Product Description
Manufactured within our heavy fabrication complex in Jingjiang, our Residue Hydrotreating Reactor Heater represents the most structurally robust process heater in modern refining, engineered to elevate atmospheric and vacuum residues mixed with treat gas to reaction conditions under severe hydrogen and hydrogen-sulfide atmospheres. Backed by our 26-year manufacturing heritage and certified under ASME "U" and "S" standards, we build each Residue Hydrotreating Reactor Heater to withstand operating pressures reaching 18 to 20 MPa, heavy metal contaminants (Ni, V), and severe coking tendencies. By utilizing heavy-wall stabilized austenitic stainless steel coils, precision narrow-gap automatic welding, and conservative radiant heat flux ratings, our heaters suppress internal coke deposition and thermal runaway, offering refinery operators an exceptionally reliable heating core for transforming low-value heavy residues into lighter, clean distillate streams.
Applications
Fixed-Bed Residue Desulfurization (VRDS/RDS): Preheating atmospheric residue (AR) and vacuum residue (VR) before entering guard beds and hydrodemetallization (HDM) reactors.
Ebullated-Bed & Slurry Hydrocracking: Supplying high-temperature heating to heavy vacuum bottoms, tar sands bitumen, and solvent deasphalter pitch under extreme pressure.
Residue Hydrotreater Fractionation Reboilers: Providing stable, high-duty thermal reboiling energy to heavy product strippers and fractionator bottoms.
Refinery Deep-Conversion Units: Serving grassroots residue upgrading units designed to maximize conversion of heavy feeds into high-value FCC feedstocks.
Technical Specifications
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Design Standards |
API 560, ASME Section VIII Div. 1/Div. 2, ASME B31.3, Class A1/A2 Heavy Vessel Regulations |
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Furnace Structural Styles |
Multi-cabin box furnace with independent firing zones, or heavy symmetrical vertical cylindrical design |
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Thermal Firing Duty |
10 MW to 65 MW per unit |
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Design Operating Pressure |
12.0 MPa to 20.0 MPa (Ultra-high pressure severe hydroprocessing service) |
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Process Outlet Temperature |
380°C to 425°C; Radiant tube skin design temperature up to 625°C |
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Process Coil Metallurgy |
Heavy-wall stabilized stainless steel (ASTM A312 / A213 TP347H, TP321H) and high-strength Cr-Mo alloy (A335 P22, P91) |
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Coil Wall Thickness |
Heavy-wall construction up to 28 mm, machined with precision bevels for narrow-gap welding |
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Radiant Heat Flux |
Conservatively limited to ≤ 25 kW/m² to prevent film over-cracking and internal tube coking |
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Efficiency Level |
90% – 93% (Integrated with convection economizers and air preheaters) |
Customization Capabilities
Heavy-Wall Narrow-Gap Orbital Welding: Specialized automated narrow-gap TIG/MIG welding procedures developed specifically for thick-wall TP347H, ensuring defect-free root passes and minimal heat-affected zones.
Anti-Coking Hydraulic Multi-Pass Layout: Symmetric 4-pass or 8-pass coil circuits engineered with equalized hydraulic resistance, ensuring high fluid shear velocities at the inner wall to dislodge coke precursors.
Dual-Fuel Low-NOx Combustion: Floor-mounted burners engineered for wide turndown ratios and stable flame patterns, preventing flame deflection onto process coils.
Severe Corrosive Metallurgy Upgrades: Upgrading tube metallurgy and external casings to resist high partial pressures of H2S, polythionic acids, and high-temperature sulfur corrosion.
Zero MOQ Restriction: Custom engineered for individual turnaround heater replacements or delivered as complete multi-heater trains for mega-refineries.
Quality Control
Certified Global Accreditations: Manufactured under ASME "U" and "S" stamps, ISO 9001:2015, ISO 14001:2015, and ISO 3834-2 welding quality management.
Full QR Code Traceability on Heavy Components: Every heavy-wall alloy pipe spool, forged high-pressure return bend, intermediate support, and pressure fitting carries a serialized QR code tied to certified material test reports.
100% Volumetric & Surface NDT: 100% Radiographic Testing (RT) and Time-of-Flight Diffraction (TOFD) on all heavy-wall butt welds; 100% Positive Material Identification (PMI) on all pressure-retaining components.
High-Pressure Hydrostatic Proof: Hydrostatic pressure testing executed in our heavy testing bay up to 1.5 times design rating using low-chloride demineralized water.
Heavy Ocean Packaging: Reinforced structural steel cradles, internal pipe vibration dampening, desiccants, and weatherproof vacuum-barrier wrapping engineered for secure international transport.
FAQ
Q: How do you maintain weld integrity and prevent cracking on thick-wall TP347H residue coils?
A: We utilize narrow-gap automated orbital TIG welding with strictly monitored heat input, control weld deposit ferrite numbers within 4% to 8%, use certified low-carbon niobium-stabilized consumables, and perform 100% TOFD/RT radiographic verification.
Q: What is the typical fabrication lead time for an ultra-high-pressure residue heater?
A: Because of heavy-wall alloy procurement, specialized welding, and extensive NDT requirements, custom fabrication typically takes 5 to 6 months from technical drawing approval to final factory dispatch.
Q: Can you accommodate our company-appointed third-party inspectors during production?
A: Yes. We routinely coordinate with third-party inspectors from BV, DNV, SGS, and TÜV for all critical hold points, including raw material PMI, weld radiography review, and final hydro-testing.
Q: What commercial terms and shipping arrangements do you support?
A: We support EXW and FOB terms, utilizing our proximity to the Yangtze River deep-water port terminals for direct barge shipment to Shanghai. Commercial payments follow a 30% advance deposit, 40% manufacturing milestone payment, and 30% balance prior to export dispatch, payable in USD, EUR, or RMB.
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