Heavy Fabrication for Chemical Reactors
Chemical reactors are the heart of the petrochemical, pharmaceutical, and fertilizer industries. Because they operate under continuous high pressure, extreme temperatures, and highly corrosive conditions, the fabrication of their outer shells demands absolute metallurgical integrity.
Openex specializes in the heavy fabrication of large-scale, custom chemical reactor shells. With our massive plate rolling capabilities and strict adherence to ASME Section VIII (Div. 1 & 2) standards, we routinely manufacture monolithic reactor vessels, heavy-wall columns, and high-pressure hydrogenation reactors weighing up to 250 tons.
Our Work: Heat Exchangers
Reactor Shell Fabrication Specifications
We custom manufacture thick-walled reactor shells to your exact P&ID and mechanical blueprints. Below are our general facility limits:
| Maximum Diameter | Up to 10,000 mm (10 Meters) |
|---|---|
| Maximum Shell Length | Up to 40 Meters (Multi-section Assembly) |
| Max Plate Rolling Thickness | Up to 200 mm (Cold & Hot Rolling Capabilities) |
| Materials Processed | Duplex/Super Duplex, 316L/304L Stainless, Inconel, Hastelloy, Carbon Steel, and Explosive Clad Plates. |
| Welding Codes | ASME Boiler & Pressure Vessel Code (BPVC), AWS, EN Standards. |
| NDT & Quality Testing | 100% Radiography (RT), Ultrasonic Testing (UT), Magnetic Particle (MT), and Hydrostatic Testing. |
The Manufacturing Process
We utilize massive multi-roll bending machines to cold or hot-roll thick steel plates into perfect cylinders (cans). Edge beveling is performed using large CNC machines to prepare the plates for deep-penetration welding.
The rolled sections are joined using automated Submerged Arc Welding (SAW). For exotic materials or clad reactor shells, our highly skilled operators utilize GTAW (TIG) welding to prevent contamination and ensure perfect metallurgical bonds.
To relieve residual stresses introduced during the rolling and heavy welding phases, the entire reactor shell is moved into our massive on-site heat treatment furnaces for controlled thermal stress relief.
Every weld undergoes stringent Non-Destructive Testing (RT/UT). Once passed, internal components (like baffle plates and agitator mounts) and external nozzle flanges are precision-machined and welded into place before final hydrostatic testing.