Abstract: The invention relates to an active coating for reducing or eliminating the build-up of coke deposits on a metal surface of a reactor component. The coating comprises a catalyst system and an adhesion/activation promoter. The catalyst system comprises at least a first compound and a second compound. The first compound is selected from one of the following groups of compounds: (a) a Group IA metal salt, (b) a Group IIA metal salt, and (c) a rare earth metal oxide, and the second compound is selected from a different group from the first compound. The adhesion/activation promoter comprises at least a first oxide and a second oxide. The first oxide is selected from one of the following groups of oxides: (d) a Group IIA oxide, (e) a Group IIIA oxide, and (f) a Group IVA oxide, and the second oxide is selected from a different group from the first oxide.

Abstract: A method of providing a protective, corrosion-resistant thin coating of a MCrX alloy on a carbon or low-alloy steel pipe or tube where M is one of nickel, cobalt or iron or combination thereof and X is one of molybdenum, silicon, tungsten or combination thereof, and heat treating the coating to metallurgically bond the coating onto a steel substrate of the pipe or tube. The coating may be deposited in one or two layers by plasma transferred arc deposition or may be deposited as a slurry coating or thermal spray coating with sintering of the coating. The steel substrate is prepared for coating by at least one of boring, honing, bright finishing, grit blasting, grinding, chemical pickling or electro-polishing of the substrate.

Abstract: A method for protecting low-carbon steel and stainless steel from coking and corrosion at elevated temperatures in corrosive environments, such as during ethylene production by pyrolysis of hydrocarbons or the reduction of oxide ores, by coating the stainless steel with a coating of MCrAlXSiT in which M is nickel, cobalt, iron or a mixture thereof, X is yttrium, hafnium, zirconium, lanthanum, scandium or combination thereof, and T is tantalum, titanium, platinum, palladium, rhenium, molybdenum, tungsten, niobium, boron or combination thereof. A blended powder composition to produce a desired MCrAlXSiT surface alloy may be applied to the substrate. The overlay coating and stainless steel substrate preferably are heat-treated at about 1000 to 1200° C. for about 10 minutes or longer effective to metallurgically bond the overlay coating to the substrate and to form a multiphased microstructure.

Abstract: A method for protecting low-carbon steel and stainless steel, and particularly high temperature stainless steel, from coking and corrosion at elevated temperatures in corrosive environments, such as during ethylene production by pyrolysis of hydrocarbons or the reduction of oxide ores, by coating the stainless steel with a coating of MCrAlXSiT in which M is nickel, cobalt, iron or a mixture thereof, X is yttrium, hafnium, zirconium, lanthanum, scandium or combination thereof, and T is tantalum, titanium, platinum, palladium, rhenium, molybdenum, tungsten, niobium, boron or combination thereof. A blended powder composition to produce a desired MCrAlXSiT surface alloy may be applied to the substrate. The overlay coating and stainless steel substrate preferably are heat-treated at about 1000 to 1200° C. for about 10 minutes or longer effective to metallurgically bond the overlay coating to the substrate and to form a multiphased microstructure.

Abstract: A cathode assembly for magnetron sputtering of a workpiece, and sputtering apparatus and methods of sputtering using same are provided. The cathode assembly includes a tubular cathode, which may be cylindrical in cross section along its length, or which may be curved or flexible, depending on the shape of workpiece that is to be sputtered, and which has a sputtering length of Ls. The cathode assembly also includes a magnet package, or a plurality of spaced magnet packages, each magnet package including either one magnet or a plurality of spaced magnets of alternating polarity, and having a magnet package length Lpkg which is less than Ls. The cathode assembly further includes one or more means for positioning, and preventing radial displacement of, the cathode along the axis of symmetry of the cathode.