High performance alloys with improved metal dusting corrosion resistance

Abstract

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.

1 - 54 . (canceled) 
     
     
         55 . The method of preventing metal dusting of claim  54 , wherein said alloy composition is from about 10 to about 200 microns in thickness. 
     
     
         56 . The method of preventing metal dusting of claim  48 , wherein said multi-layer oxide film is formed in situ during use of said alloy composition in a carbon supersaturated metal dusting environment. 
     
     
         57 . The method of preventing metal dusting of claim  48 , wherein said alloy composition comprises the inner surface of refinery apparatus and reactor systems exposed to a carbon supersaturated environment. 
     
     
         58 . An alloy composition comprising an alloy (PQR), wherein
 P is a metal selected from the group consisting of Fe, Ni, Co, and mixtures thereof wherein P comprises at least about 40 wt % of (PQR),   Q is an alloying metal comprising Cr, Mn, and Al wherein Q comprises at least about 20 wt % of (PQR), wherein Cr is at a concentration of at least about 10 wt %, Mn is at a concentration of at least about 2.5 wt %, and Al is at a concentration of at least about 2.0 wt % of said alloy (PQR), and   R is an alloying element wherein R comprises about 0.01 wt % to about 5.0 wt % of (PQR).   
     
     
         59 . The alloy composition of  claim 58 , wherein said alloying element R is selected from the group consisting of B, C, N, Si, P, Ga, Ge, As, In, Sn, Sb, Pb, Sc, La, Y, Ce, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au, and mixtures thereof. 
     
     
         60 . The alloy composition of  claim 58 , wherein said metal P comprises at least about 60 wt %, said alloying metal Q comprises at least about 30 wt %, and said alloying element R comprises about 1.0 wt % to about 5.0 wt % of said alloy (PQR), wherein Cr is at a concentration of at least about 20 wt %, Mn is at a concentration of at least about 7.5 wt %, and Al is at a concentration of at least about 4.0 wt % of said alloy (PQR). 
     
     
         61 . An alloy composition comprising an alloy (PQR), wherein
 P is a metal selected from the group consisting of Fe, Ni, Co, and mixtures thereof wherein P comprises at least about 40 wt % of (PQR),   Q is an alloying metal comprising Cr, Mn, and Si wherein Q comprises at least about 20 wt % of (PQR), wherein Cr is at a concentration of at least about 10 wt %, Mn is at a concentration of at least about 2.5 wt %, and Si is at a concentration of at least about 2.0 wt % of said alloy (PQR), and   R is an alloying element wherein R comprises about 0.01 wt % to about 5.0 wt % of (PQR).   
     
     
         62 . The alloy composition of  claim 61 , wherein said alloying element R is selected from the group consisting of B, C, N, Al, P, Ga, Ge, As, In, Sn, Sb, Pb, Sc, La, Y, Ce, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au, and mixtures thereof. 
     
     
         63 . The alloy composition of  claim 61 , wherein said metal P comprises at least about 60 wt %, said alloying metal Q comprises at least about 30 wt %, and said alloying element R comprises about 1.0 wt % to about 5.0 wt % of said alloy (PQR), wherein Cr is at a concentration of at least about 20 wt %, Mn is at a concentration of at least about 7.5 wt %, and Si is at a concentration of at least about 4.0 wt % of said alloy (PQR). 
     
     
         64 . An alloy composition comprising an alloy (PQR), wherein
 P is a metal selected from the group consisting of Fe, Ni, Co, and mixtures thereof wherein P comprises at least about 40 wt % of (PQR),   Q is an alloying metal comprising Cr, Mn, Al, and Si wherein Q comprises at least about 20 wt % of (PQR), wherein Cr is at a concentration of at least about 10 wt %, Mn is at a concentration of at least about 2.5 wt %, Al is at a concentration of at least about 2.0 wt %, and Si at a concentration of at least 2.0 wt % of said alloy (PQR), and   R is an alloying element wherein R comprises about 0.01 wt % to about 5.0 wt % of (PQR).   
     
     
         65 . The alloy composition of  claim 64 , wherein said alloying element R is selected from the group consisting of B, C, N, P, Ga, Ge, As, In, Sn, Sb, Pb, Sc, La, Y, Ce, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au, and mixtures thereof. 
     
     
         66 . The alloy composition of  claim 64 , wherein said metal P comprises at least about 60 wt %, said alloying metal Q comprises at least about 30 wt %, and said alloying element R comprises about 1.0 wt % to about 5.0 wt % of said alloy (PQR), wherein Cr is at a concentration of at least about 20 wt %, Mn is at a concentration of at least about 6 wt %, Al is at a concentration of at least about 4.0 wt %, and Si is at a concentration of at least about 4.0 wt % of said alloy (PQR).