Patent ID: 8748008

Claim:
A fired heater tube with enhanced resistance to corrosion and fouling for use in a process unit in which heavy crude or a resid stream is heated for processing, comprising: a tube having an inner surface and an outer surface, the tube comprising: a base metal layer selected from T9 low chromium steel or 347 austenitic stainless steel; a coating metal layer on the base metal layer applied by plasma powder welding and having an average surface roughness (Ra) of less than 40 micro inches (1.1 μm) located on the base metal layer on at least one of the inner surface and the outer surface, the coating metal layer comprising an alloy of 3 wt. % to 10 wt. % aluminum, 15 wt. % to 25 wt. % chromium, and 5 to 40 wt. % iron, carbon in an amount less than 0.1 wt. %, less than 0.8 wt. % silicon with the balance being Ni; and an oxide layer having a thickness of between 1 nm and 100 μm on the coating metal layer, wherein the oxide layer is substantially comprised of alumina, chromia, silica, mullite, spinels, or mixtures thereof, wherein the coating metal layer is between the base metal layer and the oxide layer.