Walter Tosto — Hydrocracking Reactors, Distillation Columns & Pressure Vessels

Global supply of heavy process equipment and high-pressure vessels by Walter Tosto S.p.A. (Italy). Heavy-wall hydrocracking reactors up to 780 tonnes, distillation columns up to 8.9 m diameter, shell & tube heat exchangers, and ASME pressure vessels for refining, petrochemical, and energy plants from SpareX.

Hydrocracking & Hydrotreating Heavy Wall Reactors

Walter Tosto manufactures heavy wall hydrocracking and hydrotreating reactors. Units are built from SA 336 F22V forgings and SA 542 plates up to 235 mm thickness. Vessels feature internal stainless cladding. Unit weights reach up to 780 tonnes.

Wall thickness envelope up to 235 mm forged SA 336 F22V shell rings
Individual hydrocracker reactor unit weight scaling up to 780 tonnes
Internal corrosion resistant austenitic stainless weld overlay cladding
Replaceable reactor internals, distributor trays, and thermowells

Atmospheric & Vacuum Distillation Columns

Walter Tosto fabricates distillation and fractionator columns up to 8.9 meters in diameter. Columns are built from SA 516 Gr.70 steel with wall thickness up to 65 mm. In-house Dino 9000 machine executes plate rolling. Unit weight reaches 581 tonnes.

Column shell diameter envelope up to 8.9 meters for refinery units
Pressure retaining shell wall thickness up to 65 mm SA 516 Gr.70 plate
Cold plate rolling executed on proprietary Dino 9000 three-roll machine
Replaceable fractionation valve trays, bubble caps, and demister pads

Delayed Coking Coke Drums

Walter Tosto builds heavy coke drums for delayed coking units processing heavy oil residues. Drums measuring 6,500 mm across are made from SA 387 Gr.11 Cl.2 steel with 30 mm wall. Design resists thermal cycles. Total unit weight reaches 170 tonnes.

Coke drum shell diameter of 6,500 mm designed for Delayed Coking units
Creep resistant SA 387 Gr.11 Cl.2 chrome-moly steel with 30 mm shell
Precision flange finishing on Waldrich Coburg 5-axis gantry machine
Replacement bottom deheading covers, slide gates, and high-temp seals

High-Pressure Shell & Tube Heat Exchangers

Walter Tosto supplies high-pressure shell and tube exchangers and sulphur condensers. Units house SA 334 Gr.6 tube bundles containing up to 980 tubes. Joints are welded via Internal Bore Welding heads. The rigid assembly prevents fluid leaks.

Tube bundle matrix accommodating up to 980 tubes in SA 334 Gr.6 alloy
Automatic orbital tube-to-sheet joint fusion via Internal Bore Welding
Heavy shell welding using Narrow-Gap TIG with magnetic oscillation
Replacement tube bundles, tubesheets, baffle plates, and gaskets

High-Pressure Separators & Flash Vessels

Walter Tosto manufactures high-pressure separators and flash drums for refinery units. Shells use 105.5 mm thick SA 387 Gr.22 Cl.2 steel with Cooperheat furnace annealing. Units handle phase separation. Vessel weight is 48 tonnes at 2,000 mm diameter.

Pressure boundary wall thickness of 105.5 mm in SA 387 Gr.22 Cl.2 steel
Full post-weld heat treatment PWHT inside 11x10x28 m Cooperheat furnace
Internal cyclone clusters, coalescing mesh pads, and boot collectors
Spare level transmitter nozzles, RTJ oval ring gaskets, and B7 studs

Chemical Synthesis Reactors & Reformers

Walter Tosto designs process reactors for ethylene oxide, methanol, and styrene synthesis. The firm builds secondary reformers and ammonia converters for severe pressures. Units meet ASME VIII Division 2/3 codes. Equipment resists aggressive gases.

Custom reactors for methanol, ethylene oxide, and styrene synthesis loops
Secondary reformers and ammonia synthesis converters for fertilizer plants
Mechanical design and finite element FEA per ASME VIII Division 2 and 3
Replacement refractory sleeves, ceramic ferrules, and catalyst screens

LPG Storage Tanks & Pressure Vessels

Walter Tosto fabricates cylindrical LPG storage tanks and heavy pressure vessels. Equipment is manufactured in Chieti and Ortona from low-temperature carbon steels. Welds pass 100% radiographic testing. Heavy units ship via deep-water quays.

