Costacurta has been manufacturing reactor internals for over 70 years, in accordance with the designs and specifications of major Technology Providers worldwide.
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Contact us nowGiven our extensive experience, we handle every stage of the production process in-house, from selecting and constructing the most suitable filtering elements to reactor internals’ manufacturing and assembly. The entire process is subject to stringent quality controls.
Watch our video, which showcases our state-of-the-art production facilities in Italy and the comprehensive quality control measures we implement to ensure the best quality for our customers.
THE IMPORTANT ROLE OF THE FILTERING ELEMENT FOR THE QUALITY OF REACTOR INTERNALS
The quality of reactor internals depends on the quality of the constituent components and, above all, the quality of the filtering element, which has an essential dual function in a reactor: holding the catalyst in place and allowing the passage of fluids to guarantee the distribution envisaged during the process design stage.
The precision of the openings and compliance with tolerances are fundamental for this function. Moreover, the filtering element must have sufficient mechanical strength to withstand the stresses during operations.
One of Costacurta’s strengths is its ability to manage the entire production process in-house, from the manufacture of the filtering elements in wire or plate – metal cloths, perforated plates and wedge wire screens – through to the finished reactor internals. This strength contributes to achieving a high-quality finished product and a high level of production flexibility, which guarantees better control of compliance with scheduled delivery times and also, in many cases, the possibility of guaranteeing fast deliveries when expediting is needed.
From thin to thick plates
Costacurta manufactures Reactor Internals from plates, mainly in stainless steel, that can be between 1 mm and 200 mm thick and it pays great attention to the quality of the plates, procuring solely from highly qualified and internationally renowned manufacturers. Over the years, Costacurta has gained experience in all the processes and, above all, in welding thick and thin plates.
FROM THE CONSTRUCTION OF INDIVIDUAL COMPONENTS TO THE CONSTRUCTION AND ASSEMBLY OF COMPONENTS AND CARTRIDGES UP TO 100 TONS
Costacurta manufactures and is capable of handling inside its own plant a broad range of reactor internals of various dimensions and weights, ranging from a few kilograms up to 100 tons.
Costacurta produces reactor internals consisting of individual components of relatively limited size and weight, such as scallops, outer baskets, center pipes, inlet distributors, distributor trays, special gratings, outlet collectors, but also assembled components of considerable size and weight, such as cartridges, which can reach lengths of 30 metres and a weights of 100 tons.
The cartridges are stainless steel vessels inside which all the reactor internals and heat exchangers are installed before being shipped from the manufacturer’s facility. Once on site, the cartridges, complete with internals and exchangers, are inserted into a flanged reactor.
CONTROLLI QUALITÀ
Il sistema qualità di Costacurta è certificato ISO 9001 da 25 anni e comprende delle procedure di controllo qualità per tutto il ciclo produttivo consistenti in:
- controlli dimensionali e identificazione delle materie prime con analizzatori portatili basati sulla fluorescenza a raggi X
- controlli dimensionali dei componenti anche con l’utilizzo di apparecchiature laser
- controlli non distruttivi delle saldature PT, VT, UT e RX eseguiti da personale certificato ASME IX.
HANDLING AND SHIPMENT OF CARTRIDGES FOR THE PRODUCTION OF AMMONIA
Watch our video showing how this process takes place at our manufacturing facility in Olginate (Lecco, Italy).
DISCOVER THE OTHER DISTINCTIVE ELEMENTS OF THE INTERIORS OF REACTORS