# US 9,039,794 B2 · Reformer tube apparatus having variable wall thickness and associated method of manufacture > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,039,794 B2 - Document ID: US9039794B2 - Status: Granted - Kind: B2 - Application number: 12/940,635 - Filed: 2010-11-05 - Published: 2012-05-10 - Granted: 2015-05-26 - Earliest claimed: 2010-11-05 - Assignees: Midrex Technologies, Inc.; MetalTek International, Inc. - Applicants: Philip Crouch; Gerald Gapinski; Robert Smickley; Brian W. Voelker; Gilbert Y. Whitten - Inventors: Philip Crouch; Gerald Gapinski; Robert Smickley; Brian W. Voelker; Gilbert Y. Whitten - Web page: https://patentgrep.com/patent/US9039794B2 ## CPC - C01B 3/38: using catalysts - B01J 8/062: {being installed in a furnace} - B01J 19/02: Apparatus characterised by being constructed of material selected for its chemically-resistant properties - B01J 2219/0277: Metal based - C01B 2203/0227: containing a catalytic reforming step - C01B 2203/06: Integration with other chemical processes - C01B 2203/0816: Heating by flames - C01B 2203/1241: Natural gas or methane - C21B 13/0073: {Selection or treatment of the reducing gases} - C21B 13/02: in shaft furnaces - C21B 2100/22: by reforming - Y10T 29/49826: Assembling or joining - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - C21B: MANUFACTURE OF IRON OR STEEL (preliminary treatment of ferrous ores or scrap C22B1/00) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The present invention provides a reformer tube apparatus, including: an axially aligned tubular structure including a flange section, a top section, a middle section, and a bottom section; wherein the top section of the axially aligned tubular structure includes a first portion having a first wall thickness; wherein the top section of the axially aligned tubular structure includes a second portion having a second wall thickness; and wherein the top section of the axially aligned tubular structure includes a third portion having a transitioning wall thickness that joins the first portion to the second portion. The flange section includes a concentric flange disposed about a top portion thereof. The bottom section of the tubular structure includes a plurality of concentric wedge structures disposed about the interior thereof. The bottom section of the tubular structure also includes a recess disposed about the exterior thereof. The axially aligned tubular structure further includes a secondary flange section coupled to the flange section, wherein the secondary flange section includes a concentric flange disposed about a top portion thereof. Optionally, the reformer tube apparatus is disposed within a reformer used in a direct reduction process. ## Claims ### Claim 1 A reformer tube apparatus, comprising: an axially aligned tubular structure disposed within a refractory lined reformer furnace housing and selectively containing a catalyst; wherein the axially aligned tubular structure comprises a first portion having a first wall thickness; wherein the axially aligned tubular structure comprises a second portion having a second wall thickness; wherein the axially aligned tubular structure comprises a third portion having a transitioning wall thickness that joins the first portion to the second portion; wherein the axially aligned tubular structure has a substantially constant internal diameter corresponding to the first portion, the second portion, and the third portion; wherein the axially aligned tubular structure further comprises a primary flange section, wherein the primary flange section comprises a primary concentric flange disposed about a top portion thereof and extending perpendicularly outward from the axially aligned tubular structure; and wherein the axially aligned tubular structure further comprises a secondary flange section, wherein the secondary flange section comprises a secondary concentric flange disposed about a top portion of the primary concentric flange of the primary flange section. ### Claim 2 (depends on 1) The reformer tube apparatus of claim 1, wherein the reformer tube apparatus is manufactured from a heat resistant alloy including Cr, Ni, and Fe plus other elements characterized within the family of superalloys. ### Claim 3 (depends on 1) The reformer tube apparatus of claim 1, wherein the axially aligned tubular structure further comprises a top section, wherein the first portion and the second portion of the axially aligned tubular structure are portions of the top section. ### Claim 4 (depends on 1) The reformer tube apparatus of claim 1, wherein the axially aligned tubular structure further comprises a middle section. ### Claim 5 (depends on 1) The reformer tube apparatus of claim 1, wherein the axially aligned tubular structure