Nickel Aluminide Slurry Coating for Metal-Dusting Burner Alloys

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing burners for hydrocarbon fuelled combustion reactors face degradation due to high temperature corrosion caused by metal dusting, particularly affecting Ni-based alloys, despite existing coatings not providing sufficient protection.

Innovation Solution

Application of a nickel aluminide diffusion coating using a Cr(VI) free, silicate-based aluminum slurry on burner parts, followed by a controlled two-step heat treatment, forming a protective and uniform coating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional coatings are applied to Ni-based alloy burners, then some protection is provided, but resistance to metal dusting corrosion is insufficient

Engineering Contradiction:

Improveresistance to metal dusting corrosionVSAvoidservice life of burner components

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent applies a nickel aluminide diffusion coating through controlled heat treatment at specific temperatures (900-1100°C) to transform the surface composition and structure of the Ni-based alloy, creating a protective layer with enhanced resistance to metal dusting corrosion while maintaining the bulk material properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure consisting of a Ni-based alloy substrate with a nickel aluminide diffusion coating layer, combining the high temperature strength of the Ni-alloy with the corrosion resistance of the aluminide layer to achieve superior overall performance

Inventive Principle:

Principle #40Composite materials

2Productivity

If high gas flow velocities are used for intensive mixing, then combustion intensity is improved, but overheating and degradation of the burner face occur

Engineering Contradiction:

Improvecombustion intensityVSAvoidoverheating and degradation of burner face

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies a protective nickel aluminide diffusion coating to the burner face before operation, creating a pre-established barrier that protects the substrate from high temperature corrosion and metal dusting attacks during high-intensity combustion operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the harmful effect of high temperature and recirculating hot gases into a beneficial controlled diffusion process during coating formation, where the same thermal conditions that cause degradation are used to create the protective coating in the first place

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 coating significantly increases the lifetime of burner components by providing resistance to high temperature corrosion, with observed lifetimes increasing from 2 months to over 2 years.

Implementation Method 1

nickel aluminide diffusion coating applied by a Cr (VI) free, silicate based aluminium slurry

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

followed by a controlled two-step heat treatment, forming a protective and uniform coating

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS12584627B2Nickel-based alloy with a slurry coating, with high resistance to metal dusting

Publication Date: 2026.03.24 HALDOR TOPSOE AS

AI summary

A nickel-based alloy is coated with a silicate based nickel aluminide slurry diffusion coating.