Hydrocarbon Contact Surfaces With Phosphorus Chelating Anti-Coking Layer

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Solution Overview

Problem

Carbonaceous deposits (coke) form on surfaces of gas turbine engine components contacting hydrocarbon fluids at elevated temperatures, leading to reduced engine performance, increased corrosion, and the need for costly de-coking procedures.

Innovation Solution

A method involving forming a contact surface from metals like nickel, palladium, or platinum and treating it with a phosphorus ligand-based metal-ligand complex to create a chelating layer that prevents coke deposition, using a multi-layer coating system with a ceramic barrier layer to inhibit interdiffusion and chemical attacks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If surfaces are exposed to hydrocarbon fluids at elevated temperatures, then engine operation is enabled, but carbonaceous deposits form on the surfaces

Engineering Contradiction:

Improveengine operationVSAvoidcoke deposition

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

A metal-ligand complex coating is applied as an intermediary layer between the metal surface and the hydrocarbon fluid. This coating includes a metal layer (nickel, palladium, or platinum) and a ligand layer (phosphorus-containing compound) that acts as a mediator to prevent direct contact between the fuel and metal surface, thereby preventing coke deposition while allowing engine operation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution uses a composite coating structure combining metal and organic ligand materials. The metal layer provides thermal stability and catalytic properties, while the phosphorus-containing ligand layer provides anti-coking properties. This composite material approach allows the surface to withstand elevated temperatures while preventing carbonaceous deposit formation

Inventive Principle:

Principle #40Composite materials

2Duration of action of stationary object

If coke deposits build up on surfaces, then engine operation continues, but material corrosion and erosion increase

Engineering Contradiction:

Improvecomponent service lifeVSAvoidcorrosion and erosion

Core Design Contradiction:

Duration of action of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The metal-ligand complex coating serves as a protective intermediary barrier that prevents coke deposits from directly contacting and corroding the underlying metal component. This mediator layer absorbs the harmful effects of carbonaceous deposits, protecting the base material from corrosion and erosion during extended engine operation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If de-coking procedures are performed frequently, then coke deposits are removed, but engine maintenance complexity and cost increase

Engineering Contradiction:

Improvedeposit-free operationVSAvoidmaintenance procedures

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The metal-ligand complex coating is applied in advance to the metal surface before engine operation begins. This preliminary protective action creates a coke-resistant surface that prevents deposit formation during normal operation, eliminating the need for frequent de-coking maintenance procedures

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The coating provides self-protecting properties to the metal surface, enabling it to resist coke deposition autonomously during engine operation. This self-service capability eliminates the need for external de-coking interventions, reducing maintenance complexity while ensuring reliable deposit-free operation

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Significantly reduces coke deposition and adhesion, enhancing engine performance by minimizing material erosion and corrosion, and eliminating the need for frequent de-coking procedures.

Implementation Method 1

treating the contact surface with a metal-ligand complex precursor comprising a phosphorus (P) ligand

Methodology Applied

Scientific EffectCoordination bonding: Chemical Bonding

Implementation Method 2

treating the contact surface with a metal-ligand complex precursor

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS11686003B2Surfaces for contacting a hydrocarbon fluid and methods for preparing the same

Publication Date: 2023.06.27 GENERAL ELECTRIC CO

AI summary

A component configured to be in contact with a hydrocarbon fluid and a method of preparing a contact surface of the component. The component may include a wall having the contact surface configured to be in contact with the hydrocarbon fluid. The contact surface is formed from a metal comprising a metal M, where M is selected from the group consisting of nickel (Ni), palladium (Pd), and platinum (Pt). A metal-ligand complex comprising phosphorus (P) is on the contact surface. The method of preparing a contact surface of the component may include treating the contact surface with a metal-ligand complex precursor comprising a phosphorus (P) ligand.