Hydrocarbon Contact Surface Coating for Coke-Resistant Engine Components

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Solution Overview

Problem

Carbonaceous deposits (coke) form on surfaces of gas turbine engine components in contact with 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 a contact surface formed from metals like nickel, palladium, or platinum, treated with a phosphorus ligand metal-ligand complex to prevent coke deposition, using a multi-layer coating system with a ceramic barrier layer to inhibit interdiffusion and chemical reactions.

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 operationVSAvoidcarbonaceous deposits
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 prevents direct contact between the fuel and the metal surface, thereby preventing carbonaceous deposit formation while allowing the engine to operate normally at elevated temperatures

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If de-coking procedures are performed to remove deposits, then engine performance is restored, but component lifespan is reduced and maintenance costs increase

Engineering Contradiction:
Improveengine performanceVSAvoidcomponent lifespan
Core Design Contradiction:
ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The metal-ligand complex coating is applied in advance to the metal surface before exposure to hydrocarbon fluids. This preliminary protective action prevents carbonaceous deposits from forming in the first place, eliminating the need for subsequent de-coking procedures and extending component lifespan

Inventive Principle:
Principle #10Preliminary action

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 the formation and adhesion of carbonaceous deposits, enhancing engine performance and extending component lifespan by minimizing corrosion and maintenance costs.

Implementation Method 1

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

Methodology Applied
Scientific EffectAdsorption: Adsorption

Implementation Method 2

using a multi-layer coating system with a ceramic barrier layer to inhibit interdiffusion and chemical reactions

Methodology Applied
Scientific EffectDiffusion barrier: Diffusion Barrier

Data Source

PatentUS12116678B2Surfaces for contacting a hydrocarbon fluid and methods for preparing the same
Publication Date: 2024.10.15 GENERAL ELECTRIC CO
  • US12116678B2 patent drawing
  • US12116678B2 patent drawing
  • US12116678B2 patent drawing

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.