In petrochemical industry. For more than 40 years, Manoir Industries (Business Unit Petrochem and Nuclear) has been offering high-quality solutions with a wide range of technical expertise and relevant quality assurance standards.
by developing a number of innovative patented alloys MANAURITE.
In casting technology
using a combination of modern equipment and the latest technologies for the production of tubes and adapters by centrifuging, as well as fittings and tube plates by static casting.
In metalworking technology
using the most appropriate processing and welding technology.
In high quality assurance standards
taking advantage of the outstanding experience of the most actual markets including nuclear power plants. The commitment to always be one step ahead prompted us to develop an R&D strategy to be able to offer unsurpassed solutions to more and more developing types of industry.
There are also innovative concepts such as:
specially developed and patented micro-alloyed steel grades for the petrochemical industry (XMR material with improved creep resistance for reforming furnaces, XO material with improved carburization resistance for cracking units), centrifuged tubes with internal fining for a larger heat exchange area.
Manoir Industries (Business Unit Petrochem and Nuclear), an expert in foundry and forging
The Group covers 10 different markets with an international sales network, including offices and representatives to meet the special requirements of customers.
With manufacturing plants located throughout the world the Group is actively involved in the development of new alloys and processes to improve the mechanical and metallurgical characteristics of petrochemical furnaces. High quality standards, an extensive history of know-how, commitment to excellence combined with a qualified and experienced team, modern technology and production facilities are aimed at meeting the requirements of our customers.
Company Manoir Industries (Business Unit Petrochem and Nuclear) constantly offers new solutions among its range of alloys to optimize creep and carburizing resistance, heat resistance, specific corrosion resistance.
All materials specialized in resistance to harsher working conditions have a longer expected life.
To calculate the highest working temperatures and the most severe working conditions, Manoir Industries (Business Unit Petrochem and Nuclear) developed its own specific range of high nickel/high-chromium alloys known and patented under the name Manaurite, as well as appropriate technologies for processing and welding metals.
Practical experience in machining and welding
The Manoir Industries (Business Unit Petrochem and Nuclear) company's policy is 100% processing of its molded products using CNC machines. The inner surface of each tube element of any diameter is processed by a single pass.
The surface treatment class reaches 125 RMS maximum, but it can be 63 RMS and better, if necessary, for any tube diameter.
Manoir Industries (Business Unit Petrochem and Nuclear) develops new technologies for the machining of small-diameter tubes, for example, an internal diameter of 1 inch, offering an alternative to welded tubes in steam cracking furnaces of any design.
Quality Assurance and Control
Depending on the requirements of the customer, verification is carried out in accordance with GOST, ASME, ASTM, STOOMWEZEN, TUV, PED and other international standards. Company Manoir Industries (Business Unit Petrochem and Nuclear) also has an ISO-certified quality control system.
The verification confirms the authenticity of the external and internal diameter of the tube along the entire length and allows the company Manoir Industries (Business Unit Petrochem and Nuclear) to provide its customers with products of the highest quality. The macrostructure and microstructure are tested on control samples or on the final product. Laboratories at our plant in Pitre (France) have the necessary equipment for testing materials and provide our customers with material testing protocols for each manufactured product.
In the petrochemical industry, there are a limited number of areas where high temperatures are a real challenge to the aging of materials. Among them, 4 main activities: production of ethylene by steam cracking, production of ammonia, methanol, hydrogen and synthetic gas by steam reforming.
Here the ability of materials to withstand creep is a real challenge, since the temperature range is 870°C – 1100°C.
Such furnaces use centrifugal cast tubes (“high alloy” is a general term) or HP-modified tubes, with materials containing 25% chromium and 35% nickel, as well as microadditives.
Production Standard Manaurite XM
In the 1980s, while the industry still used chimneys made of НК40 material, company Manoir Industries entered the market with the real discovery of Manaurite 36X, in subsequent years improved by microalloy additives and called Manaurite XM.
In the early 80s, the first tubes from Manaurite XM were installed both on ethylene cracking units and in reforming furnaces. Those years Manaurite XM was able to resist the yielding of metal at very high temperatures, and could also be welded after aging.
Manaurite XM в те годы был способен противостоять растяжению пластического течения металла при очень высоких температурах, а также мог свариваться после старения.
Carburizing resistance was also one of the characteristics, although this property was later achieved through another alloy. Manaurite XM as it is was designed to be suitable with its properties and chemical composition for both reforming and steam cracking.
