Centrifugal Cast Tubes for Reactor Charge Heaters

Product Application: Centrifugal Cast Tubes in Reactor Charge Heaters

Centrifugal cast tubes are vital for reactor charge heaters, which preheat feedstocks for processes like hydrocracking, hydrotreating, and catalytic reforming in refining and petrochemical industries. WALKSON’s tubes are designed for the following applications:

· Oil Refining Industry:

Hydrocracking Systems: Tubes preheat heavy feedstocks in high-pressure hydrogen environments, operating at temperatures up to 700°C while resisting corrosion.

Hydrotreating Processes: Support desulfurization and impurity removal, requiring tubes with exceptional resistance to hydrogen-induced degradation.

Catalytic Reforming Units: Enable high-octane gasoline production, with tubes enduring thermal cycling and carburizing atmospheres.

· Petrochemical Processing:

Aromatics Manufacturing: Facilitate the heating of hydrocarbon streams for producing benzene, toluene, and xylene in high-temperature reactors.

· Additional Applications:

Gas-to-liquid (GTL) systems, syngas generation, and other heater systems demanding robust, high-performance tubing.

These tubes are engineered to perform under severe conditions, including temperatures up to 800°C, pressures up to 100 bar, and exposure to corrosive and erosive media, ensuring operational reliability in reactor charge heaters.

Functions of WALKSON Centrifugal Cast Tubes

WALKSON’s centrifugal cast tubes deliver essential functionality in reactor charge heaters:

· Superior Heat Transfer: Precision-engineered tubes maximize heat transfer to feedstocks, improving reactor efficiency and process output.

· High-Temperature Stability: Constructed from high alloy and nickel-based materials (e.g., Inconel 601, Hastelloy C22, HP alloys), tubes maintain integrity under extreme thermal loads.

· Corrosion and Erosion Resistance: Nickel-based alloys protect against sulfidation, carburization, and hydrogen attack, ensuring long-term durability.

· Enhanced Structural Strength: The centrifugal casting process produces a compact, uniform microstructure, boosting creep resistance and mechanical performance.

· Customizable Specifications: Available in diverse diameters, thicknesses, and lengths to fit specific heater configurations.

Manufacturing Process: Precision and Standards Compliance

WALKSON’s centrifugal cast tubes are manufactured using state-of-the-art technology and strict adherence to international standards, ensuring exceptional quality. Below is a detailed overview of the production stages:

1. Material Selection and Verification

· Standards: ASTM A351, ASTM A494, DIN EN 10295, and client-specific requirements.

· Materials: High alloy steels (e.g., HH, HK) and nickel-based alloys (e.g., Inconel 718, Hastelloy B2).

· Process: Materials are sourced from certified suppliers and analyzed for chemical composition per ASTM E350 to confirm alloy purity and compliance.

· Equipment: Advanced optical emission spectrometers for precise material analysis.

2. Alloying and Melting

· Standards: ISO 9001 and ASME Section IX for consistent melt quality.

· Process: Alloys are melted in electric arc or induction furnaces, refined to eliminate contaminants, and conditioned for uniform composition.

· Equipment: High-efficiency electric arc furnaces (EAF) and vacuum induction melting systems.

· Quality Control: Melt samples are tested to meet ASTM E350 standards.

3. Centrifugal Casting

· Standards: ASTM A781, EN 12680, and API 553 for casting integrity.

· Process: Molten alloy is poured into a rotating mold, where centrifugal force compacts the material, forming a dense, defect-free tube with a refined microstructure.

· Equipment: Automated horizontal centrifugal casting machines with precise control over rotation and temperature.

· Benefits: Produces tubes with superior strength, thermal stability, and accurate geometry.

4. Thermal Processing

· Standards: ASTM A703, ASME Section VIII, and client-defined protocols.

· Process: Tubes are heat-treated through annealing, quenching, or tempering to enhance creep resistance, toughness, and corrosion properties.

· Equipment: Programmable heat treatment furnaces with real-time monitoring.

· Quality Control: Thermal cycles are tracked to comply with ISO 9001 standards.

5. Machining and Surface Finishing

· Standards: ISO 2768 for dimensional accuracy, ASME B16.9 for fittings, and ASTM A999 for surface quality.

· Process: Tubes are machined to exact specifications using CNC equipment, with surface finishes optimized for performance. Flanges or connectors are integrated as needed.

· Equipment: CNC lathes, boring machines, and polishing systems.

