Petrochemical Furnace Tubes

With a combined legacy of more than 175 years on the cuttingedge of centrifugal and static casting technology, two of theworld’s leading producers of heat resistant alloys are one.Together, the Wisconsin Centrifugal and Carondelet divisionsof MetalTek are creating new product solutions to meet today’s critical production challenges and deliver improved performance.

Wisconsin Centrifugal pioneered such superior products as vertical centrifugal cast concentric reducers, transition cones, tees and flanges. Notable for fully sound and uniform wall sections, these centrifugals are not subject to failure due to internalshrinkage or voids, and cost less than comparable machined forgings. Wisconsin Centrifugal was also the first U.S. producer to improve furnace tube quality and thermal dynamics by pull boring. Our latest developments include microalloyed materials thatprovide cost effective enhancements in the mechanical properties of furnace tubes. Each alloy is custom formulated to balance rupture strength, creep strength, carburization resistance,ductility, toughness and weldability to suit varying client operatingconditions.

Carondelet introduced such innovative techniques aselectric melting for alloy and high strength cast iron products twogenerations ago. Resulting work on higher alloys, with particularemphasis on stainless steel, brought us worldwide renown andrespect. Carondelet was also the first U.S. producer to upgrade from the Shell to the Isocure Process for high production molding, a system exclusively engineered by our company. As a leading quality producer of complex tube sheet castings, we offer custom products in more than 380 alloy compositions for use in a widerange of heat, corrosion, and abrasion resistant applications. We are one of the most aggressive, successful and responsive static castfoundries in the world.

The Wisconsin Centrifugal and Carondelet divisions are both certified to therigorous standards of ISO 9001: 2000. As your production demands increase, we invite you to put the synergy of our firms’ capabilities towork for you

Improved Furnace Tube Performance

MetalTek International offers an impressive array of engineeringand product resources for the petrochemical industry.For steam reformers,25 Cr - 35 Ni, HP-modified materials with high stress rupture strength deliver longer operatinglife with reduced wall sections that minimize destructive thermalgradients. Pull bored tubes have smooth, shrinkage-free insidediameters for high thermal efficiency, increased catalyst volume and reduced occurrence of catalyst voids.

For ethylene pyrolysis, MTek™ 25 - 35 Nb and 35 - 45 Nb micro-alloys provide strength at high temperatures, excellentcarburization resistance and creep rupture strength to avoid hangersupport problems, bowing and bulging. A controlled equiaxedgrain structure increases grain boundaries contributing to reducedcarburization rates. Pull bored tubes have smooth, shrinkage-freeinside diameters that eliminate carburization initiation sites.

For Direct Reduction of Iron (DRI), dedicated tooling and facilities at our Wisconsin Centrifugal location provide for thecomplete casting and production of these reformer tube assemblies.We supply specialty tubes to job sites around the world, for“Greenfield” plants, and for your re-tubing and turn-around needs.

Extensive fabrication capabilitiesinclude tube, coil andmanifold assembly. The latest computer-controlled welding systemsgive us improved weld fusion levels and consistency.

Backed By Extensive Process Control

Process control is one of our highest priorities, so it is supported with the most comprehensive control methods in theindustry. Quality and control are carefully built in at every step, fromorder placement through manufacture. Each individual on the teamadheres to procedures documented and certified as ISO 9001: 2000 standards. As a result, everything is produced according to the customer’s specifications, governing standards of the ASME code,ANSI B31.3, API RP-530, plus applicable local BS, DIN and JIS standards.

Product Traceability

Leading edge bar code technology tracks componentsthroughout the manufacturing process. Radio communication scanners at each operation tap real-time information to indicateindividual component status. These scanners display job, material andcast heat identification, chemistry and lab testing compliance, NDTcompliance and production status. This system ensures error-prooftraceability of components, and guarantees full compliance with thetesting frequencies and testing order that you require.