Horizontal cylindrical storage vessels engineered for LPG and propane
Submerged-arc double-sided automatic longitudinal and girth seam welding
Full 100% volumetric non-destructive examination via RT, UT, and MPI
Spare relief valve manifolds, bottom drain sumps, and sealing gaskets

Nuclear & Fusion Big Science Components

Walter Tosto participates in building the vacuum vessel for the ITER fusion reactor. The plant delivered five stainless steel vessel sectors weighing 650 tonnes each. Quality conforms to ASME N nuclear standards. The group also built JT-60SA coil cases.

Five stainless steel vacuum vessel sectors for ITER tokamak weighing 650 t each
Toroidal field coil containment casing modules for the JT-60SA fusion project
Conformity to nuclear quality standards under ASME N and ASME NPT
Precision austenitic fasteners, high-vacuum metal seals, and thermal shields

Engineering Principles of Walter Tosto Heavy Wall Reactors

Walter Tosto S.p.A. engineers heavy wall hydrocracking and hydrotreating reactors designed for continuous operation under severe hydrogen partial pressures and elevated process temperatures.

The pressure boundary is forged from vanadium-modified SA 336 F22V chrome-moly alloy steel combined with SA 542 plates up to 235 mm thickness. The internal diameter is lined with an austenitic stainless steel weld overlay using automatic SAW STRIP cladding to prevent hydrogen attack.

Large-Diameter Fractionation Columns and In-House Plate Rolling

Fabrication of refinery distillation and fractionator columns up to 8.9 meters in diameter requires unique forming power. Walter Tosto operates the Dino 9000 plate bending roll, an in-house engineered 3-roll system delivering 9,000 tonnes of pressing force for cold-rolling plates over 300 mm thick.

Shell sections are shaped without cracking, and internal tray support rings are welded with tight planarity tolerances for optimal mass transfer.

Delayed Coking Drums and Cyclic Thermal Stress Mitigation

Coke drums endure severe cyclic service where high-temperature feed fill cycles alternate with rapid water quench and hydraulic coke cutting. Walter Tosto utilizes creep-resistant SA 387 Gr.11 Cl.2 alloy steel with 30 mm shell thickness and engineered skirt-to-cone transition geometries.

Finite element analysis ensures stress redistribution, preventing fatigue cracking and skirt deformation over decades of refinery operation.

High-Pressure Shell & Tube Heat Exchangers with IBW Tube Welding

For demanding heat transfer in refining and fertilizer units, Walter Tosto fabricates high-pressure shell and tube heat exchangers and condensers housing up to 980 tubes in SA 334 Gr.6 steel.

The critical tube-to-tubesheet connection is executed via automated Internal Bore Welding (IBW) heads operating from within the tube bore. This eliminates crevices between tube and sheet, preventing localized crevice corrosion.

Severe Service High-Pressure Separators and PWHT Heat Treatment

High-pressure gas-liquid separators manufactured by Walter Tosto feature pressure retaining shells up to 105.5 mm thick fabricated from SA 387 Gr.22 Cl.2 chrome-moly steel.

Following welding, full post-weld heat treatment (PWHT) is performed inside specialized furnaces, including the Ortona facility furnace measuring 11 x 10 x 28 meters with Cooperheat combustion, ensuring uniform stress relief and hydrogen degassing.

ASME N Nuclear Quality Assurance and ITER Vacuum Vessel Fabrication

In the nuclear fusion sector, Walter Tosto built five stainless steel vacuum vessel sectors for the ITER tokamak, each weighing 650 tonnes. The company complies with ASME N and ASME NPT nuclear code standards, authorizing the construction of nuclear Class 1 components.

Walter Tosto also delivered toroidal field coil casing structures for the JT-60SA project, proving advanced precision assembly capabilities.

Walter Tosto S.p.A. / Walter Tosto and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of Walter Tosto S.p.A. / Walter Tosto and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.