Patent application number | Description | Published |
20080199349 | High performance alloys with improved metal dusting corrosion resistance - Alloy compositions which are resistant to metal dusting corrosion are provided by the present invention. Also provided are methods for preventing metal dusting on metal surfaces exposed to carbon supersaturated environments. The alloy compositions include an alloy (PQR), and a multi-layer oxide film on the surface of the alloy (PQR). The alloy (PQR) includes a metal (P) selected from the group consisting of Fe, Ni, Co, and mixtures thereof, an alloying metal (Q) comprising Cr, Mn, and either Al, Si, or Al/Si, and an alloying element (R). When the alloying metal (Q) includes Al, the multi-layer oxide film on the surface of the alloy includes at least three oxide layers. When the alloying metal (Q) includes Si, the multi-layer oxide film on the surface of the alloy (PQR) includes at least four oxide layers. When the alloying metal (Q) includes Al and Si, the multi-layer oxide film on the surface of the alloy (PQR) includes at least three oxide layers. The multi-layer oxide film is formed in situ during use of the alloy composition in a carbon supersaturated metal dusting environment. Advantages exhibited by the disclosed alloy compositions include improved metal dusting corrosion resistance at high temperatures in carbon-supersaturated environments having relatively low oxygen partial pressures. The disclosed alloy compositions are suitable for use as the inner surfaces in reactor systems and refinery apparatus. | 08-21-2008 |
20080245183 | Advanced erosion resistant oxide cermets - One embodiment of the invention includes a cermet composition represented by the formula (PQ)(RS) comprising: a ceramic phase (PQ) and a binder phase (RS) wherein, | 10-09-2008 |
20080257454 | COMPOSITION GRADIENT CERMETS AND REACTIVE HEAT TREATMENT PROCESS FOR PREPARING SAME - Cermets, particularly composition gradient cermets can be prepared starting with suitable bulk metal alloys by a reactive heat treatment process involving a reactive environment selected from the group consisting of reactive carbon, reactive nitrogen, reactive boron, reactive oxygen and mixtures thereof. | 10-23-2008 |
20080268230 | Advanced erosion-corrosion resistant boride cermets - A cermet composition represented by the formula (PQ)(RS) comprising: a ceramic phase (PQ) and binder phase (RS) wherein, | 10-30-2008 |
20080276757 | EROSION-CORROSION RESISTANT CARBIDE CERMETS FOR LONG TERM HIGH TEMPERATURE SERVICE - Cermets are provided in which the ceramic phase is selected from the group consisting of Cr | 11-13-2008 |
20090186211 | Bimodal and multimodal dense boride cermets with low melting point binder - Multimodal cermet compositions having lower melting point metal binders and methods of making are provided. The multimodal cermet compositions having a low melting point metal binder include: a) a ceramic phase, and b) a low melting point metal binder phase, wherein the ceramic phase is a metal boride with a multimodal distribution of particles, wherein the metal of the metal boride is chosen from Group IV, Group V, Group VI elements of the Long Form of the Periodic Table of Elements, and mixtures thereof, and wherein the low melting metal binder phase is represented by the formula (DEF), wherein D is a base metal chosen from Fe, Ni, Co, Mn and mixtures thereof, E is an alloying metal comprising Cr, Si, and B, and F is an alloying element chosen from C, N, P, Al, Ga, Ge, As, In, Sn, Sb, Pb, Sc, La, Y, Ce, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Re, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au and mixtures thereof, and wherein said low melting metal binder phase has a melting point less than 1250° C. The multimodal cermet compositions having a low melting point metal binder may be formed by a powder metallurgy process or an infiltration process. One or more advantages of the multimodal cermets with low melting point binder are high packing density of the ceramic phase, high fracture toughness, and improved erosion resistance at high temperatures up to 1000° C. The multimodal cermets with low melting point binder are suitable in high temperature erosion/corrosion applications in various chemical and petroleum environments. | 07-23-2009 |
