Nickel Aluminide Burner Coating for Metal Dusting Resistance
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Solution Overview
Problem
Conventional burners for hydrocarbon fuelled combustion reactors face challenges in cases where the operating conditions are particularly difficult. The problems experienced in those cases have been degradation of the oxidant nozzle edge of the tube. To address these problems, known art suggests the use of a variety of coatings.
Innovation Solution
The burner includes a surface that potentially comes into contact with a fuel. The surface potentially coming into contact with the flame side of a burner for a gasification reactor that is fuelled with solid or liquid fuel, wherein special embodiments relate to the application of even a plurality of ceramic layers by means of the application technique of plasma spraying, particularly the materials zirconium/yttrium oxide. The service life of the burner is increased by the described coating of the burner cooling parts. Thus the availability of the system is increased while at the same time minimizing maintenance effort. Additionally, less expensive metal materials can be used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coatings (e.g., MCrAlY overlay alloy coating) are applied to protect the burner heat shield, then the resistance to high temperature corrosion is improved, but the coating complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies a composite coating system consisting of an MCrAlY overlay alloy coating combined with an Al2O3 barrier layer. This composite structure provides synergistic protection: the MCrAlY layer offers corrosion resistance while the Al2O3 layer provides a stable barrier against metal dusting, achieving superior reliability without excessive complexity
Solution Approach 2:
The patent applies different coating compositions and thicknesses to different regions of the burner heat shield based on their specific exposure conditions. The coating formulation is optimized for local corrosion environments, providing targeted protection where metal dusting occurs most aggressively
2Productivity
If the burner face is exposed to high gas flow velocities for high combustion intensity, then the combustion efficiency is improved, but the burner face degradation accelerates due to overheating and recirculating hot combustion products
Solution Approach 1:
The patent applies protective coatings to the burner heat shield before operation to cushion against the harsh conditions of high velocity gas flow and recirculating hot products. The MCrAlY and Al2O3 coating layers act as pre-established protective barriers that prevent direct damage to the underlying metal, enabling the burner to withstand high combustion intensities without rapid degradation
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
The burner's service life is extended, and the efficiency of the gasification process is enhanced due to the higher permissible temperature of the supplied oxidizing agent.
Implementation Method 1
a diffusion coating formed from an Al containing slurry
Implementation Method 2
heat treating the Ni-based alloy with the applied silicate based Al containing slurry
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
At least a part of a burner for a catalytic reactor is coated with a silicate based nickel aluminide slurry diffusion coating.