complete feed preparation facility capable of crushing, grinding, sizing, mixing, and agglomerating feed in batches from a few kg up to 1,000s of kg. For melting and smelting experimentation, the PDD has a state-of-the-art facility that allows for laboratory-scale (a few kg) up to pilot-scale (500 to 1,000 kg per hour of product) experimental trials that can be designed to last from a few seconds to more than 100 hours of continuous operation. With the excellent support that includes a state-of-the-art analytical laboratory , an outstanding mechanical testing facility, a world class metallography laboratory, a unique corrosion testing facility , and an experienced wear testing group, all products can be given a complete characterization with respect to chemical and phase composition, physical and mechanical properties, and wear and corrosion resistance.