20090250377 | Advanced Materials for Regenerative Pyrolysis Reactors, Methods, and Reactors Using the Same - In one aspect, the invention includes an apparatus for pyrolyzing a hydrocarbon feedstock in a regenerative pyrolysis reactor system, the apparatus comprising a regenerative pyrolysis reactor comprising a stabilized refractory grade zirconia in a reactive region of the reactor system. In another aspect, this invention includes a method for pyrolyzing a hydrocarbon feedstock using a reverse flow regenerative pyrolysis reactor comprising the steps of providing a reverse flow regenerative pyrolysis reactor including a stabilized refractory grade zirconia in a heated reaction zone of the reactor; and pyrolyzing a hydrocarbon feedstock within the reactive region. | 10-08-2009 |
20100126907 | Heat Stable Formed Ceramic, Apparatus And Method Of Using The Same - In one aspect, the invention includes a heat stable, formed ceramic component that includes a multimodal grain distribution including (i) at least 50 wt % of coarse grains including stabilized zirconia, the coarse grains comprising a D50 grain size in the range of from 5 to 800 μm, based upon the total weight of the component; and (ii) at least 1 wt % of fine grains comprising a D50 average grain size not greater than one-fourth the D50 grain size of the coarse grain, dispersed within the coarse grains, based upon the total weight of the component; wherein after sintering, the component has porosity at ambient temperature in the range of from 5 to 45 vol. %, based on the formed volume of the component. In other embodiments, the invention includes a process for the manufacture of a hydrocarbon pyrolysis product from a hydrocarbon feed using a regenerative pyrolysis reactor system, comprising the steps of: (a) heating a pyrolysis reactor comprising a bi-modal stabilized zirconia ceramic component to a temperature of at least 1500° C. to create a heated reactive region, wherein after exposing the component to a temperature of at least 1500° C. for two hours the component has a bulk porosity measured at ambient temperature in the range of from 5 to 45 vol. %, based on the bulk volume of the component; (b) feeding a hydrocarbon feed to the heated pyrolysis reactor to pyrolyze the hydrocarbon feed and create a pyrolyzed hydrocarbon feed; and (c) quenching the pyrolyzed hydrocarbon feed to produce the hydrocarbon pyrolysis product. | 05-27-2010 |
20100288617 | Pyrolysis Reactor Materials and Methods - In one aspect, the invention includes a reactor apparatus for pyrolyzing a hydrocarbon feedstock, the apparatus including: a reactor component comprising a refractory material in oxide form, the refractory material having a melting point of at least 2060° C. and which remains in oxide form when exposed to a gas having carbon partial pressure of 10 | 11-18-2010 |
20100290978 | Pyrolysis Reactor Materials and Methods - In one aspect, the invention includes a refractory material for a pyrolysis reactor for pyrolyzing a hydrocarbon feedstock, the refractory material comprising an yttria stabilized zirconia, the refractory material comprising at least 21 wt. % yttria based upon the total weight of the refractory material. In another aspect, this invention includes a method for mitigating carbide corrosion while pyrolyzing a hydrocarbon feedstock at high temperature using a pyrolysis reactor system comprising the steps of: (a) providing a pyrolysis reactor system comprising stabilized zirconia in a heated region of the reactor, the stabilized zirconia including at least 21 wt. % yttria and having porosity of from 5 vol. % to 28 vol. %; (b) heating the heated region to a temperature of at least 1500° C.; and (c) pyrolyzing a hydrocarbon feedstock within the heated region. | 11-18-2010 |
20100292522 | Stabilized Ceramic Composition, Apparatus and Methods of Using the Same - In one aspect, the invention includes a refractory material, said material comprising: (i) at least 20 wt. % of a first grain mode stabilized zirconia based upon the total weight of said material, said first grain mode having a D50 grain size in the range of from 5 to 2000 μm, said stabilized zirconia including a matrix oxide stabilizer; (ii) at least 1 wt. % of a second grain mode having a D50 grain size in the range of from 0.01 μm up to not greater than one-fourth the D50 grain size of said first grain mode zirconia, based upon the total weight of said material; and (iii) at least 1 wt. % of a preservative component within at least one of said first grain mode stabilized zirconia, said second grain mode stabilized zirconia, and an optional another grain mode; wherein after sintering, said material has porosity at 20° C. in the range of from 5 to 45 vol %. | 11-18-2010 |
