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<p>Severe-service materials in cracking reactors face complex corrosion-fouling phenomena driven by sulfur-rich heavy oil. Nickel-based alloys (Inconel 718—IN718) and cobalt-based coatings (Wallex 50—W50) are common materials in petrochemical equipment, but their degradation behavior under heavy oil cracking conditions is seldom explored. Bare IN718 and high-velocity oxygen fuel (HVOF) sprayed W50 were exposed to cracking environments—445&#xa0;°C and &gt; 11&#xa0;MPa, varying hydrogen, catalyst, and agitation—simulating realistic refinery environments. Optical imaging of the surface allowed to semi-quantitatively assess the surface fouling intensity, while SEM-EDS analysis of cross-sections and surfaces offered new perspectives about the sulfidation mechanism, and XRD identified oxides and sulfides in the degradation scale. W50 formed scales with reduced coke accumulation, especially on smoother surfaces. In contrast, IN718 developed more unstable, delaminating scales with severe grain boundary corrosion, particularly under catalytic hydrocracking conditions. The findings suggest that IN718 fouling is primarily governed by the kinetics of sulfidation-induced chemical reactions, whereas W50 fouling is controlled by mass transfer of sulfur-containing species. A phenomenological model is proposed to describe the interplay between the sulfidation mechanism and scale microstructure evolution.</p>

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Heavy Oil Corrosion Fouling of Ni-Based Alloy and Co-Based Thermal Sprayed Coatings

  • 期刊论文

  • 发表日期：

    2025年10月20日

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  • Fellipy S. Rocha,
  • Pedro R. T. Avila,
  • Fadila Khelfaoui,
  • Luc Vernhes,
  • Gregory S. Patience,
  • Kevin J. Smith,
  • Jolanta E. Klemberg-Sapieha,
  • Ludvik Martinu

摘要

Severe-service materials in cracking reactors face complex corrosion-fouling phenomena driven by sulfur-rich heavy oil. Nickel-based alloys (Inconel 718—IN718) and cobalt-based coatings (Wallex 50—W50) are common materials in petrochemical equipment, but their degradation behavior under heavy oil cracking conditions is seldom explored. Bare IN718 and high-velocity oxygen fuel (HVOF) sprayed W50 were exposed to cracking environments—445 °C and > 11 MPa, varying hydrogen, catalyst, and agitation—simulating realistic refinery environments. Optical imaging of the surface allowed to semi-quantitatively assess the surface fouling intensity, while SEM-EDS analysis of cross-sections and surfaces offered new perspectives about the sulfidation mechanism, and XRD identified oxides and sulfides in the degradation scale. W50 formed scales with reduced coke accumulation, especially on smoother surfaces. In contrast, IN718 developed more unstable, delaminating scales with severe grain boundary corrosion, particularly under catalytic hydrocracking conditions. The findings suggest that IN718 fouling is primarily governed by the kinetics of sulfidation-induced chemical reactions, whereas W50 fouling is controlled by mass transfer of sulfur-containing species. A phenomenological model is proposed to describe the interplay between the sulfidation mechanism and scale microstructure evolution.