Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L9/00—Rigid pipes
  • F16L9/02—Rigid pipes of metal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K10/00—Welding or cutting by means of a plasma
  • B23K10/02—Plasma welding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K10/00—Welding or cutting by means of a plasma
  • B23K10/02—Plasma welding
  • B23K10/027—Welding for purposes other than joining, e.g. build-up welding
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G75/00—Inhibiting corrosion or fouling in apparatus for treatment or conversion of hydrocarbon oils, in general
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
  • C10G9/14—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils in pipes or coils with or without auxiliary means, e.g. digesters, soaking drums, expansion means
  • C10G9/18—Apparatus
  • C10G9/20—Tube furnaces
  • C10G9/203—Tube furnaces chemical composition of the tubes
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C19/00—Alloys based on nickel or cobalt
  • C22C19/03—Alloys based on nickel or cobalt based on nickel
  • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L9/00—Rigid pipes
  • F16L9/02—Rigid pipes of metal
  • F16L9/04—Reinforced pipes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/18—Dissimilar materials
  • B23K2103/20—Ferrous alloys and aluminium or alloys thereof

Definitions

• a large amount of heavy resid content is characteristic of heavy oils.
• the atmospheric resid must be subjected to more refining. Following the atmospheric tower, the resid is further heated in another series of heat exchangers and then another furnace and sent to a vacuum distillation tower, where light vacuum gas oil and heavy vacuum gas oil are extracted from the resid.
• the remaining tarry fluid left near the base of the vacuum tower, the vacuum residue can either be (i) claimed as asphalt, or (ii) subject to further processing, such as coking.
• the delayed coking process is one of the most widely commercially practiced of the coking processes.
• the resid is heated to the coking temperature by flowing through a long tube in a furnace and then allowed to react at this elevated temperature after flowing into the bottom of a high cylindrical insulated drum.
• the volatile products are removed to a fractionator and coke accumulates in the drum.
• the heavy liquid product from the fractionator is recycled back to the furnace.
• the feed is switched to a second drum.
• the coke is mined out of the drum by drilling a hole down the center with high pressure water and cutting out the remainder also with high-pressure water to get the drum ready for the next coke accumulation cycle.
• the radiant coil of the refinery process furnace has an inlet pipe section and an outlet pipe section.
• a plurality of essentially straight horizontal pipe sections is arranged in at least two vertical banks.
• the vertical banks are parallel and horizontally spaced apart.
• a plurality of bent pipe sweep return bends are arranged in vertical banks at either end of the straight pipe banks. Each bend connects a pair of straight pipe sections in adjacent vertical banks thereof.
• the return bends are sloped between horizontal and vertical, and one of the straight pipe sections in the pair connected by a return bend is elevated with respect to the other.
• a tubeside fluid flow path is provided from the inlet pipe section through an alternating series of the straight pipe sections and the return bends to the outlet pipe section.
• Figure 1 depicts a cross-sectional scanning electron microscope (SEM) image of the bimetallic tube revealing the outer 9Cr (T9) steel layer and the inner alumina- forming plasma powder welding (PPW) layer.
• SEM scanning electron microscope
• Figure 2 depicts an energy dispersive x-ray spectroscopy (EDXS) concentration line profile of each main element of an alumina- forming bimetallic tube of the present disclosure.
• EDXS energy dispersive x-ray spectroscopy
• the present disclosure provides compositions of, methods of making and methods of using alumina forming bimetallic tubes for a radiant coil of the refinery process furnace.
• the present disclosure also provides novel compositions and methods to achieve stable, durable surfaces to resist high temperature corrosion and coking refinery process furnaces, and more particularly in furnace radiant coils, and other components in refinery process furnaces for transporting or conveying hydrocarbon process streams, which may be prone to coking.
• the present disclosure also provides novel compositions and methods to achieve stable, durable surfaces to resist high temperature corrosion and fouling in fired heater tubes, in refinery process furnaces and other components used for transporting or conveying process streams, which may be prone to fouling.
• the alumina forming bulk alloy may further include intermetallic precipitates at from 0.1 wt.% to 30.0 wt.%, including, but not limited to, Ni 3 Al, NiAl and sigma-phase.
• the alumina forming bulk alloy may further include inclusions at from 0.01 wt.% to 5.0 wt.%, including, but not limited to, oxide, carbide, nitride and carbonitride inclusions.
• These intermetallic precipitates and inclusions are forrmed from the constituting elements of the alumina forming bulk alloy including, but not limited to, Fe, Ni, Cr, Al and Si. Both intermetallic precipitates and oxide, carbide, nitride and carbonitride inclusions may provide improved high temperature creep strength.
• the present disclosure also provides a method for reducing corrosion, coking and/or fouling in refinery process furnaces, and more particularly in furnace radiant coils for the transport of hydrocarbon feedstocks in refinery process operations.
