Exxonmobil Chemical Patents Inc.

Jorge J Perdomo

Changmin Chun

Larry Lee Iaccino

ChangMin Chun

John Slocum Coleman

Ning Ma

Ivan A Morales

Methods and compositions are provided for improving metal dusting corrosion, abrasion resistance and/or erosion resistance for various materials, preferably for applications relating to high-temperature reactors, including dense fluidized bed reactor components. In particular, cermets comprising (a) at least one ceramic phase selected from the group consisting of metal carbides, metal nitrides, metal borides, metal oxides, metal carbonitrides, and mixtures of thereof and (b) at least one metal alloy binder phase are provided. Ceramic phase materials include chromium carbide (CrC). Metal alloy binder phase materials include β-NiAl intermetallic alloys and NiSnintermetallic alloys, as well as alloys that contain α-Cr and/or γ'-NiAl hard phases. Preferably, bimetallic materials are provided when the cermet compositions are applied using a laser, e.g., a laser cladding method such as high power direct diode (HPDD) laser, or by plasma-based methods such as plasma transfer arc (PTA) welding and powder plasma welding (PPW).

Bimetallic materials comprising cermets with improved metal dusting corrosion and abrasion/erosion resistance

Reactor components formed using an erosion resistant alloy having desirable high temperature mechanical strength are provided. The erosion resistant components can include, but are not limited to, tubes, reactors walls, fittings, and/or other components having surfaces that can be exposed to a high temperature reaction environment in the presence of hydrocarbons and/or that can provide pressure containment functionality in processes for upgrading hydrocarbons in a high temperature reaction environment. The erosion resistant alloy used for forming the erosion resistant component can include 42.0 to 46.0 wt. % nickel; 32.1 to 35.2 wt. % chromium; 0.5 to 2.9 wt. % carbon; 0 to 2.0 wt. % titanium; 0 to 4.0 wt. % tungsten, and iron, with at least one of titanium and tungsten is present in an amount of 1.0 wt. % or more. The iron can correspond to the balance of the composition. Optionally, the erosion resistant alloy can provide further improved properties based on the presence of at least one strengthening mechanism within the alloy, such as a carbide strengthening mechanism, a solid solution strengthening mechanism, a gamma prime strengthening mechanism, or a combination thereof.

Erosion resistant alloy for thermal cracking reactors

This application relates to a heat transfer tube, its method of manufacture and its use for thermal cracking hydrocarbon feeds, such as thermal cracking in furnaces. The heat transfer tube comprises a chromium and aluminum carburization-resistant alloy capable of generating a typically continuous aluminum oxide scale under thermal cracking conditions that reduces coking and thereby enhances heat transfer. The carburization-resistant alloy comprises 25.1 to 55.0 wt. % nickel; 18.1 to 23.9 wt. % chromium; 4.1 to 7.0 wt. % aluminum; and iron. Additionally, the carburization-resistant alloy has at least one strengthening mechanism to provide desirable mechanical properties. The carburization-resistant alloy composition is also resistant to the formation of cracks during centrifugal casting.

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Kingwood, TX, United States of America

Jorge J Perdomo