Reformer Tubes & Related Components
Reformer tubes and related components are heat-resistant centrifugally cast alloy tubes used in steam reformer furnaces for producing hydrogen, an essential material for such processes as desulfurization at petroleum refining plants, ammonia synthesis for fertilizer production, methanol production, and direct reduced iron production. In the steam reforming process, mostly naphtha and steam are heated at a pressure of 3 MPa or higher up to a temperature of 750-1000°C. Reformer tubes used in extreme environments under high temperatures and pressures are required to have high resistance to heat and extremely high resistance to creep damage.
Reformer tubes convert a hydrocarbon feedstock (usually natural gas) into hydrogen and carbon oxides. Hydrogen is used for applications such as refining petroleum, producing fertilizer, processing foods, and the direct reduction of iron.
During steam methane reforming a heated mixture of the feedstock and steam flow through catalyst-filled reformer tubes within a fired heater. The process takes place at temperatures up to 1,000°C. Hydrogen producers expect reformer tubes to last for 10 to 12 years or longer in this extreme, high-heat environment with only minimal downtime, resisting material stress and thermal creep.
GEP has decades of experience in sourcing centrifugally cast reformer tubes, outlet manifolds, and related components for industrial gas producers, refineries, and ammonia and methanol plants.
Why Centrifugal Casting?
Centrifugal casting is the preferred metal casting process for applications demanding high strength and reliability, such as petrochemical furnace tubes and reformer tubes and components. Centrifugal casting produces defect-free parts with excellent material integrity.
In Centrifugal casting molten metal is poured into a spinning die, which rotates on a vertical or horizontal axis depending on the part’s design. Vertical centrifugal casting is commonly used for rings and cylinders, while horizontal centrifugal casting is ideal for tubes. Each can yield multiple parts from a single casting, increasing efficiency.
Intense centrifugal force pushes denser metal to the outer diameter (O.D.) and drives impurities and oxides toward the inner diameter (I.D.), where they can be removed by machining. Directional solidification under pressure ensures a uniform structure, preventing mid-wall shrinkage and eliminating defects such as gas pockets or cavities.
We can Use Centrifugal Casting for:
Centrifugal casting is a good choice when your application requires:
· Symmetrical shapes such as tubes, rings, and cylinders
· Improved material properties over sand casting
· Eliminating centreline shrinkage to improve structural integrity
· Limited I.D. features
· Large parts up to 55,000 kg
· Uniform grain structure for enhanced strength and performance
Rigorous quality control - Minimal Downtime
To meet the high-level requirements of design specifications, we have rigorous quality control in place. This is based on process control values and inspection criteria of even higher standards, and strict enforcement thereof. By continuously supplying high-quality, long-life products, GEP has been making major contributions to the reduction of plant maintenance costs.