Exxon Research and Engineering Company

Exxonmobil Research and Engineering Company

Exxonmobile Research and Engineering Company

Trikur Anantharaman Ramanarayanan

ChangMin Chun

Ian A Cody

Mark Alan Greaney

Changmin Chun

Thomas Bruno

Guido Sartori

David William Savage

Martin Leo Gorbaty

David J Martella

Saul Charles Blum

Bruce Henry Ballinger

Adnan Ozekcin

Michael Paul Anderson

James Dirickson Mumford

Ruzica Petkovic-Luton

James D Mumford, Iii

Vinod K Pareek

Raghavan Ayer

Michel A Daage

Russell John Koveal

Horst Witzke

Long Y Chiang

Ashok Uppal

Leroy Russell Clavenna

LeRoy A Clavenna

Kenneth E Bagnoli

G Phillip Anderson

Hyacinth L Vedage

David Chester Long

Claude Clarence Culross

James D Mumford

A method of providing sulfidation corrosion resistance and corrosion induced fouling resistance to a heat transfer component surface includes providing a silicon containing steel composition including an alloy and a Si-partitioned non-metallic film formed on a surface of the alloy. The alloy is formed from the composition &#x3b7;, &#x3b8;,and &#x3c4;, in which &#x3b7; is a metal selected from the group consisting of Fe, Ni, Co, and mixtures thereof, &#x3b8; is Si, and &#x3c4; is at least one alloying element selected from the group consisting of Cr, Al, Mn, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Sc, La, Y, Ce, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au, Ga, Ge, As, In, Sn, Sb, Pb, B, C, N, P, O, S and mixtures thereof. The Si-partitioned non-metallic film comprises at least one of sulfide, oxysulfide and mixtures thereof.

Silicon-containing steel compostition with improved heat exchanger corrosion and fouling resistance

A method of providing sulfidation corrosion resistance and corrosion induced fouling resistance for a heat transfer component is disclosed. The heat transfer component includes a heat exchange surface formed from a chromium-enriched oxide containing material formed from the composition &#x3b4;, &#x3b5;, and &#x3b6;, wherein &#x3b6; is a steel containing at least about 5 to about 40 wt. % chromium, &#x3b5; is a chromium enriched oxide (MOor MOor mixtures thereof) formed on the surface of the steel &#x3b6;, wherein M is a metal containing at least 5 wt. % Cr based on the total weight of the metal M, and &#x3b4; is a top layer formed on the surface of the chromium-enriched oxide &#x3b5;, comprising sulfide, oxide, oxysulfide, and mixtures thereof. The top layer &#x3b4; comprises iron sulfide (FeS), iron oxide (FeO), iron oxysulfide, iron-chromium sulfide, iron-chromium oxide, iron-chromium oxysulfide, and mixtures thereof. The metal M of the chromium enriched oxide (MOor MOor mixtures thereof) may comprise Fe, Cr, and constituting elements of the steel &#x3b6;. The steel &#x3b6; may be selected from low chromium steels, ferritic stainless steels, martensitic stainless steels, austenitic stainless steels, duplex stainless steels and precipitation-hardenable alloys.

Chromiun-enriched oxide containing material and preoxidation method of making the same to mitigate corrosion and fouling associated with heat transfer components

A heat transfer component that is resistant to both corrosion and fouling is disclosed having a heat exchange surface formed from a silicon containing steel composition including an alloy and a non-metallic film formed on a surface of the alloy. The alloy is formed from the composition &#x3b7;, &#x3b8;, and &#x3c4;, in which &#x3b7; is a metal selected from the group consisting of Fe, Ni, Co, and mixtures thereof, &#x3b8; is Si, and &#x3c4; is at least one alloying element selected from the group consisting of Cr, Al, Mn, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Sc, La, Y, Ce, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au, Ga, Ge, As, In, Sn, Sb, Pb, B, C, N, P, O, S and mixtures thereof. The non-metallic film comprises sulfide, oxide, carbide, nitride, oxysulfide, oxycarbide, oxynitride and mixtures thereof. The surface roughness of the heat transfer component is less than 40 micro inches.

Silicon-containing steel composition with improved heat exchanger corrosion and fouling resistance

A heat transfer component that is resistant to corrosion and fouling is disclosed. The heat transfer component includes a heat exchange surface formed from a chromium-enriched oxide containing material formed from the composition &#x3b4;, &#x3b5;, and &#x3b6;, wherein &#x3b6; is a steel containing at least about 5 to about 40 wt. % chromium, &#x3b5; is a chromium enriched oxide (MOor MOor mixtures thereof) formed on the surface of the steel &#x3b6;, wherein M is a metal containing at least 5 wt. % Cr based on the total weight of the metal M, and &#x3b4; is a top layer formed on the surface of the chromium-enriched oxide &#x3b5;, comprising sulfide, oxide, oxysulfide, and mixtures thereof. The top layer &#x3b4; comprises iron sulfide (FeS), iron oxide (FeO), iron oxysulfide, iron-chromium sulfide, iron-chromium oxide, iron-chromium oxysulfide, and mixtures thereof. The metal M of the chromium enriched oxide (MOor MOor mixtures thereof) may comprise Fe, Cr, and constituting elements of the steel &#x3b6;. The steel &#x3b6; may be selected from low chromium steels, ferritic stainless steels, martensitic stainless steels, austenitic stainless steels, duplex stainless steels and precipitation-hardenable alloys.

