Reformer Tube Failures Explained: A Practical Guide for Engineers
Identifying, Preventing, and Overcoming the Most Common Reformer Tube Challenges in Industrial Plants In industrial environments like petrochemical refineries, DRI plants, ethylene crackers, and fertilizer units, reformer tubes work relentlessly under extreme thermal and mechanical loads. Operating beyond 800°C with fluctuating pressures, these tubes are critical to the success of high-temperature reforming processes. But when they fail, it’s more than downtime—it’s a direct hit to safety, efficiency, and profitability. Illustration showing carburization and oxide layer formation in reformer tubes under extreme conditions. In this guide, we explore the top reformer tube failure modes , how to spot them early, and the proven preventive measures trusted by industry leaders. 1. Creep Damage Visual clue: Gradual deformation over time. Why it matters: At extreme temperatures, alloy microstructures deteriorate, causing elongation, wall thinning, and cracks. Prevention tip:...