further comprises a bottom section. ### Claim 6 (depends on 5) The reformer tube apparatus of claim 5, wherein the bottom section of the tubular structure comprises a plurality of concentric wedge structures disposed about the interior thereof. ### Claim 7 (depends on 5) The reformer tube apparatus of claim 5, wherein the bottom section of the tubular structure comprises a recess disposed about the exterior thereof. ### Claim 8 (depends on 1) The reformer tube apparatus of claim 1, wherein the reformer tube apparatus is disposed within a reformer used in a direct reduction process. ### Claim 9 A reformer tube apparatus, comprising: an axially aligned tubular structure disposed within a refractory lined reformer furnace housing and selectively containing a catalyst, the axially aligned tubular structure comprising a primary flange section, a top section, a middle section, and a bottom section; wherein the top section of the axially aligned tubular structure comprises a first portion having a first wall thickness; wherein the top section of the axially aligned tubular structure comprises a second portion having a second wall thickness; wherein the top section of the axially aligned tubular structure comprises a third portion having a transitioning wall thickness that joins the first portion to the second portion; wherein the axially aligned tubular structure has a substantially constant internal diameter corresponding to the first portion, the second portion, and the third portion; wherein the primary flange section comprises a primary concentric flange disposed about a top portion thereof and extending perpendicularly outward from the axially aligned tubular structure; and wherein the axially aligned tubular structure further comprises a secondary flange section, wherein the secondary flange section comprises a secondary concentric flange disposed about a top portion of the primary concentric flange of the primary flange section. ### Claim 10 (depends on 9) The reformer tube apparatus of claim 9, wherein the reformer tube apparatus is manufactured from a heat resistant alloy including Cr, Ni, and Fe plus other elements characterized within the family of superalloys. ### Claim 11 (depends on 9) The reformer tube apparatus of claim 9, wherein the first wall thickness is greater than the second wall thickness. ### Claim 12 (depends on 9) The reformer tube apparatus of claim 9, wherein the bottom section of the tubular structure comprises a plurality of concentric wedge structures disposed about the interior thereof. ### Claim 13 (depends on 9) The reformer tube apparatus of claim 9, wherein the bottom section of the tubular structure comprises a recess disposed about the exterior thereof. ### Claim 14 (depends on 9) The reformer tube apparatus of claim 9, wherein the reformer tube apparatus is disposed within a reformer used in a direct reduction process. ### Claim 15 A method for providing a reformer tube apparatus, comprising: providing an axially aligned tubular structure disposed within a refractory lined reformer furnace housing and selectively containing a catalyst, the axially aligned tubular structure comprising a primary flange section, a top section, a middle section, and a bottom section; wherein the top section of the axially aligned tubular structure comprises a first portion having a first wall thickness; wherein the top section of the axially aligned tubular structure comprises a second portion having a second wall thickness; wherein the top section of the axially aligned tubular structure comprises a third portion having a transitioning wall thickness that joins the first portion to the second portion; wherein the axially aligned tubular structure has a substantially constant internal diameter corresponding to the first portion, the second portion, and the third portion; wherein the primary flange section comprises a primary concentric flange disposed about a top portion thereof and extending perpendicularly outward from the axially aligned tubular structure; and wherein the axially aligned tubular structure further comprises a secondary flange section, wherein the secondary flange section comprises a secondary concentric flange disposed about a top portion of the primary concentric flange of the primary flange section. ### Claim 16 (depends on 15) The method of claim 15, wherein the first wall thickness is greater than the second wall thickness. ### Claim 17 (depends on 15) The method of claim 15, wherein the bottom section of the tubular structure comprises a plurality of concentric wedge structures disposed about the interior thereof. ### Claim 18 (depends on 15) The method of claim 15, wherein the bottom section of the tubular structure comprises a recess disposed about the exterior thereof.