• the method provides a bimetallic tube for use in the refinery process furnaces, and more particularly in furnace radiant coils, including: i) an outer tube layer being formed from carbon steels or low chromium steels comprising less than 15.0 wt.% Cr based on the total weight of the steel; ii) an inner tube layer being formed from an alumina forming bulk alloy comprising 5.0 to 10.0 wt.% of Al, 20.0 wt.% to 25.0 wt.% Cr, less than 0.4 wt.% Si, and at least 35.0 wt.% Fe with the balance being Ni, wherein an inner tube layer is formed by a PPW process on the inner surface of the outer tube layer; and iii) an oxide layer formed on the surface of the inner tube layer, wherein the oxide layer
• compositions disclosed herein include, but are not limited to, a reduction of carburization and sulfidation corrosion and the reduction of coking in fired heater tubes in refining processing facilities, refinery process furnaces, more particularly in furnace radiant coils, and in other ancillary and related industries such as synthetic fuels processes (e.g., coal to liquids, coal gasification and gas to liquids) and other components used for transporting or conveying hydrocarbon process feedstocks, which may be prone to corrosion and coking.
• synthetic fuels processes e.g., coal to liquids, coal gasification and gas to liquids
• the present disclosure also relates to the reduction of corrosion and coking associated with process streams, which include, but are not limited to hydrocarbon feedstock streams encountered in refinery process furnaces. It more particularly relates to methods of reducing corrosion and coking in fired heater tubes in refinery process furnaces by use of alumina forming bimetallic tube.
• the bimetallic tubes of the present disclosure described herein may be utilized in the following non-limiting types of applications and uses.
• Surfaces of the fired heater tubes which would benefit from the alumina forming bulk alloy of the instant disclosure include apparatus, reactor systems and units that are in contact with hydrocarbon process streams at any time during use.
• these apparatus, reactor systems and units include, but are not limited to, atmospheric and vacuum distillation pipestills, cokers and visbreakers in refinery processing facilities and other components used for transporting or conveying process streams, which may be prone to corrosion and fouling.
• the resultant bimetallic tube was comprised of: i) a 9.5 mm thick outer tube layer of T9 low chromium steel; ii) a 2.0 mm thick inner tube layer being formed from an alumina forming bulk alloy; and iii) a 50 nm thick native alumina film formed on the surface of the inner tube layer.
• the cross sectional image of the bimetallic tube revealing the outer 9Cr steel layer and the inner alumina- forming PPW layer is shown in Figure 1.
• EDXS is not as accurate as EPMA, but still provides a result that the inner tube layer being formed from an alumina forming bulk alloy is comprised of 5.0 to 10.0 wt.% of Al, 20.0 wt.% to 25.0 wt.% Cr, less than 0.4 wt.% Si, and at least 35.0 wt.% Fe with the balance being Ni. Scattering of each data point is due to presence of intermetallic precipitates, Cr-rich carbide precipitates, and aluminum nitride inclusions in the PPW layer.
• Example 2 Crack- free alumina- forming bimetallic tube made out of 9Cr (T9 low chromium steel.
• Example 3 (Comparative Example): Cracked alumina- forming bimetallic tube made out of 9Cr (T9 low chromium steel.
• the resultant bimetallic tube was comprised of: i) a 9.5 mm thick outer tube layer of T9 low chromium steel; ii) a 2.0 mm thick inner tube layer being formed from an alumina forming bulk alloy; and iii) a 50 nm thick native alumina film formed on the surface of the inner tube layer.
• the cross sectional image of the bimetallic tube revealing the outer 9Cr steel layer and the inner alumina- forming PPW layer is shown in Figure 1.
• the chemical composition of alumina forming bulk alloy determined by EPMA was Balanced Ni:22.10Cr:6.90Al:36.30Fe:0.20Si in wt.%. Since Si concentration was less than 0.4 wt.%, Fe concentration was at least 35.0 wt.%, and Cr concentration was 20.0 wt.% to 24.0 wt.%, a crack-free alumina-forming bimetallic tube was fabricated. Detailed microscopic examination by use of SEM revealed columnar grain structure of the inner tube layer being formed from an alumina forming bulk alloy by a PPW process. Also observed in the microstructure were Al-rich Ni 3 Al or NiAl type grains, aluminum nitride inclusions and Cr-rich carbide precipitates.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Organic Chemistry (AREA)
• Oil, Petroleum & Natural Gas (AREA)
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• Chemical Kinetics & Catalysis (AREA)
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• Materials Engineering (AREA)
• Plasma & Fusion (AREA)
• Thermal Sciences (AREA)
• Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)

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• 2011
  • 2011-10-17 CN CN2011800615015A patent/CN103282137A/zh active Pending
  • 2011-10-17 BR BR112013009481A patent/BR112013009481A2/pt not_active IP Right Cessation
  • 2011-10-17 CA CA2815357A patent/CA2815357A1/en not_active Abandoned
  • 2011-10-17 KR KR1020137012848A patent/KR20130138805A/ko not_active Application Discontinuation
  • 2011-10-17 WO PCT/US2011/056528 patent/WO2012054377A1/en active Application Filing
  • 2011-10-17 EP EP11834922.4A patent/EP2629903A1/en not_active Withdrawn
  • 2011-10-17 JP JP2013534985A patent/JP2014501620A/ja active Pending

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