Corrosion resistant material for reduced fouling, a heat transfer component having reduced fouling and a method for reducing fouling in a refinery
AssigneeExxonMobil Research and Engineering Company
InventorsMark A. GREANEY, Thomas BRUNO, Ashley E. COOPER, Ian A. CODY, ChangMin CHUN
Life of this patent
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Abstract
A method and device for reducing sulfidation corrosion and depositional fouling in heat transfer components within a refining or petrochemical facility is disclosed. The heat transfer components are formed from a corrosion and fouling resistant steel composition containing a Cr-enriched layer having a surface roughness of less than 40 micro inches (1.1 μm) and a protective layer formed thereon.
Claims14
A method of reducing fouling in a heat exchanger for crude oil, wherein the heat exchanger having a plurality of existing heat exchanger tubes, the method comprising:
- removing at least a portion of the plurality of existing heat exchanger tubes from the heat exchanger;
- installing a plurality of replacement heat exchanger tubes, wherein each of the plurality of replacement heat exchanger tubes having a surface roughness of less than 40 micro inches (1.1 μm),
- wherein each of the plurality of replacement heat exchanger tubes being formed from a steel composition comprising X, Y, and Z,
- wherein X is a metal selected from the group consisting of Fe, Ni, Co and mixtures thereof,
- wherein is Y is Cr, and
- wherein Z is at least one alloying element selected from the group consisting of Si, Al, Mn, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Sc, Y, La, Ce, Pt, Cu, Ag, Au, Ru, Rh, Ir, Ga, In, Ge, Sn, Pb, B, C, N, O, P, and S,
- wherein each of the plurality of replacement heat exchanger tubes having a Cr-enriched layer formed on at least one of an inner surface or an exterior surface of the tube, wherein the Cr-enriched layer also being formed from the steel composition X, Y, and Z, wherein the ratio of Y to X in the Cr-enriched layer being greater than the ratio of Y to X in the remaining portion of the tube;
- and
- forming a protective layer on an outer surface of the Cr-enriched layer, wherein the protective layer comprises a material selected from the group consisting of a magnetite, an iron-chromium spinel, a chromium oxide, oxides of the same and mixtures thereof.
A method of providing sulfidation corrosion resistance and corrosion induced fouling resistance to a metal surface that is subject to a process stream at high temperatures, the method comprising:
- providing a metal layer formed from a steel composition comprising X, Y, and Z, wherein X is a metal selected from the group consisting of Fe, Ni, Co and mixtures thereof, wherein is Y is Cr, and wherein Z is at least one alloying element selected from the group consisting of Si, Al, Mn, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Sc, Y, La, Ce, Pt, Cu, Ag, Au, Ru, Rh, Ir, Ga, In, Ge, Sn, Pb, B, C, N, O, P, and S, wherein a Cr-enriched layer is located on the metal layer, wherein the Cr-enriched layer also being formed from the steel composition X, Y, and Z, wherein the ratio of Y to X in the Cr-enriched layer being greater than the ratio of Y to X in the metal layer, wherein the Cr-enriched layer having a surface roughness of less than 40 micro inches (1.1 μm);
- and
- forming an protective layer on a surface of the Cr-enriched layer, wherein the protective layer comprises an oxide selected from the group consisting of a magnetite, an iron-chromium spinel, a chromium oxide, and mixtures thereof.
A corrosion resistant barrier layer for use in reducing fouling, comprising:
- a steel composition layer comprising X, Y, and Z, wherein X is a metal selected from the group consisting of Fe, Ni, Co and mixtures thereof, wherein is Y is Cr, and wherein Z is at least one alloying element selected from the group consisting of Si, Al, Mn, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Sc, Y, La, Ce, Pt, Cu, Ag, Au, Ru, Rh, Ir, Ga, In, Ge, Sn, Pb, B, C, N, O, P, and S;
- a Cr-enriched layer formed on the steel composition layer, wherein the Cr-enriched layer also being formed from X, Y and Z, wherein the ratio of Y to X in the Cr-enriched layer being greater than the ratio of Y to X in the steel composition layer, wherein the Cr-enriched layer having a surface roughness of less than 40 micro inches (1.1 μm);
- and
- a protective layer formed on the Cr-enriched layer, wherein the protective layer comprises an oxide selected from the group consisting of a magnetite, an iron-chromium spinel, a chromium oxide, and mixtures thereof.
Dependencies are inferred from the claim text.