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The Application of Ceramic Coatings to Extend Radiant Tube Life in Process Heaters and Improve Operational Efficiency with Cost Benefit Analysis

Picture for The Application of Ceramic Coatings to Extend Radiant Tube Life in Process Heaters and Improve Operational Efficiency with Cost Benefit Analysis
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Ceramic coatings technologies are an effective surface engineering tool in the management of heat flux on metal surfaces. Thin ceramic coatings can be employed to either increase or decrease heat transfer on metal surfaces by modulation of emissivity. While this characteristic is relatively easily impressed on a surface, long term coating sustainability and oxidation protection of the underlying metal is not readily achieved. This presentation provides a technical data-based introduction to the function, performance, testing, and installation of ceramic coatings on two key pieces of refining equipment.
• Process heaters are critical production assets for the downstream hydrocarbon processing industries such as refineries and petrochemical plants. The efficient operation of these units is vital to plant productivity since they consume large amounts of energy to provide the required heat for the process. They may also bottleneck feed throughout due to heat transfer limits. Scaling and hot spots in the radiant tube section can cause local coking and premature material failure. Improvements in operating efficiency and reliability can yield significant cost benefits and a fast return on investment. Additionally, radiant transfer properties of existing refractory systems can be improved, increasing process efficiencies. Know ceramic performance metrics can be used to predictively model performance improvement. • Flare tips routinely suffer from material overheat, creep and oxidation. Ceramic systems are employed to mitigate these, through the installation of both low emissivity and low conductive heat transfer materials. This paper and case study discusses how different ceramic systems can be used in the management of heat transfer, the protection of surfaces from corrosion, and provide insight into the less intuitive mode by which heat transfer can be promoted.

Product Number: MPWT19-14438
Author: John Bacon, Johannes Poth and Iain Hall
Publication Date: 2019
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Mitigation of Caustic Corrosion: Alloy and Process Considerations for High Velocity Thermal Spray Cladding

Product Number: MPWT19-14436
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The use of High-Velocity Thermal Spray (HVTS) technology has been well adopted for sour conditions; particularly where low, or locally low, pH conditions result in corrosion and shell thinning. High alloy systems resistant to low pH or acidic conditions are effective at providing a metallurgical barrier, protecting the underlying substrate from material loss. Moreover, HVTS processes have also been employed for mitigating environmentally induced cracking (EIC) in sour service. This paper discusses the suitability and performance of modified HVTS alloys for service where high pH general corrosion or caustic cracking (CSCC) may occur. Extensive testing has been undertaken in both ambient and high pressure and temperature autoclave conditions to better understand material performance in caustic environments. While Nickel Alloy 200 and Monel 400 may be deemed appropriate based on traditional material selections, thermal spray process considerations in the material deposition and the impact of ancillary elements in the process stream, such as halides, render these alloys unsuitable. More complex Nickel alloy cladding systems are evaluated in this study with suitable material recommendations for remediation without the deleterious heat impact of welding or to protect surfaces where heat affected zones have been created and post weld heat treatment is problematic.
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Test Method for Coatings under Thermal Insulation

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06458 UNDER-DEPOSIT CORROSION MECHANISMS IN BOILERS

Product Number: 51300-06458-SG
ISBN: 06458 2006 CP
Author: A.G. Howell
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Under-deposit corrosion is a common mode of failure in boiler tubes. Mechanisms include phosphate attack, caustic gouging, hydrogen damage, and wall thinning due to metal loss. Many aspects of these mechanisms and their mitigation are well-understood, while certain specific details remain uncertain or subject to controversy.

 
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