CoatAlloy Barrier Coating for Reduced Coke Formation in Steam Cracking Reactors: Experimental Validation and Simulations

Olahová, Natália; Symoens, Steffen H.; Djokic, Marko; Ristic, Nenad; Sarris, Stamatis A.; Couvrat, Mathieu; Riallant, Fanny; Chasselin, Hugues; Reyniers, Marie-Françoise

doi:10.1021/acs.iecr.7b04271

Cited by 14 publications

(11 citation statements)

References 24 publications

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“…All the findings show that the coating is capable of reducing coke formation and maintains its anticoking activity over multiple cracking-decoking cycles, while reducing the CO and CO 2 yields. 49 2.3.2. AlcroPlex.…”

Section: Coatingsmentioning

confidence: 99%

State-of-the-art of Coke Formation during Steam Cracking: Anti-Coking Surface Technologies

Symoens

Olahová

Gandarillas³

et al. 2018

Ind. Eng. Chem. Res.

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Although steam cracking is a mature technology, mitigation of coke formation remains one of the main challenges in the petrochemical industry. To increase the olefin output of existing plants, coil materials that can withstand higher temperatures are desired. This work reviews material technologies that were developed and tested in the past three decades to minimize the rate of coke deposition and extend the furnace run length. The material not only determines the mechanical properties of the coil but also affects the coking rate substantially. In some cases, differences in coking rates by more than a factor 10 have been observed. SiC materials could be operated at significantly higher temperatures, and this leads to higher olefin selectivity if one includes acetylene hydrogenation; however, the mechanical joints make it currently impossible to take advantage of their superior temperature resistance. On the industrial scale, operational improvements have been reported with advanced reactor surface technologies such as high-performance alloys and coatings during the past decade. Catalytic coatings go a step further than barrier coatings by actively removing coke that is deposited on the coils. Another trend is to add aluminum to the coil material, which forms a protective aluminum oxide layer on the reactor wall during operation and results in reduced carburization. To optimize the coking mitigation capabilities of the coils, the state-of-the-art materials and/or coatings should be combined with 3D reactor technologies, which is not always possible for all materials because of the advanced machining that is needed.

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Section: Coatingsmentioning

confidence: 99%

State-of-the-art of Coke Formation during Steam Cracking: Anti-Coking Surface Technologies

Symoens

Olahová

Gandarillas³

et al. 2018

Ind. Eng. Chem. Res.

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“…This is the dominant route for fouling in the early cracking stages because of the largely accessible coil surface . Hence, development of surface technologies, such as high-performance alloys, , coatings, , optimization of coil pretreatment, and additives , is part of the strategies for mitigation of coke formation.…”

Section: Introductionmentioning

confidence: 99%

Crude to Olefins: Effect of Feedstock Composition on Coke Formation in a Bench-Scale Steam Cracking Furnace

Geerts

Ristic

Djokic

et al. 2020

Ind. Eng. Chem. Res.

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A novel experimental unit has been designed, allowing the examination of the fouling tendency in all relevant sections of a steam cracking furnace, that is, dry feed preheater (DFP), dilute feed preheater I & II (DFPH I & II), radiant section, and transfer line exchanger in a single experiment, using among others an electrobalance. Large differences in coke deposition have been observed in each of these sections when cracking a wide range gas oil (WRGO) and a naphtha fraction (NF). WRGO results in fouling rates which are 20, 86, 253, and 10 times higher in the DFP, DFPH I, DFPH II, and transfer line heat exchanger sections compared to the NF, whereas the fouling rate in the radiant section is 56% lower. The standard deviations are 13, 18, and 7% for DFP, DFPH I, and DFPH II, respectively. Online effluent analysis reveals that significantly less valuable olefins and more Pygas and pyrolysis fuel oil (PFO) are formed during WRGO cracking compared to NF cracking, that is, 16.2 wt % versus 21.9 wt % ethylene, 12.1 wt % versus 14.1 wt % propylene, 24.8 wt % versus 19.6 wt % Pygas, and 14.1 wt % versus 11.3 wt % PFO. This unit can thus provide vital information to develop single step crude to olefin process by examining possible heavy feedstocks.

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“…By 2001, CoatAlloy TM coatings were installed in 25 furnaces globally and typically resulted in a decrease in coking rate by about 90% with no reported effect on carbon oxides formation [43]. Recently, Olahová et al [45], evaluated the performance of CoatAlloy™ at a pilot plant, by measuring the total amount of coke and providing CO and CO 2 yields. In all coating technologies no exact details are provided on decoking, pretreatment or cracking conditions, nor a one-to-one comparison is done, therefore the real impact of one particular element to coke formation is difficult to assess.…”

Section: Introductionmentioning

confidence: 99%

Alumina-based Coating for Coke Reduction in Steam Crackers

et al. 2020

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Alumina-based coatings have been claimed as being an advantageous modification in industrial ethylene furnaces. In this work, on-line experimentally measured coking rates of a commercial coating (CoatAlloy™) have pointed out its superiority compared to an uncoated reference material in an electrobalance set-up. Additionally, the effects of presulfiding with 500 ppmw DMDS per H2O, continuous addition of 41 ppmw S per HC of DMDS, and a combination thereof were evaluated during ethane steam cracking under industrially relevant conditions (Tgasphase = 1173 K, Ptot = 0.1 MPa, XC2H6 = 70%, dilution δ = 0.33 kgH2O/kgHC). The examined samples were further evaluated using online thermogravimetry, scanning electron microscopy and energy diffractive X-ray for surface and cross-section analysis together with X-ray photoelectron spectroscopy and wavelength-dispersive X-ray spectroscopy for surface analysis. The passivating coating illustrated a better performance than the reference Ni-Cr Fe-base alloy after application of an improved pretreatment, followed by piddling changes on the product distribution. Presulfiding of the coating affected negatively the observed coking rates in comparison with the reference alloy, so alternative presulfiding and sulfur addition strategies are recommended when using this barrier coating.

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CoatAlloy Barrier Coating for Reduced Coke Formation in Steam Cracking Reactors: Experimental Validation and Simulations

Cited by 14 publications

References 24 publications

State-of-the-art of Coke Formation during Steam Cracking: Anti-Coking Surface Technologies

State-of-the-art of Coke Formation during Steam Cracking: Anti-Coking Surface Technologies

Crude to Olefins: Effect of Feedstock Composition on Coke Formation in a Bench-Scale Steam Cracking Furnace

Alumina-based Coating for Coke Reduction in Steam Crackers

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