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07419 The Effect of Plasma Powder Welded Overlay on Carburization and Coke Formation in Ethylene Pyrolysis Furnace Tubes

Picture for 07419 The Effect of Plasma Powder Welded Overlay on Carburization and Coke Formation in Ethylene Pyr
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Product Number: 51300-07419-SG
ISBN: 07419 2007 CP
Author: Toshihide Maeda and F.X. Terwijn
Publication Date: 2007
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Ethylene pyrolysis furnace tubes with a high-Cr, high-Ni alloy, weld overlaid by Plasma Powder Welding (PPW) technique, were evaluated in a laboratory and in commercial furnaces. These tubes have a thick layer (approx. 2.0mm) of 45 % Cr, 50 % Ni and 1 % Mo alloy welded on the entire inner surface of HP-mod or 35Cr/45Ni base tubes. The carburization behavior of these furnace tubes has been evaluated in the commercial furnaces for over 6 years as well as under accelerated conditions in a laboratory. The results show that if the PPW overlay was applied, no carburization was observed in the base tube under real-life operation conditions where severe carburization occurred in tubes made of conventional materials. This significant tube life improvement can be explained by the mechanism of carbon diffusion through the boundary of PPW overlay and the base tube metal. In addition, a continuous, self healing, and catalytic coke inhibiting chromium oxide layer, recognized on the PPW overlaid surface, results in longer run length, higher ethylene yield, and higher conversion.
Ethylene pyrolysis furnace tubes with a high-Cr, high-Ni alloy, weld overlaid by Plasma Powder Welding (PPW) technique, were evaluated in a laboratory and in commercial furnaces. These tubes have a thick layer (approx. 2.0mm) of 45 % Cr, 50 % Ni and 1 % Mo alloy welded on the entire inner surface of HP-mod or 35Cr/45Ni base tubes. The carburization behavior of these furnace tubes has been evaluated in the commercial furnaces for over 6 years as well as under accelerated conditions in a laboratory. The results show that if the PPW overlay was applied, no carburization was observed in the base tube under real-life operation conditions where severe carburization occurred in tubes made of conventional materials. This significant tube life improvement can be explained by the mechanism of carbon diffusion through the boundary of PPW overlay and the base tube metal. In addition, a continuous, self healing, and catalytic coke inhibiting chromium oxide layer, recognized on the PPW overlaid surface, results in longer run length, higher ethylene yield, and higher conversion.
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02386 A NEW CARBURIZATION RESISTANT ALLOY FOR ETHYLENE PYROLYSIS FURNACE TUBES

Product Number: 51300-02386-SG
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A new wrought alloy has been developed for use as furnace tubes in ethylene pyrolysis plants. This alloy has an excellent carburization resistance due to uniform formation of protective Al2O3 oxide scale on the metal surface. Laboratory corrosion tests have been carried out to evaluate carburization resistance of the developed alloy.
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Tube coils in a radiant section of an ethylene cracking furnace are subject to corrosion.  Repair welding of these tube coils is difficult. A degraded tube section is replaced by welding in a virgin tube section. The current paper presents the test results of a weld joint between a service-exposed tube and virgin tube using automatic orbital and manual gas-tungsten-arc welding (GTAW) processes.
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