· Quality Control: Dimensional checks are performed using coordinate measuring machines (CMM).

6. Quality Control and Testing

WALKSON implements stringent testing protocols to ensure tube reliability, offering full transparency to clients and third-party inspectors (e.g., SGS, Bureau Veritas). Clients can witness all tests as outlined in our Inspection and Test Plan (ITP).

Non-Destructive Testing (NDT)

· 100% X-Ray Inspection:

Standard: ASTM E142, EN 12681.

Purpose: Identifies internal flaws like voids, cracks, or inclusions.

Equipment: High-resolution digital X-ray systems.

Process: Full scanning of tubes with detailed reporting of results.

· 100% Eddy Current Testing:

Standard: ASTM E309, EN 1971.

Purpose: Detects surface and near-surface defects, such as micro-cracks or pitting.

Equipment: Multi-frequency eddy current testing units.

Process: Comprehensive surface testing for defect-free assurance.

· Ultrasonic Testing (UT):

Standard: ASTM A388, EN 12680.

Purpose: Verifies wall thickness consistency and internal integrity.

Equipment: Automated ultrasonic scanners with high-frequency probes.

Process: Full-length scanning to ensure structural compliance.

Destructive Testing (where applicable)

· Tensile Strength Testing:

Standard: ASTM E21.

Purpose: Evaluates strength and ductility under stress.

Equipment: High-capacity tensile testing machines.

· Creep Resistance Testing:

Standard: ASTM E292.

Purpose: Assesses performance under sustained high-temperature loads.

Equipment: Specialized creep testing ovens.

· Microstructure Analysis:

Standard: ASTM E1351.

Purpose: Verifies grain structure and material uniformity.

Equipment: Metallographic microscopes with digital imaging.

Hydraulic Pressure Testing

· Standard: ASME B31.3, API 553, and client requirements.

· Purpose: Confirms the tube’s ability to withstand design pressures (e.g., up to 100 bar for reactor charge heaters).

· Process: Tubes are pressurized with water to 1.5 times the design pressure and held to check for leaks or deformation.

· Equipment: Automated hydraulic testing systems with digital pressure gauges.

· Client Witnessing: Clients or third-party inspectors are invited to observe testing for compliance verification.

Documentation

· Inspection and Test Plan (ITP): Comprehensive ITP details all inspection and testing phases, available for client review.

· Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR): Pre-qualified per ASME Section IX for welded components, provided upon request.

· Material Test Reports (MTR): Issued per EN 10204 Type 3.1 or 3.2, documenting chemical, mechanical, and test data.

· Inspection Reports: Detailed records of NDT, pressure tests, and dimensional checks, certified by third-party inspectors if required.

· Reference List: Available to showcase WALKSON’s successful delivery of centrifugal cast tubes to global refining and petrochemical projects.

Advantages of Choosing WALKSON

Selecting WALKSON for centrifugal cast tubes offers distinct advantages, positioning us as the top choice for reactor charge heater components:

1. Exceptional Quality: Our tubes adhere to the highest international standards, supported by 100% NDT and meticulous quality checks.

2. Bespoke Engineering: Custom sizes, alloy formulations, and configurations tailored to specific heater requirements.

3. Global Credibility: Trusted by leading refineries and petrochemical plants worldwide, with a reference list highlighting successful project deliveries.

4. Full Transparency: Third-party inspections (e.g., SGS, BV) and client-witnessed testing ensure trust and accountability.

5. Innovative Manufacturing: Advanced centrifugal casting, CNC machining, and NDT technologies guarantee precision and durability.

6. Expert Guidance: Our skilled engineers offer end-to-end support, from design consultation to system integration.

7. Timely Delivery: Optimized production and logistics ensure fast turnaround without sacrificing quality.

8. Eco-Conscious Practices: Sustainable manufacturing minimizes environmental impact, meeting global green standards.

9. Long-Term Savings: Robust tubes reduce maintenance and downtime, lowering overall operational costs.

Consult with WALKSON Today

Transform your reactor charge heaters with WALKSON’s high alloy and nickel-based centrifugal cast tubes. Designed for resilience, corrosion resistance, and compliance with rigorous industry standards, our tubes deliver outstanding performance in the toughest refining and petrochemical environments.

Contact WALKSON now to explore your project requirements, request a quote, or arrange a consultation with our technical specialists. Visit www.walkson.com or email info@walkson.com (mailto:info@walkson.com). Choose WALKSON as your trusted partner for high-quality centrifugal casting solutions.