Reactor Internals – dimension and processes

Reactor Internals

At its plant, Costacurta manufactures and is able to handle a wide range of Reactor Internals of different sizes and weights, ranging from a few tons to more than 100 tons.

Costacurta produces Reactor Internals consisting of components of relatively limited size and weight, such as ‘scallops’, ‘inlet distributors’, ‘outlet collectors’ and ‘distributor trays’ but also Reactor Internals of a large size and weight such as  ‘cartridges’ that can reach lengths of 30 metres and a weight of more than 100 tons.

The ‘cartridges’ are stainless steel containers in which all the individual components of the Reactor Internals are installed before being shipped. Once at the plant, the ‘cartridges’, complete with all the Internals, are inserted in a flanged reactor. The main components of the Reactor Internals can be: ‘outer baskets’ and ‘inner baskets’ or ‘special gratings’ and ‘distributors’ and heat exchangers.

Continuous improvement of the manufacturing process

Costacurta invests in machinery and equipment with the aim of improving product quality and productivity. It now has a wide range of machines and equipment that enable a high level of automation. Costacurta has also invested and continues to invest in the expansion of the production plant areas and in increasing the lifting and handling capacity to be able to manufacture large, heavy Reactor Internals.

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    VICO-Vibrations

    VICO-Vibrations

    The VICO-Vibrations product category includes crimped wire meshes and some types of woven wire cloths characterised by a high open area and by the wire’s high tensile strength, high yield point and considerable wear proof steels. VICO-Vibrations are normally made from square or rectangular mesh, with compensated crimping to guarantee that the mesh will not lose its shape. The material used must have a high yield point and a yield point/tensile strength ratio that is not too close to one. In this way, the wires can be permanently deformed during working with a guarantee that no cracks or excessively fragile crystal structures are produced at any of the points of maximum elongation.

    Materials

    Spring steel.

    Supply

    VICO-Vibrations can be supplied in rolls, even if they are more frequently supplied in flat panels with tensioning hooks.

    Use

    These meshes are mainly used in sieving systems, for a range of materials and applications.

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      VICO-Anchors

      VICO-Anchors

      VICO-Anchors are ‘V’-shaped anchors made from metal rods.

      Materials

      AISI 304, AISI 410, AISI 310, AISI 321.

      Supply

      VICO-Anchors are made in accordance with the specifications of the major engineering companies and/or to the clients’ specifications. In accordance with these specifications, Costacurta is able to carry out any kind of anchoring using rods and/or plates.

      Use

      They are used to armour thick anti-abrasive and anti-corrosion refractory linings (up to 500 mm)

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        VICO-Rep

        VICO-Rep

        VICO-Rep consists of S-shaped anchors, obtained from plate of different thicknesses, used to armour and contain anti-abrasive and anti-corrosion resisting refractory linings.

        Materials

        AISI 304H, AISI 410S, AISI 310S and carbon steel.

        Supply

        VICO-Rep can be made in any shape, in accordance with the specifications and technical drawings supplied by the client.

        Use

        VICO-Rep is a special application for the repair of refractory lining in areas where it is necessary to remove and/or repair damaged hexagonal mesh. On those occasions, the VICO-Rep (S-bar) anchors are essential to make rapid and effective repairs.

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          Lining fittings

          Lining fittings

          Lining fittings are made from plate of different thicknesses cut, perforated and bent to make the lining fittings suitable for many uses and applications.

          Materials

          AISI 304H, AISI 410S, AISI 310S and carbon steel.

          Supply

          Lining fittings can be made in any shape and thickness simply by connecting the autocad file to our laser cutting machine.

          Use

          Lining fittings are specifically designed to guarantee continuity in anti-abrasive and anti-corrosion refractory linings, joining unaligned surfaces. Their function is fundamental to prevent potential breakages and guarantee the stability of the refractory lining by means of specific hooks sunk into the cement.