This alloy has since been established worldwide and has become a production standard.
Due to the increased demand for hydrogen production, hydrogen producers are increasingly developing their plants to operate more than 100,000 project hours, and tubes are becoming thicker.
The thickness of the reforming tubes designed for more than 100,000 hours in accordance with API 530 is significantly increased. As a result, the heat transfer and the ability of the tube to adapt to stress relaxation during thermal cycles will decrease.
Heat cycles cause cracks in the tubes, since the outer and inner diameters are cooled and heated not at the same speed. Heat transfer also directly depends on the thickness of the tube ¬– the thicker the tube, the lower the efficiency.
Based on achievements and metallurgical knowledge, Manoir Industries (Business Unit Petrochem and Nuclear) developed the composition ManXM for use in reforming tubes.
As shown in Figure 1, Mn and Si have a direct effect on corrosion resistance and therefore the number of these two elements can be reduced for use in reforming tubes.
Since these changes affect the flow of titanium, several further changes in the practice of melt occur accordingly.
With the help of specialized production equipment for melting/casting the above composition is changed and another micro-alloy element is used, creep characteristics ManXM is tremendously improved and reaches 15% growth. This alloy is called ManXMR.
Figure 2 shows the direct effect on creep resistance between XM and XMR characteristics.
Conclusions for tube manufacturing
The above changes in composition from the standpoint of production are considered insignificant and do not affect the casting, processing and welding of the material.
Figure 3 shows the effect of one sample of this new alloy on the calculation of the wall thickness of the tube. The thinner the tube, the better it will be adapted to the loads of thermal cycles. In addition, weight of the tube is significantly reduced, as well as price.
Third party laboratory test
To assess the accuracy of the creep test results obtained by Manoir Industries (Business Unit Petrochem and Nuclear), a European laboratory well known for its creep research was involved. TNO Company (Netherlands) performed similar tests to indicate different points of values on the creep curve. These data are shown in Figure 4.
While it is clearly established that a breakthrough in creep characteristics can hardly be achieved, since almost all possible combinations have been tried, the Manaurite XMR provides the industry with a technical solution that will have a certain impact on the capital costs.
For end users, revenue from creep characteristics can be converted to super productivity if revenue is used to increase the internal diameter of the tubes. In any case, the gain in weight, and, therefore, in the price for this position is very important.
Company Manoir Industries (Business Unit Petrochem and Nuclear) is currently working with a notifying authority to obtain PMA (Permanent Material Appraisal) under the PED (Pressure Equipment Directive) in order to provide European users with this technical achievement.
Located in the upper part of the furnace, designed to distribute the raw materials to the catalysts / reformer tubes. Made from chrome-molybdenum, stainless steel, or high-nickel materials.
Usually located in the lower part of the furnace, used to transfer process gases to the waste heat boiler. Manufactured from chrome-molybdenum materials, with internal refractory lining.
Normal size: 1m diameter, 40-50 m length.
Cold Outlet Manifolds and Transmission Lines
Scraper traps are located at the end of the pipeline. They are used to start cleaning, automated cleaning of the pipeline at set intervals, or to inspect the pipeline for defects.
Scraper Trap Materials:
From carbon steel to 22% two-phase and 25% super-two-phase chromium stainless steel.
Hardened Fittings are used in furnaces to reduce the temperature of cracking gases. They are mainly manufactured from high-temperature chromium-molybdenum or high-nickel alloys.
For the production of Vulcan finned tubes, a new treatment process is applied, which allows to improve their heat transfer. This process allows you to increase the surface of the internal diameter of the tube by more than 25%.
These tubes were delivered to Italy, USA, India, Canada. Internal finned cast tubes are an adequate replacement for extruded tubes in terms of mechanical properties. Finned tubes have a longer service life, because the temperature of the metal of the tube is lower at the same performance, and heat transfer is higher. Energy is also saved.
Resistance to carbon deposits with suppression of catalytic soot and low formation of amorphous soot
The advantage of coated coils in a gas cracking unit is a longer service life, improved conversion and greater productivity. It protects tubes from carburization, improves their resistance to corrosion and heat shock, compared to uncoated tubes. Additional advantages of such a coating are plasticity, thermal stability, long service life, and cost reduction. Some furnaces equipped with this coating are already working.
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