Chromium-enriched oxide containing material and preoxidation method of making the same to mitigate corrosion and fouling associated with heat transfer components

High performance coated metal compositions resistant to metal dusting corrosion and methods of providing such compositions are provided by the present invention. The coated metal compositions are represented by the structure (PQR), wherein P is an oxide layer at the surface of (PQR), Q is a coating metal layer interposed between P and R, and R is a base metal. P includes alumina, chromia, silica, mullite or mixtures thereof. Q includes Ni and Al, and at least one element selected from the group consisting of Cr, Si, Mn, Fe, Co, B, C, N, P, Ga, Ge, As, In, Sn, Sb, Pb, Sc, La, Y, Ce, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au and mixtures thereof. R is selected from the group consisting of carbon steels, low chromium steels, ferritic stainless steels, austenetic stainless steels, duplex stainless steels, Inconel alloys, Incoloy alloys, Fe&#x2014;Ni based alloys, Ni-based alloys and Co-based alloys. Advantages exhibited by the disclosed coated metal compositions include improved metal dusting corrosion resistance at high temperatures in carbon-supersaturated environments having relatively low oxygen partial pressures. The coated metal compositions are suitable for use in syngas generation process equipment.

High performance coated material with improved metal dusting corrosion resistance

A metal dusting resistant composition comprises an alloy capable of forming a thermally stable titanium carbide coating on its surface when exposed to a carbon supersaturated environment and, a protective coating on the alloy surface comprising an outer oxide layer and an inner carbide layer between the alloy surface and the outer layer.

Metal dusting resistant stable-carbide forming alloy surfaces

Alloy compositions which are resistant to metal dusting corrosion are provided by the present invention. Also provided are methods for preventing metal dusting on metal surfaces exposed to carbon supersaturated environments. The alloy compositions include an alloy (PQR), and a multi-layer oxide film on the surface of the alloy (PQR). The alloy (PQR) includes a metal (P) selected from the group consisting of Fe, Ni, Co, and mixtures thereof, an alloying metal (Q) comprising Cr, Mn, and either Al, Si, or Al/Si, and an alloying element (R). When the alloying metal (Q) includes Al, the multi-layer oxide film on the surface of the alloy includes at least three oxide layers. When the alloying metal (Q) includes Si, the multi-layer oxide film on the surface of the alloy (PQR) includes at least four oxide layers. When the alloying metal (Q) includes Al and Si, the multi-layer oxide film on the surface of the alloy (PQR) includes at least three oxide layers. The multi-layer oxide film is formed in situ during use of the alloy composition in a carbon supersaturated metal dusting environment. Advantages exhibited by the disclosed alloy compositions include improved metal dusting corrosion resistance at high temperatures in carbon-supersaturated environments having relatively low oxygen partial pressures. The disclosed alloy compositions are suitable for use as the inner surfaces in reactor systems and refinery apparatus.

High performance alloys with improved metal dusting corrosion resistance

The present invention is directed to a process for producing pearlite from an iron containing article comprising the steps of, (a) heating an iron containing article comprising at least 50 wt % iron for a time and at a temperature sufficient to convert at least a portion of said iron from a ferritic structure to an austenitic structure, (b) exposing said austenitic structure, for a time sufficient and at a temperature of about 727 to about 900&#xb0; C., to a carbon supersaturated environment to diffuse carbon into said austenitic structure and (c) cooling said iron containing article to form a continuous pearlite structure.

Reactive heat treatment to form pearlite from an iron containing article

A method for inhibiting metal dusting corrosion of surfaces exposed to supersaturated carbon environments comprising constructing said surfaces of, or coating said surfaces with a copper based alloy. The invention is also directed to a composition resistant to metal dusting.

Metal dusting resistant copper based alloy surfaces

The invention includes a composition of matter which is resistant to metal dusting and a method for preventing metal dusting on metal surfaces exposed to carbon supersaturated environments.

Metal dusting resistant alloys

The invention relates to processes for treating acidic crudes or fractions thereof to reduce or eliminate their acidity and corrosivity by addition of suitable amounts of Group IA or Group IIA oxides, hydroxides and hydrates and Group IIA metal naphthenate salts. The process has the additional benefits of reducing materials handling problems associated with treating acidic crude oils using liquid solvents and in reducing emulsion formation.

Process for decreasing the acid content and corrosivity of crudes

Furnace run length extension by fouling control utilizing a pigging-passivation process.

Furnace run length extension by fouling control

Process for neutralization of petroleum acids using overbased detergents

Corrosion of conventional refinery steels due to sulfur bearing, carboxylic acid containing hydrocarbon materials is minimized by forming on the surface of the steel a fine grain iron sulfide film where at least the steel surface is substantially all of a pearlite microstructure.

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Somerset, NJ, United States of America

Trikur Anantharaman Ramanarayanan