Optimizing Performance and Life Cycle of reformer tubes: A Comprehensive Approach to NDT, Skilled Operation, and Life Prediction Methods

The current study focuses on the critical contribution that working circumstances make to the performance and lifespan of reformer tubes used in the Direct Reduced Iron (DRI) process. We look in depth at tube failures brought on by hot patches, localized overheating, and uneven thermal gradients throughout the tube. Eddy Current Testing, Diametric Tube Growth/OD Profilometry, and Tube Wall Temperature (TWT)/Tube Metal Temperature measurement are just a few of the inspection and monitoring approaches being investigated to meet these difficulties. Notably, it is advised to sometimes use IR Pyrometric temperature Imagers to make sure that the temperature gradient profile along the tube s length is good. To further avoid catalyst breakage and guarantee optimal plant performance, emphasis is placed on constant monitoring of input gas temperature and steam-to-carbon ratio. The pressure decrease across the tube must be measured and monitored often to ensure safe functioning. During plant operation, it is crucial to visually examine all tubes and note any anomalies, such as hot spots, bending, or changes in tube color. In-depth logs of visual inspections should be kept, coupled with IR Thermal Images for TWT measurement, and frequently reviewed. To deal with any discovered anomalies, the knowledgeable Technical Team must conduct an immediate investigation. By putting these complete safeguards into place, reformer tube operation will become safer and more effective, improving plant performance and tube life.