Air Pre-Heater Tubes Made from Centrifugal Casting

Product Application: Air Pre-Heater Tubes in Industrial Systems

Air pre-heater tubes are critical components in air pre-heaters, which recover heat from flue gases to preheat combustion air, improving energy efficiency in high-temperature systems. WALKSON’s centrifugal cast air pre-heater tubes are designed for the following applications:

· Petrochemical Industry:

Atmospheric-Vacuum Distillation Units: Tubes enhance heat recovery in refining processes, operating at temperatures up to 600°C while resisting corrosive flue gases.

Hydrogen Reformers and Catalytic Cracking Furnaces: Support efficient air preheating, ensuring optimal combustion in high-pressure environments.

· Metallurgical Industry:

Cold Rolling Continuous Annealing Lines: Tubes improve energy efficiency in radiant tube heaters and furnace rollers, withstanding thermal cycling and oxidation.

Rotary Hearth Furnaces: Facilitate heat recovery in screw discharging devices, enduring abrasive and high-temperature conditions.

· Additional Applications:

Styrene steam superheaters, EDC cracking furnaces, and industrial furnaces in large steel plants, where tubes enhance combustion efficiency and reduce fuel consumption.

These tubes are engineered to perform under challenging conditions, including temperatures up to 650°C, pressures up to 30 bar, and exposure to corrosive gases and particulate matter, ensuring durability in air pre-heater systems.

Functions of WALKSON Air Pre-Heater Tubes

WALKSON’s centrifugal cast air pre-heater tubes deliver essential functionality in industrial systems:

· Optimized Heat Recovery: Precision-crafted tubes maximize heat transfer from flue gases to incoming air, boosting energy efficiency and reducing operational costs.

· High-Temperature Resilience: Made from high alloy and nickel-based materials (e.g., Inconel 600, Hastelloy C276, HP alloys), tubes maintain structural stability in extreme heat.

· Corrosion and Abrasion Resistance: Nickel-based alloys protect against oxidation, sulfidation, and erosion from flue gas particulates, ensuring extended service life.

· Mechanical Reliability: The centrifugal casting process produces a dense, uniform microstructure, enhancing creep resistance and structural integrity.

· Customizable Specifications: Offered in various diameters, wall thicknesses, and lengths to suit diverse air pre-heater designs.

Manufacturing Process: Precision and Standards Compliance

WALKSON’s air pre-heater tubes are manufactured using cutting-edge technology and strict adherence to international standards, reflecting our ISO 9001, ISO 14001, ISO 45001, and O/TSY 1002.1 certifications. Below is a detailed overview of the production stages, leveraging our expertise as a high-tech enterprise with 11 state invention patents, including centrifugal casting technology for Inconel 600:

1. Material Sourcing and Analysis

· 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 625, Hastelloy B2).

· Process: Materials are procured from certified vendors and analyzed for chemical composition per ASTM E350 to ensure alloy purity and compliance.

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

2. Melting and Alloy Refining

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

· Process: Alloys are melted in electric arc or induction furnaces, purified to eliminate impurities, and treated for uniform composition.

· Equipment: High-capacity 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 934 for casting quality.

· 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. This process, refined through our collaboration with the Chinese Academy of Sciences, ensures exceptional quality.

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

· Benefits: Delivers tubes with superior strength, thermal stability, and precise geometry.

4. Heat Treatment

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

· Process: Tubes undergo heat treatments like solution annealing or quenching 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 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. Fittings or connectors are added 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’s rigorous testing protocols, backed by our complete quality management system and long-term partnerships with research universities, ensure tube reliability. We offer full transparency to clients and third-party inspectors (e.g., SGS, Bureau Veritas), with clients invited to 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: Detects 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: Identifies 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 934, and client requirements.

· Purpose: Confirms the tube’s ability to withstand design pressures (e.g., up to 30 bar for air pre-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): Detailed ITP outlines 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: Comprehensive 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 air pre-heater tubes to global refining and metallurgical projects.

Advantages of Choosing WALKSON

Choosing WALKSON for air pre-heater tubes offers distinct advantages, positioning us as the preferred supplier for petrochemical and metallurgical applications:

1. Proven Quality: Our tubes meet stringent international standards, backed by 100% NDT and a robust quality management system certified to ISO 9001, ISO 14001, and ISO 45001.

2. Tailored Solutions: Custom tube designs, alloy formulations, and configurations to meet specific air pre-heater requirements, leveraging our 11 state invention patents.

3. Global Expertise: Trusted by industry giants like SINOPEC, CNPC, and CNOOC, with a reference list highlighting successful deliveries to large refining and steel projects worldwide.

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

5. Innovative Technology: Advanced centrifugal casting, CNC machining, and NDT systems, developed in collaboration with the Chinese Academy of Sciences, deliver precision and durability.

6. Comprehensive Support: Our expert team, backed by our Academician Workstation, provides end-to-end guidance from design to installation.

7. Timely Delivery: Streamlined production and logistics ensure fast turnaround without compromising quality, supporting critical project timelines.

8. Sustainable Practices: Eco-friendly manufacturing aligns with ISO 14001 standards, minimizing environmental impact.

9. Cost Efficiency: Durable tubes reduce maintenance and downtime, lowering long-term operational costs for refining and metallurgical plants.

Consult with WALKSON Today

Elevate your air pre-heater systems with WALKSON’s high alloy and nickel-based centrifugal cast tubes. Engineered for energy efficiency, corrosion resistance, and compliance with rigorous industry standards, our tubes deliver outstanding performance in petrochemical, metallurgical, and industrial furnace applications.

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). Partner with WALKSON, a high-tech enterprise recognized by Jiangsu Province, for high-quality centrifugal casting solutions trusted by global industry leaders.