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            Calendered wire cloth

            Calendered wire cloth

            Calendered wire cloth is a weave with a pre-crimped weft, where the weft wires are also specially calendered to give the wire cloth a relatively flat surface.

            Materials

            These wire cloths are usually made in carbon steel but can also be made in stainless steels.

            Supply

            They can be supplied in rolls of various widths and lengths and in flat panels cut to size.

            Use

            Thanks to their good mechanical strength, these wire cloths are used in the cement industry for wet milling process and in the electrochemical industry for the production of cathodic fingers for Chlorine-Caustic Soda cells.

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              Twilled dutch weave

              Twilled dutch weave

              A twilled dutch weave is a wire cloth in which each weft wire passes successively over two and under the next adjacent pair of warp wires. With this weave, larger diameter wires can be used compared to plain dutch wire cloths; this means that extremely compact wire cloths can be produced, obtaining a retention of as little as 5 microns.

              Materials

              These wire cloths can be manufactured using all metal materials and alloys that can be drawn into wire, such as carbon steel, stainless steels, Nickel-Chromium alloys, pure metals.

              Supply

              Twilled dutch weave cloths can be supplied in rolls of various widths and lengths and in flat panels in different geometric shapes.

              Use

              Twilled dutch weave cloths are used almost exclusively for filtering applications and, above all, when, along with high stiffness and strength, very high filtering values (5 microns) have to be reached. This type of wire cloth is used, for example, for the extrusion of plastics or in filter presses such as those used in the cocoa processing industry.

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                Plain dutch weave

                Plain dutch weave

                Plain dutch weave is a special weave where the weft wires, that are normally of a smaller diameter than the warp wires, are woven so that they are fully joined together. There is no mesh opening, only a transversal passage where the weft wires alternate.

                Materials

                These wire cloths can be made from all metal materials and alloys that can be drawn into wire, such as carbon steel, stainless steels, Nickel-chromium alloys, pure metals.

                Supply

                Plain dutch weave wire cloths can be supplied in rolls of various widths and lengths and in flat panels in different geometric shapes.

                Use

                Plain dutch weave wire cloths are used almost exclusively for filtering, in particular when a high level of stiffness and strength is required.

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                  Herringbone twilled weave

                  Herringbone twilled weave

                  Herringbone twilled weave is a special twilled weave that is used when it is important to prevent the mesh sides forming angles that are not 90°.  In this weave, the direction of the twill is reversed every 20, 50, 100, 200, 500 millimetres depending on the width and specific use. In this way, balanced strengths are created without any external elements that could deform the cloth. This type of weaving is used when the wire cloth is to be deep-drawn, or for very fine wire cloths for which plain weave is not possible.

                  Materials

                  These wire cloths can be made from all metal materials and alloys that can be drawn into wire, such as carbon steel, stainless steels, Nickel-chromium alloys, pure metals.

                  Supply

                  Herringbone twilled weave wire cloths can be supplied in rolls of various widths and lengths and in flat panels in different geometric shapes.

                  Use

                  Often used for applications that require critical level of sieving and filtering, thanks to their extremely small openings (these wire cloths are used above all in the pharmaceutical and chemical sectors).

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                    Twilled weave

                    Twilled weave

                    In twilled weave, each warp wire and each weft wire are passed successively over two and under the next adjacent pair of wires. Due to the residual tension of the unbalanced weaving, the mesh sides tend to form angles that are not perfectly 90°. This type of weaving is used when the wire cloth is to be deep-drawn, or for very fine wire cloths for which plain weave is not possible.

                    Materials

                    Twilled weaves can be made from all metal materials and alloys that can be drawn into wire, such as carbon steel, stainless steels, Nickel-chromium alloys, pure metals.

                    Supply

                    Twilled weave wire cloths can be supplied in rolls of various widths and lengths and in flat panels in different geometric shapes.

                    Use

                    These wire cloths are often used in the chemical and pharmaceutical sectors for applications that require critical level sieving and filtering (minimum filtering value 25 microns).

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