Nickel based alloys to prevent metal dusting degradation

Abstract

An article of manufacture for reducing susceptibility of a metal pipe to metal dusting degradation. The article includes a multi-layer tubing having an alloy layer and a copper layer. The alloy layer can include a Ni based, an Al based and an Fe based alloy layer. In addition, layers of chrome oxide, spinel and aluminum oxide can be used.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS [0001] This application claims the benefit under 35 USC 119(e) of U.S. Application 60 / 686,480, filed Jun. 1, 2005, incorporated herein by reference in its entirety.GOVERNMENT INTEREST [0002] The United States Government has certain rights in the invention pursuant to Contract No. W-31-109-ENG-38 between the U.S. Department of Energy and the University of Chicago operating Argonne National Laboratory.BACKGROUND OF THE INVENTION [0003] This invention relates to a method of manufacture and alloy composition for preventing metal dusting degradation. More particularly the invention relates to nickel-based alloys with aluminum addition and also to the use of a copper-based layer to prevent metal dusting-corrosion. [0004] Metal dusting is a catastrophic corrosion phenomenon that leads to the deterioration of structural metals and alloys into a dust composed of fine particles of the metal / alloy and carbon. This is usually a localized form of at...

AI Technical Summary

Benefits of technology

[0012] The solubility and diffusion rate of carbon in copper are low. Therefore, copper is an excellent material to prevent metal dusting. However, the mechanical strength of copper at high temperature is too low. It is thus difficult to directly use pure copper as a structural material at elevated temperatures. Most of the materials used in metal dusting environment are in the form of vessels, tubing, and piping. Therefore, bimetallic tubing was prepared with an inner copper tubing and an outer Fe or Ni-base alloy tubing to prevent metal dusting corrosion. This dense copper layer on the inside diameter stops the formation / deposit of carbon and also stops the diffusion of carbon, thereby preventing the outer alloy tube from metal dusting corrosion.

[0013] The present invention also relates to several Ni-base alloys as materials for use to provide superior resistance to metal dusting degradation when exposed to highly carbonaceous gaseous environments that are prevalent in hydrogen-, methanol-, and ammonia-reformers and in syngas plants. In addition, the alloys developed have adequate strength properties for use as monolithic structural materials in the chemical, petrochemical, and syngas plants at temperatures up to 900° C. The alloys developed have composition ranges (in wt. %) as follows: C 0.02-0.2, Cr 22-29, Al 2.3-3.3, Fe 0-1, Ti 0.3, Zr 0.1-0.2, Y 0-0.1, Balance Ni (all ranges are approximate). The Ti, Zr and C additions are made to control the carbide precipitation and thereby improve the mechanical strength properties at elevated temperatures. Zr and Y additions also contribute to improve the adhesion of the oxide scale to the substrate alloy. The Cr and Al additions in the alloy greatly assist in resisting metal dusting.

Problems solved by technology

However, carbon atoms still can diffuse through the defects in oxide scale and reduce the Fe-containing spinel phase to form channels for carbon diffusion.

Whenever the channels form, there is no way to stop the diffusion of carbon into alloys.

This process leads to initiation and propagation of pitting corrosion.

However, the mechanical strength of copper at high temperature is too low.

It is thus difficult to directly use pure copper as a structural material at elevated temperatures.

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