Centrifugal Cast Heat Exchanger Tubes for Petrochemical Industries

Product Application: Centrifugal Cast Heat Exchanger Tubes in Petrochemical Industries

Centrifugal cast heat exchanger tubes are critical components in petrochemical plants, enabling efficient heat transfer between process fluids in high-temperature and corrosive conditions. WALKSON’s tubes are tailored for the following applications:

· Petrochemical Industry:

Reforming Furnaces: Tubes facilitate heat exchange in hydrogen production, operating at temperatures up to 900°C and resisting corrosive gases like methane and ammonia.

Catalytic Cracking Furnaces: Support heat transfer in hydrocarbon cracking processes, enduring pressures up to 50 bar and carburizing environments.

Styrene Steam Superheaters: Ensure efficient heat exchange in steam-intensive systems, withstanding thermal cycling and chemical exposure.

· Oil Refining Industry:

Atmospheric-Vacuum Distillation Units: Enable heat transfer in crude oil processing, resisting corrosion from sulfur and acidic compounds.

Hydrogenation Heaters: Manage heat exchange in high-pressure hydrogen environments, maintaining integrity under extreme conditions.

· Additional Applications:

EDC Cracking Furnaces: Support heat transfer in chlorinated hydrocarbon systems, resisting aggressive chemical attack.

Pressure Vessels and Towers: Provide reliable tubing for heat exchangers in large refining projects, ensuring leak-free performance.

These tubes are engineered to perform under severe conditions, including temperatures up to 950°C, pressures up to 50 bar, and exposure to corrosive and erosive media, delivering outstanding reliability in petrochemical heat exchangers.

Functions of WALKSON Centrifugal Cast Heat Exchanger Tubes

WALKSON’s centrifugal cast heat exchanger tubes deliver essential functionality in petrochemical industries:

· Efficient Heat Transfer: Precision-crafted tubes optimize thermal conductivity, ensuring effective heat exchange and energy efficiency in process systems.

· High-Temperature Stability: Made from high alloy and nickel-based materials (e.g., Inconel 600, Hastelloy C22, HP alloys), tubes withstand extreme heat without deformation.

· Corrosion Resistance: Nickel-based alloys protect against sulfidation, oxidation, and pitting, ensuring durability in aggressive chemical environments.

· Structural Reliability: The centrifugal casting process produces a dense, uniform microstructure, enhancing creep resistance and mechanical strength.

· Customizable Specifications: Available in various diameters, wall thicknesses, and lengths to meet specific heat exchanger designs.

Manufacturing Process: Precision and Standards Compliance

WALKSON’s centrifugal cast heat exchanger 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 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 625, Hastelloy C276).

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

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

2. Melting and Alloy Purification

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

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

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

· Quality Control: Melt samples are analyzed 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, enhanced through our collaboration with the Chinese Academy of Sciences, ensures superior performance.

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

· Benefits: Produces tubes with exceptional thermal stability, corrosion resistance, and accurate geometry.

4. Heat Treatment

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

· Process: Tubes undergo heat treatments like solution annealing or stress relieving to optimize corrosion resistance, toughness, and creep 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 heat transfer and corrosion resistance. Fittings or flared ends 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, supported by our comprehensive quality management system and 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 50 bar for petrochemical heat exchangers).

· 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 heat exchanger tubes to global petrochemical projects.

Advantages of Choosing WALKSON

Choosing WALKSON for centrifugal cast heat exchanger tubes offers distinct advantages, positioning us as the preferred supplier for petrochemical applications:

1. Superior 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. Customized Engineering: Tailored tube designs, alloy formulations, and configurations to meet specific heat exchanger requirements, leveraging our 11 state invention patents.

3. Global Credibility: Trusted by industry leaders like SINOPEC, CNPC, and CNOOC, with a reference list highlighting successful deliveries to large petrochemical and refining 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. Expert 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 petrochemical plants.

Consult with WALKSON Today

Enhance your petrochemical heat exchangers with WALKSON’s high alloy and nickel-based centrifugal cast tubes. Engineered for optimal heat transfer, corrosion resistance, and compliance with rigorous industry standards, our tubes deliver outstanding performance in the most demanding 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, email info@walkson.com (mailto:info@walkson.com), or reach out via WhatsApp/WeChat. Partner with WALKSON, a high-tech enterprise recognized by Jiangsu Province, for high-quality centrifugal casting solutions trusted by global industry leaders.