Titanium Pressure Vessel Hemispherical Tank Gr2 Gr5 Gr7 Head Titanium Dish Titanium Head Dish Titanium Equipment

Titanium Pressure Vessel Hemispherical Tank Gr2 Gr5 Gr7 Head Titanium Dish Titanium Head Dish Titanium Equipment

Titanium hemispherical heads are integral components in pressure vessels, tanks, and reactors used in various industries, including chemical processing, petrochemical, aerospace, and marine. These hemispherical heads are typically formed from high-quality titanium alloys such as Grade 2 (Gr2), Grade 5 (Gr5), and Grade 7 (Gr7), which offer exceptional properties for handling pressure, corrosion resistance, and high temperatures.

Titanium Dish Shaped Hemispherical Heads

A dish-shaped hemispherical head is one of the most common types of pressure vessel heads. The hemispherical shape is ideal for pressure applications due to its structural efficiency in distributing pressure uniformly across the surface. Titanium is particularly well-suited for these applications due to its high strength-to-weight ratio and corrosion resistance.

Titanium Alloys Used for Hemispherical Tank Heads

1. Titanium Grade 2 (Gr2) Hemispherical Head

• Grade 2 is the most commonly used commercially pure titanium alloy. It has excellent corrosion resistance, especially in acids, chlorides, and seawater, making it ideal for environments where corrosion is a significant concern, but high strength is not as critical.
• Applications: Chemical reactors, storage tanks, marine applications, seawater desalination plants, and heat exchangers.
• Advantages:
  • Outstanding resistance to general corrosion.
  • Excellent weldability.
  • Lower cost compared to higher-strength titanium alloys.
  • Ideal for moderate pressure and temperature conditions.

2. Titanium Grade 5 (Gr5) Hemispherical Head (Ti-6Al-4V)

• Grade 5 (Ti-6Al-4V) is an alpha-beta alloy that offers significantly higher strength than Grade 2 due to the presence of aluminum and vanadium. This makes it suitable for high-pressure, high-temperature applications.
• Applications: Aerospace components, high-pressure vessels, reactors, heat exchangers, and oil and gas.
• Advantages:
  • Superior strength-to-weight ratio.
  • Better performance at high temperatures (up to around 400°C).
  • Good corrosion resistance, though not as resistant to aggressive acids as Grade 2.
  • Suitable for high-stress applications like pressure vessels and reactors.

3. Titanium Grade 7 (Gr7) Hemispherical Head

• Grade 7 (Ti-0.2Pd) is a titanium-palladium alloy, specifically designed for use in extremely corrosive environments. It combines the properties of titanium with the added benefit of palladium, which enhances its resistance to reducing acids (such as sulfuric acid) and other aggressive chemicals.
• Applications: Chemical processing, petrochemical industries, and other applications requiring superior corrosion resistance.
• Advantages:
  • Excellent resistance to sulfuric acid and chlorine environments.
  • Suitable for highly aggressive chemical environments, including hydrochloric acid.
  • Provides both strength and excellent corrosion resistance, especially in reducing acids.
  • Ideal for highly corrosive applications that would degrade Grade 2 or Grade 5.

Manufacturing of Titanium Dish Shaped Hemispherical Heads

The manufacturing process for titanium dish-shaped hemispherical heads involves several key steps:

1. Material Selection: Choose the appropriate titanium alloy (Gr2, Gr5, or Gr7) based on the application's strength, corrosion resistance, and temperature requirements.

2. Forming: Titanium sheets are heated and then shaped into a dish or hemispherical form. Techniques used include:

   • Deep drawing: A process where a flat sheet is drawn into the shape of a hemisphere using a die.
   • Pressing: Applying pressure to form the titanium into the required shape.
   • Hot forming: Heating the titanium to high temperatures to make it more malleable before forming.

3. Welding: If the dish head needs to be welded to a cylindrical body or other components, high-precision welding methods like TIG (Tungsten Inert Gas) welding are used. Titanium is highly sensitive to contamination during welding, so the process must be performed in a controlled environment (often using inert gases to avoid oxidation).

4. Surface Treatment: After forming, titanium heads may undergo surface treatments such as:

   • Pickling: A chemical treatment to remove oxide layers and improve surface quality.
   • Passivation: A process that enhances the titanium's natural oxide layer, further increasing its corrosion resistance.
   • Polishing: For aesthetic or performance reasons, especially in applications that require smooth surfaces.

5. Inspection and Testing: Rigorous inspection methods are used to ensure the quality and integrity of the titanium heads:

   • Visual inspection to detect any surface defects.
   • Non-destructive testing (NDT) such as ultrasonic testing or X-ray inspection to detect internal flaws.
   • Pressure testing to confirm the structural integrity of the heads for their intended application.

