SBIR Phase II: Mitigation of Coke Deposits on Heat Transfer Surfaces Via Ion Implantation

这个小企业创新研究（SBIR）第二阶段项目涉及使用离子注入来改变金属合金的表面性质，以减缓碳氢化合物热裂解生产烯烃过程中在炉管上形成的催化焦的生长。由于焦炭沉积降低了传热速率、热效率和产品产率，因此控制炉管中的焦炭生长速率可以显著提高烯烃生产的盈利能力。在第一阶段中，通过离子注入选定的元素，金属试样上的焦炭形成速率显著降低。离子注入产生焦炭抑制表面层，与使用替代处理方法形成的纯涂层相比，该焦炭抑制表面层在热裂解器的苛刻条件下不易于降解。在第二阶段，将使用被称为等离子体离子浸没注入和沉积（PIIID）的保形处理方法来制备测试样本，并且将使用实验室测试仪来测量注入物组合物对焦炭抑制的影响。 热裂解反应器该方法将用于处理将在中试规模的焦化反应器中进行测试的工业炉管段。 该项目开发的技术将使用于生产乙烯、丙烯和丁烯等烯烃的热裂解炉的处理炉管的在线时间、效率和产品收率大幅提高。焦炭形成估计花费现代乙烯设施每年约10，000，000美元。

This Small Business Innovation Research(SBIR) Phase II project involves use of ion implantation for modifying the surface properties of metal alloys to mitigate the growth of catalytic coke that forms on furnace tubes during the thermal cracking of hydrocarbons for the production of olefins. Because coke deposits diminish heat transfer rates, thermal efficiencies and product yields, the control of coke growth rate in furnace tubes can significantly enhance the profitability of olefins production. A substantial reduction in the the rate of coke formation on metal coupons by ion implantation of selected elements was demonstrated in Phase I. Ion implantation produces a coke-inhibiting surface layer that is less prone to degradation under the harsh conditions of a thermal cracker compared to pure coatings formed using alternate treatment methods. In Phase II, test specimens will be prepared using a conformal treatment method known as plasma ion immersion implantation and deposition (PIIID), and the effect of implant composition on coke inhibition will be measured using a lab- scale thermal cracking reactor. The method will be used to treat an industrial furnace tube section that will be tested in a pilot-scale coking reactor. The technology developed in this program will lead to treated furnace tubes with substantially increased on-line time, efficiency and product yield for thermal crackers used to produce olefins such as ethylene, propylene and butylene. Coke formation is estimated to cost a modern ethylene facility about $10,000,000 per year.