20100292523 | Pyrolysis Reactor Materials and Methods - In one aspect, the invention includes a reactor apparatus for pyrolyzing a hydrocarbon feedstock, the apparatus including: a reactor component comprising a refractory material in oxide form, the refractory material having a melting point of at least 2060° C. and which remains in oxide form when exposed to a gas having an oxygen partial pressure of 10 | 11-18-2010 |
20110094627 | Erosion Resistant Cermet Linings For Oil & Gas Exploration, Refining and Petrochemical Processing Applications - The present invention is directed to a method for protecting metal surfaces in oil & gas exploration and production, refinery and petrochemical process applications subject to solid particulate erosion at temperatures of up to 1000° C. The method includes the step of providing the metal surfaces in such applications with a hot erosion resistant cermet lining or insert, wherein the cermet lining or insert includes a) about 30 to about 95 vol % of a ceramic phase, and b) a metal binder phase, wherein the cermet lining or insert has a HEAT erosion resistance index of at least 5.0 and a K | 04-28-2011 |
20110104383 | Erosion Resistant Cermet Linings for Oil & Gas Exploration, Refining and Petrochemical Processing Applications - The present invention is directed to a method for protecting metal surfaces in oil & gas exploration and production, refinery and petrochemical process applications subject to solid particulate erosion at temperatures of up to 1000° C. The method includes the step of providing the metal surfaces in such applications with a hot erosion resistant cermet lining or insert, wherein the cermet lining or insert includes a) about 30 to about 95 vol % of a ceramic phase, and b) a metal binder phase, wherein the cermet lining or insert has a HEAT erosion resistance index of at least 5.0 and a K | 05-05-2011 |
20110104384 | Erosion Resistant Cermet Linings for Oil & Gas Exploration, Refining and Petrochemical Processing Applications - The present invention is directed to a method for protecting metal surfaces in oil & gas exploration and production, refinery and petrochemical process applications subject to solid particulate erosion at temperatures of up to 1000° C. The method includes the step of providing the metal surfaces in such applications with a hot erosion resistant cermet lining or insert, wherein the cermet lining or insert includes a) about 30 to about 95 vol % of a ceramic phase, and b) a metal binder phase, wherein the cermet lining or insert has a HEAT erosion resistance index of at least 5.0 and a K | 05-05-2011 |
20110120853 | Porous Pyrolysis Reactor Materials And Methods - In one aspect, the invention includes a reactor apparatus for pyrolyzing a hydrocarbon feedstock, said apparatus including: a reactor component comprising a refractory material in oxide form, the refractory material having a melting point of no less than 2060° C. and which remains in oxide form when exposed to a gas having carbon partial pressure of 10 | 05-26-2011 |
20120177933 | Multi-scale cermets for high temperature erosion-corrosion service - A cermet composition represented by the formula (PQ)(RS)X comprising: a ceramic phase (PQ), a binder phase (RS) and X wherein X is at least one member selected from the group consisting of an oxide dispersoid E, an intermetallic compound F and a derivative compound G wherein said ceramic phase (PQ) is dispersed in the binder phase (RS) as particles of diameter in the range of about 0.5 to 3000 microns, and said X is dispersed in the binder phase (RS) as particles in the size range of about 1 nm to 400 nm. | 07-12-2012 |
20130231238 | Stabilized Ceramic Composition, Apparatus and Methods of Using the Same - In one aspect, the invention includes a refractory material, said material comprising: (i) at least 20 wt. % of a first grain mode stabilized zirconia based upon the total weight of said material, said first grain mode having a D50 grain size in the range of from 5 to 2000 μm, said stabilized zirconia including a matrix oxide stabilizer; (ii) at least 1 wt. % of a second grain mode having a D50 grain size in the range of from 0.01 μm up to not greater than one-fourth the D50 grain size of said first grain mode zirconia, based upon the total weight of said material; and (iii) at least 1 wt. % of a preservative component within at least one of said first grain mode stabilized zirconia, said second grain mode stabilized zirconia, and an optional another grain mode; wherein after sintering, said material has porosity at 20° C. in the range of from 5 to 45 vol %. | 09-05-2013 |