Manufacturing Process of Titanium Dish Shaped Hemispherical Heads

The process of manufacturing titanium dish shaped hemispherical heads involves several steps, including:

1. Material Selection: Sheets of Grade 2 or Grade 5 titanium are selected based on the specific requirements of the application.

2. Forming: The titanium sheet is heated to a temperature suitable for forming, and then it is mechanically pressed or drawn into the hemispherical shape. This can be done using deep drawing, hot forming, or pressing techniques.

3. Welding: If the dish head needs to be welded to other parts, such as a cylindrical body, precision welding techniques like TIG welding (Tungsten Inert Gas welding) are used to join titanium parts. Care must be taken to avoid contamination and maintain the integrity of the material.

4. Post-Processing: After the head is formed and welded, it may undergo additional processes such as pickling to remove oxides, polishing to improve surface finish, or passivation to enhance corrosion resistance.

5. Testing and Inspection: The finished heads are subjected to rigorous quality control checks, including non-destructive testing (NDT) like X-ray, ultrasonic testing, or pressure testing, to ensure they meet the required strength and durability standards.

Titanium Hemispherical Head Manufacturing Process

Titanium hemispherical heads are typically produced using processes like deep drawing, hot forming, or pressing. The general process includes:

1. Sheet Preparation: Titanium alloy sheets are cut to the required size.
2. Forming: The titanium sheet is heated and then pressed or drawn into the hemispherical shape using a press or a forming die.
3. Welding: If needed, the hemispherical head is welded to the cylindrical body of the vessel or tank. Titanium welding requires careful control of heat and the welding environment to prevent contamination.
4. Post-Processing: After forming and welding, the titanium hemispherical heads may undergo treatments such as pickling, polishing, or passivation to enhance corrosion resistance and surface quality.

Advantages of Titanium Hemispherical Heads

1. Corrosion Resistance:
   • Titanium alloys, particularly Grade 1 and Grade 2, are known for their superior corrosion resistance, which is crucial in chemical and marine environments.
2. Strength-to-Weight Ratio:
   • Titanium offers a high strength-to-weight ratio, meaning that the heads can withstand high internal pressures without adding significant weight, which is important in industries like aerospace and marine.
3. Longevity:
   • Due to titanium’s excellent resistance to corrosion, hemispherical heads made from this material have a long service life with minimal maintenance.
4. High Temperature Resistance:
   • Titanium Grade 5, in particular, is suitable for high-temperature applications, ensuring structural integrity in extreme heat environments.
5. Biocompatibility:
   • Grade 1 and Grade 2 titanium are biocompatible, making them ideal for applications in medical equipment, such as implants and surgical instruments.

Applications of Titanium Hemispherical Heads

1. Pressure Vessels:
   • Used in industries such as petrochemical, pharmaceuticals, and food processing where internal pressure needs to be safely contained.
2. Heat Exchangers:
   • Titanium heads are used in heat exchangers due to their resistance to corrosion and ability to withstand high thermal loads.
3. Storage Tanks:
   • Used in storage tanks that require excellent resistance to corrosion from chemicals or acids.
4. Aerospace:
   • The strength and lightweight properties of titanium make it ideal for aerospace applications, including in fuel tanks and pressurized components.
5. Marine Applications:
   • Ideal for seawater contact, where titanium’s resistance to chloride-induced corrosion is crucial.
6. Power Generation:
   • Used in the construction of reactors and other high-pressure, high-temperature components in the power generation industry.

Types of Dish Heads Based on Shape

Dish heads are classified based on their geometric shapes, and each type serves specific structural or functional needs.

Convex Heads:

• These heads feature an outwardly convex surface and are commonly used to ensure the structural integrity of containers that must withstand internal pressure.
• Examples include hemispherical heads, oval heads, disc heads, and unflanged spherical heads.
• Hemispherical heads are often used in high-pressure vessels because their shape can evenly distribute the internal pressure.
• Oval heads and disc heads can also be used depending on the design and pressure requirements.
• Some gas cylinders use convex inward heads, sometimes referred to as combined bottom heads, which enhance strength and safety by providing a more efficient load distribution.

Conical Heads:

• Conical heads feature a tapered shape and are typically used in applications where a smooth transition between cylindrical and conical shapes is necessary, such as in certain types of reactors and towers.
• These heads are particularly useful in handling both internal and external stresses due to their tapered nature.

Flat Heads:

• Flat heads are less common than convex or conical heads and are used in containers where internal pressure is relatively low or absent. They are simpler to manufacture and weld but are generally less effective at handling high internal pressure.

Combination Shapes:

• Some heads combine different geometric shapes to achieve specific design or structural benefits. These heads may combine convex and conical shapes, or use flat and convex elements, to meet the functional needs of the vessel.

Specifications of Titanium Heads:

Chemical composition

Mechanical Property