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Custom Tube Sheets and Baffles Supply for EO Reactor: Case Study

Tube sheets and baffles play a crucial role in the efficient functioning of Ethylene Oxide (EO) reactors. These specialized components are responsible for directing the flow of fluids within the reactor and ensuring optimal heat transfer.

tube sheets and baffles drilling

Understanding Tube Sheets and Ethylene Oxide Reactors

Tube sheets are thick, flat plates with precisely drilled holes used to support and guide tubes in heat exchangers and reactors. They are typically constructed from high-quality materials to withstand extreme temperatures and pressure differentials. Tube sheets act as a barrier between the shell side and tube side of the reactor, facilitating heat transfer and preventing fluid leakage.

Ethylene Oxide reactors are essential in the production of ethylene oxide, a key raw material for the manufacturing of various chemicals and products. These reactors utilize a tube bundle configuration, with tube sheets and baffles strategically placed to optimize heat exchange and maintain process efficiency. The baffles, with their specific hole patterns, provide uniform distribution of the reactants across the tube bundle.

Project Infomation

This project involves the fabrication of 10 custom tube sheets and baffle plates made from Q345R material. The baffles have a diameter of 7900mm and a thickness of 30mm, with each plate containing 32500 holes. These tube sheets and baffles are tailored precisely to the customer's provided drawings, fulfilling their specific requirements. The customer places a high emphasis on flatness and aperture accuracy, demanding components that meet their stringent quality standards.

tube sheets and baffles for EO reactor

Manufacturing Process

The production of custom tube sheets and baffles is a meticulous process that requires advanced manufacturing techniques and expertise. The following steps were undertaken to meet the project's requirements:

  1. Design and Engineering: Detailed drawings provided by the customer were thoroughly analyzed by our experienced engineering team. The specifications, including diameter, thickness, and number of holes, were carefully considered to develop an optimal design plan.
  2. Material Selection: Q345R, a high-strength and heat-resistant material, was chosen for its excellent mechanical properties and compatibility with EO reactor applications. Its durability and corrosion resistance ensures prolonged operational life.
  3. Precision Drilling: State-of-the-art drilling equipment was employed to create the 32,500 precise holes in each baffle plate. Advanced CNC (Computer Numerical Control) technology was utilized to ensure accuracy and consistency in hole placement.
  4. Flatness and Aperture Accuracy: Specialized machining processes were employed to achieve the desired flatness and aperture accuracy, meeting the customer's stringent requirements. Thorough quality checks were performed at each stage to ensure the highest standards were maintained.

tube sheet multi hole drilling

The utilization of custom tube sheets offers several benefits for EO reactors. By customizing tube sheets according to specific reactor designs, manufacturers can ensure precise alignment and compatibility with the reactor's unique configuration. This customization helps achieve optimal heat transfer, reduces pressure drops, and enhances overall reactor performance.

In the case of the EO reactor project, the customer's high requirement for flatness and aperture accuracy of the tube sheets and baffles further highlights the significance of customization. These strict specifications ensure efficient fluid flow, prevent leakage, and maximize heat transfer efficiency, resulting in enhanced reactor performance and productivity.

At Openex, we specialize in the manufacturing of custom metal parts for a wide range of industrial applications, including EO reactors. With our extensive expertise, state-of-the-art facilities, and commitment to quality, we ensure that our customers receive tailor-made solutions that meet their unique requirements.

If you're in need of custom tube sheets and baffles supply or any other customized metal parts, feel free to contact us today. Our team will be delighted to discuss your project requirements and provide you with the highest-quality solutions tailored to your needs.

About Openex

Openex is home to a full-service, one-stop-shop, contract manufacturing company producing custom large machined parts and fabrications. Our full large fabrication services including large machining, cutting, welding, rolling, punching, braking, testing, painting, and others.
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