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Materials of construction for a gas turbine

a technology of gas turbines and construction materials, applied in the direction of engines, machines/engines, mechanical equipment, etc., to achieve the effect of cost-effective improvement of power recovery in pta production plants

Active Publication Date: 2014-06-03
KOCH TECH SOLUTIONS LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent text describes a coating that protects components of a gas turbine from corrosion caused by the composition of off-gas streams from para-xylene oxidation. This coating can be used to improve power recovery on a PTA production plant by using standard gas turbines. The technical effect of this coating is to prevent the gas turbine components from getting damaged due to the corrosion caused by the off-gas streams. This results in higher power output from the gas turbine and reduced maintenance costs.

Problems solved by technology

The consequence of these combined problems is the need to protect the internal components of a gas turbine against corrosion or degradation due to the composition of off-gas streams from para-xylene oxidation.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0021]Thermodynamic stability has been calculated to estimate the performance of a range of metals in the alternative range of conditions. Calculations have been made for 950, 1000and 1050° C. and 16 bara for the metallic elements Al, Cr, Co, Cu, Fe, Nb, Ni, Mo, Mn, Si and W to determine the equilibrium composition in a gas with the following composition that contains more than 1.5×the maximum anticipated level of HBr in service:

[0022]

TABLE 1Gas composition for thermodynamic stability calculationsBasisN2CO2O2COH2OHBr% v / v86.6 7.90.50.015.0 30 ppm(balance)% w / w84.212.10.60.013.1166 ppm(balance)

[0023]Phase diagrams have been calculated for a range of oxygen and bromine fugacities, from a gas bromine level of 10−6 to 10−2 bar; the higher fugacities to illustrate the potential effects of bromine concentration at the bases of cracks in protective oxides / coatings.

[0024]The calculations predicted copper forms volatile bromides across the whole range of bromine concentrations. No other meta...

example 2

Experimental Tests—1

[0025]A series of tests was undertaken at 1 bara, with a gas composition as shown in Table 2. The HBr level is about 3×the maximum anticipated level of HBr in service:

[0026]

TABLE 2Gas composition for experimental tests - 1BasisN2CO2O2COH2OHBr% v / v84.54.00.50.0311.0100 ppm(balance)% w / w85.86.40.60.03 7.2294 ppm(balance)

[0027]Samples of the alloy / coating systems in Table 3 were tested in an unloaded condition for a total of 1000 h. Samples were subjected to daily cooling to temperatures below 200° C. for 3 hours and re-heating up to temperatures between 850 and 1050° C. for 21 hours.

[0028]

TABLE 3Test conditions for experimental tests - 1RepresentativeTempera-ComponentAlloyCoatingtures ° C.Blades / bucketsNi-basedUncoated950 / 1050Aluminised950 / 1050HVOF MCrAlY950 / 1050Ni-basedUncoated850 / 950Chromised850 / 950Nozzles / vanesNi-basedUncoated950 / 1050Aluminised950 / 1050Co-basedUncoated950 / 1050Aluminised950 / 1050Combustors / Ni-basedHVOF MCrAlY950 / 1050ductsHVOF MCrAlY + TBC950 / 1050Di...

example 3

Experimental Tests—2

[0033]A series of tests were undertaken at 1 bara gases to investigate whether cracks in protective oxides / coatings are sites of increased corrosion risk. Three gas compositions were used:[0034]low oxygen gas (Table 1)[0035]laboratory air containing up to 4% v / v water to simulate a typical combustion gas with relatively high oxygen content from a conventional application[0036]intermediate oxygen concentration and containing more than 3×the maximum anticipated level of HBr in service (Table 4)

[0037]

TABLE 4Gas composition for experimental tests - 2BasisN2CO2O2COH2OHBr% v / v74.14.06.950 ppm15100 ppm(balance)% w / w75.76.48.150 ppm9.8295 ppm(balance)

[0038]In these three environments, samples of different alloy / coating systems were tested.[0039]i) A commercial diffusion coating formed from an applied slurry comprising about 36% w / w aluminium and about 6% w / w silicon.[0040]ii) MCrAIY / LPPS a commercial, cobalt-based coating comprising about 32% w / w nickel, about 21% w / w ch...

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Abstract

The present invention relates to a means to protect gas turbine components against corrosion from a gaseous stream, produced from an oxidation reaction the reaction being conducted in a continuous oxidation reactor

Description

FIELD OF THE INVENTION[0001]This invention relates to gas turbine components for reduced corrosion when in contact with off gas from paraxylene oxidation. Specifically, the invention relates to gas turbine components constructed of nickel and cobalt based super alloys with aluminide and MCrAIY coatings.BACKGROUND OF THE TECHNOLOGY[0002]The production of terephthalic acid (TA) typically involves the liquid phase oxidation of para-xylene (PX) feedstock using molecular oxygen in acetic acid as a process solvent, in the presence of a dissolved heavy metal catalyst system usually incorporating a promoter, such as bromine as disclosed in U.S. Pat. No. 2,833,816. In general, acetic acid, molecular oxygen in the form of air, para-xylene and catalyst are fed continuously into the oxidation reactor at elevated temperature and pressure, typically a temperature from about 150° C. to about 250° C. and a pressure from about 100 kPa to about 5000 kPa.[0003]Para-xylene oxidation produces a high-pre...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): F02C7/30C22C19/03C22C19/07
CPCF01D5/28F01D25/005F01D25/007F02C7/30C22C19/03C22C19/07
Inventor RICHARDSON, JAMES ANTHONY
Owner KOCH TECH SOLUTIONS LLC
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