Product Description
Manufactured within our specialized fabrication base in Jingjiang, our Insulated Cold Wall Header is an internally insulated collection manifold engineered to gather high-temperature effluent gas from catalyst reformer tubes inside steam methane reforming (SMR) and hydrogen production furnaces. Building upon our 26 years of heavy equipment manufacturing experience and certified under ASME "U" and "S" stamps, we build each Insulated Cold Wall Header using an outer carbon steel pressure shell protected by multi-layer refractory castable lining and internal alloy thermal expansion sleeves. This innovative internal insulation design keeps outer shell temperatures below 100°C while handling 850°C hydrogen-rich effluent, eliminating the need for expensive external high-alloy pressure piping. Delivering dependable structural integrity and safety under severe hydrogen conditions, this reliable Insulated Cold Wall Header provides global refinery and syngas operators with a cost-effective, low-maintenance collection manifold built for long-term continuous service.
Applications
Steam Methane Reformers (SMR): Serving as the bottom radiant outlet collection header gathering 800°C–880°C hydrogen-rich syngas from catalyst tubes.
Secondary & Autothermal Reformers: Acting as hot syngas transfer headers and collection manifolds connecting primary and secondary reforming stages.
Refinery Hydrogen Production Units: Upgrading hot-wall reformer headers to cold-wall designs to eliminate external high-alloy creep issues and improve plant safety.
Ammonia & Methanol Synthesis Plants: Providing high-integrity effluent collection manifolds for large-scale reforming furnace trains.
Technical Specifications
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Design & Fabrication Standards |
ASME Section VIII Div. 1, ASME B31.3, API 560, Class A Boiler / Pressure Vessel Regulations |
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Structural Architecture |
Outer carbon steel pressure shell + high-temperature refractory castable lining + stainless steel internal liner sleeves |
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Pressure Shell Metallurgy |
Low-alloy or carbon steel (ASTM A516 Gr. 70, A387 Gr. 11/22) protected from hydrogen exposure |
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Internal Expansion Sleeves |
High-temperature stainless steel (TP304H, TP316L, TP321, or Incoloy 800H) accommodating free thermal movement |
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Internal Refractory Lining |
Multi-layer low-iron, high-alumina refractory castable lining engineered for high-pressure hydrogen environments |
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Internal Process Temperature |
Syngas operating temperatures from 800°C to 890°C |
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Outer Shell Design Temperature |
Maintained below 95°C to 120°C under normal ambient conditions |
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Operating Pressure |
1.5 MPa to 4.5 MPa (Gauged to reformer operating profiles) |
Customization Capabilities
Tailored Tube Inlets & Spool Geometries: Customizing the number, diameter, and spacing of top inlet nozzles to match any reformer tube array and pigtail arrangement.
Floating Expansion Sleeve Design: Engineering specialized internal sliding sleeves that allow unrestrained thermal expansion of internal alloy components without stressing the outer pressure shell.
Refractory Anchor Metallurgy: Customizing high-alloy refractory retaining anchors (Inconel 601, TP310S) with expansion caps to ensure long-term refractory integrity under thermal cycling.
Integrated Instrumentation Ports: Pre-installing skin thermocouple blocks, pressure taps, and purge connections directly on the outer pressure shell.
Zero MOQ Flexibility: Providing single custom header replacements for reformer turnaround modernizations or multiple header trains for grassroots projects.
Quality Control
Certified Quality Standards: Certified under ASME "U" and "S" stamps, ISO 9001:2015, and ISO 3834-2 International Welding Quality System.
Component-Level QR Code Traceability: Every pressure shell plate, forged nozzle neck, refractory batch, and internal sleeve carries an individual QR code linked to certified test reports.
100% Comprehensive NDT & Hydro-Testing: 100% Radiographic Testing (RT) / Ultrasonic Testing (UT) on shell welds, 100% Positive Material Identification (PMI), and hydrostatic pressure testing before refractory casting.
Refractory Application Quality Assurance: Strict dry-out curve documentation, test block crushing strength verification, and visual inspection of internal refractory linings prior to dispatch.
Heavy Seaworthy Export Packaging: Structural steel shipping cradles with internal cushioning, moisture barrier wrapping, and end caps to protect internal refractory linings during ocean transit.
FAQ
Q: How does a cold-wall header compare to a conventional hot-wall collection manifold?
A: Conventional hot-wall headers require thick-wall high-nickel alloy materials that are expensive and prone to high-temperature creep damage and thermal fatigue. Our cold-wall header uses internal refractory lining to isolate process heat, allowing a carbon steel outer pressure shell that lowers material costs, reduces exterior heat loss, and significantly extends operational lifespan.
Q: What is the typical fabrication lead time for a custom Insulated Cold Wall Header?
A: A complete custom header package typically requires 4 to 6 months from technical drawing approval and refractory dry-out scheduling to final delivery. Standard replacement spools can be completed in approximately 3 months.
Q: What warranty coverage do you provide for international deliveries?
A: We provide an 18-month warranty from site arrival or 12 months from commercial operation (whichever comes first), backed by responsive technical engineering support.
Q: What payment terms and currencies do you support for export contracts?
A: We support EXW and FOB shipping terms. Our standard commercial milestones are 30% advance deposit, 40% manufacturing milestone payment, and 30% balance prior to factory dispatch, payable in USD, EUR, or RMB.
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