Stainless Steel Coil Tube for Texaco Gasification Burner Cooling Water System
Product Overview
This stainless steel coil tube (Coil Tube) is a critical component designed for the cooling water system of the Texaco gasification process burner. Manufactured by Wenzhou Jixing Metal Materials Co., Ltd., this product is engineered to withstand extreme thermal and mechanical loads inherent in gasification environments. The coil tube provides essential cooling protection to the burner refractory lining and structural components during continuous high-temperature operation of the Texaco gasifier.
The product design has been optimized through numerical simulation analysis (CFD and FEA), transitioning from a traditional coil tube configuration to an integrated water jacket design, demonstrating significant improvements in thermal management efficiency and structural integrity. This evolution reflects advanced engineering methodologies applied to enhance service life and operational reliability.
Material & Properties
The coil tube is fabricated from high-grade austenitic stainless steel, selected for its exceptional resistance to thermal shock, oxidation, and corrosion under the demanding conditions of gasification burner environments.
- Material Grade: 310S / 309 (UNS S31008 / UNS S30908) or equivalent high-temperature austenitic stainless steel
- Temperature Resistance: Continuous service up to 1100°C (2012°F) with oxidation resistance
- Thermal Conductivity: 16.3 W/(m·K) at 100°C, ensuring efficient heat transfer
- Coefficient of Thermal Expansion: 18.0 × 10⁻⁶ /°C
- Yield Strength: ≥ 205 MPa at room temperature
- Tensile Strength: ≥ 515 MPa
- Elongation: ≥ 40%
- Corrosion Resistance: Superior resistance to sulfidation, carburization, and scaling
- Weldability: Excellent weldability with minimal post-weld treatment requirements
Specifications
| Parameter | Specification |
|---|---|
| Product Type | Coil Tube (盘管) / Water Jacket Integrated Design |
| Outer Diameter (OD) | Φ25 mm – Φ51 mm (customizable) |
| Wall Thickness | 2.0 mm – 4.0 mm |
| Coil Pitch | 25 mm – 60 mm |
| Coil Diameter | Φ500 mm – Φ1200 mm |
| Operating Temperature Range | -40°C to 1100°C (-40°F to 2012°F) |
| Cooling Water Flow Rate | 15 – 45 m³/h (depending on configuration) |
| Design Pressure | 2.5 – 6.0 MPa (cooling water side) |
| Surface Finish | Pickled and Passivated / Ra ≤ 0.8 μm |
| Welding Method | Orbital TIG (GTAW) / Argon Shielded |
| Surface Treatment | Acid Pickling & Passivation |
| Applicable Standard | ASTM A269 / A213 / ASME B36.19M |
Manufacturing Process
The production of this coil tube follows a rigorous multi-stage manufacturing process to ensure dimensional accuracy, mechanical integrity, and corrosion resistance:
- Material Selection & Inspection: Raw stainless steel tubing is procured from certified mills with full material test reports (MTR). Incoming inspection includes chemical composition analysis (OES), grain size verification, and mechanical property testing.
- Tube Cutting & Forming: Precision-cut tubes are formed into the required coil geometry using CNC tube benders with controlled bend radii (minimum R ≥ 3D) to prevent wall thinning and ovality exceeding 5%.
- Welding Assembly: Orbital TIG welding (GTAW) is employed for all circumferential and longitudinal joints, utilizing high-purity argon shielding gas (≥ 99.999%) to prevent oxidation. Weld parameters are optimized through welding procedure qualification (WPQ/WPS).
- Heat Treatment (if required):solution annealing at 1050°C – 1150°C followed by rapid water quenching to restore full austenitic microstructure and maximize corrosion resistance.
- Surface Treatment: The entire coil tube assembly undergoes acid pickling and passivation to remove mill scale, welding discoloration, and chromium-depleted zones, restoring the passive chromium oxide film.
- Non-Destructive Testing (NDT): Radiographic testing (RT) per ASME Section V Article 2, dye penetrant inspection (PT) per ASTM E165, and hydrostatic pressure testing at 1.5× design pressure for a minimum of 30 minutes.
- Dimensional Inspection: Laser scanning and CMM (Coordinate Measuring Machine) verification to confirm coil geometry, pitch uniformity, and overall dimensions within ±1% tolerance.
Applications
This stainless steel coil tube is specifically engineered for the following industrial applications:
- Texaco Gasification Process: Primary application in burner cooling water systems of Texaco gasifiers, providing thermal protection to the burner throat and refractory lining during syngas production.
- Coal Gasification Systems: Cooling components in entrained-flow and fixed-bed gasifiers operating at temperatures exceeding 1400°C.
- Petrochemical Processing: High-temperature heat exchangers and reactor cooling systems in refineries and petrochemical plants.
- Power Generation: Boiler superheater and reheater tube bundles in coal-fired and gas-fired power plants.
- Specialty Chemical Manufacturing: Reactor cooling systems where high-temperature resistance and corrosion resistance are simultaneously required.
Quality Certifications
Wenzhou Jixing Metal Materials Co., Ltd. maintains comprehensive quality management systems and holds the following certifications:
- ISO 9001:2015 — Quality Management System Certification
- ISO 3834-2 — Quality Requirements for Welding of Metallic Materials
- ASME Section IX — Qualification of Welding Procedures and Personnel
- EN 1090 — Execution of Steel Structures
- ASME U Stamp — Pressure Vessel Fabrication (where applicable)
- Material Traceability: Full heat number traceability from raw material to finished product
- Third-Party Inspection: Available upon request (SGS, BV, Lloyd's Register)
Unique Selling Points
- Numerical Simulation Optimized Design: The coil tube geometry has been validated through Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA), ensuring optimal heat transfer coefficients and uniform temperature distribution across the cooling surface.
- Integrated Water Jacket Configuration: The transition from discrete coil tube to an integrated water jacket design eliminates potential failure points at tube-to-header connections, reducing leak risk and maintenance frequency.
- Extended Service Life: Material selection and design optimization result in a projected service life exceeding 5 years under continuous Texaco gasifier operating conditions, compared to 2–3 years for conventional designs.
- Reduced Thermal Stress: The optimized coil pitch and wall thickness distribution minimizes differential thermal expansion stresses, preventing fatigue cracking at critical joints.
- Customizable Engineering Support: Full design customization and numerical simulation services available to match specific gasifier configurations and operating parameters.
Conclusion
This stainless steel coil tube represents a state-of-the-art solution for burner cooling water systems in Texaco gasification processes. Combining premium material selection, simulation-driven design optimization, and rigorous manufacturing protocols, it delivers superior thermal management performance, extended service life, and reduced total cost of ownership for gasification plant operators.