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Used stainless steel reactor maintenance after normal use it?
DATE:2016-6-22 HITS:238
Stainless steel reactor maintenance:
 Stainless steel reactor vessel by the body, kettle cover, jacket, agitator, gear, shaft sealing device, support and other components. Material generally carbon steel, stainless steel, zirconium, nickel (Hastelloy, Monel) alloys and other composite materials; the manufacturing structure of the reactor can be divided into flat open reactor lid, open welded flange reactor and closed reactor three categories.
 Stainless steel stirred reactor in the form of generally anchor, paddle, turbine, propelled or box type, etc., a stirring device in height to diameter is large, multi-usable stirring blades, can be arbitrarily selected according to user requirements, stainless steel the reactor can be divided into different types of seal: packing seal, mechanical seal and magnetic seal. Heating electric heating, cooling jacket for the cooling coil and the autoclave was cooled.
 Stainless steel reactor is widely used in petroleum, chemical, rubber, pesticides, dyes, pharmaceuticals, food, used to complete the vulcanization, hydrogenation, alkylation, polymerization, condensation process pressure vessels, such as reactors, reactor, decomposition of the pot, polymerization reactor and the like.
 Stainless steel reactor maintenance:
 Stainless steel must be closed when the reactor coolant inlet pipe valve, put the pot with the best of the remaining refrigerant and the jacket, and then enter the material, agitator, and then open the steam valve and electric power, after reaching the desired temperature, should be closed steam valves and electric power, over 2 to 3 minutes, then turn off the agitator after the end of the process, after the release of the pot to make the remaining condensate and a jacket, should rinse with warm water as soon as possible, brush off the slimy material, and then 40 ℃ ~ 50 ℃ alkaline thorough cleansing of the inner wall of the container, and rinse with water, especially stainless steel kettle pot no material (heat medium) empty pot case not open the steam valve and an electric power supply, pay special attention to the use of steam pressure, can not be higher than the fixed operating pressure.
 Material and material contact parts are made of stainless steel autoclave 304 or 316L stainless steel and other high-quality, in line with GMP standards. , Stirred stainless steel reactor parts in the form of multi-purpose mixing box, make sure the material evenly to reconcile in a short time; while adopting sanitary mechanical seals need to use frame type, anchor, paddle and other sealing, and can ensure that the pressure tank prevent tank leakage of materials and cause unnecessary pollution; interface uses ISO standard quick clamp, convenient health; sterile respirator, CIP cleaning nozzles, sight glass, flange, sanitary quick open manhole using a stainless steel reactor for a long time need to be cleaned to ensure the efficiency of its operations, the stainless steel reactor how we can correct it for cleaning?
 Cleaning stainless steel reactor main chemical cleaning and mechanical cleaning two categories. Chemical cleaning must first know the scale-like components within the device, preferably sampling and analysis. After determining soil ingredients do first test, with the choice of cleaning agents
 When determined by tests on stainless steel reactor does not cause corrosion. Then set up temporary site cleaning liquid circulation means circulating in the equipment, and wash away dirt. Mechanical cleaning is the use of high-pressure cleaning device, the high-pressure water through the nozzle 150-200MPa scour dirt.
 Both methods have advantages and disadvantages, chemical cleaning less labor, cleaning time is short, a thorough cleaning, but may result in a stainless steel autoclave chemical attack; mechanical cleaning will not cause corrosion of the reactor, on the hard dirt can be effectively cleaned, but using when the long, labor-intensive. Therefore, application of chemical cleaning dirt soft, thin conditions, mechanical cleaning applications in the dirt hard, thick conditions.
 Stainless steel reactor which defects in the manufacturing process
(1) confused with full volume and the nominal volume concept, the whole volume is usually the device is the kettle all the space cylinder and the upper and lower head contains, nominal volume only is the volume of the kettle jacket correspondence, that is, it can feed volume. The latter significantly less than the former. Typically, the feeding amount according to user requirements is the nominal volume, but a considerable number of the manufacturer intends to fool the full volume. Users do not care, you can take advantage of a large, users see through, but also to pretend to misunderstand, there is a reason to excuse. But the harm is when a user unknowingly, over charge coefficient and excessive feeding, resulting in reactor work overload, the danger is self-evident.
(2) reducer misconfigured. At higher shaft sealing demanding applications, such as the use of mechanical seals, should be used in a smaller swing shaft gear, and some manufacturers will use relatively inexpensive turbine reducer, because a large swing axis, the joint swinging agitator shaft In this case, the mechanical seal can not be guaranteed due to operating conditions and failure. When the autoclave under pressure, seal leakage worse. If the vessel is within the flammable, explosive, toxic, corrosive media, the harm can be imagined.
(3) In order to ensure the stability of the actuator, the kettle should cover the base as a platform, often reduced to three-point support, because this structure thin, stiffness difference. In addition to the use of forced kettle on low speed, but in the conventional reactor could easily lead to the agitator shaft, gear racks and motor jitter. Resulting in seal failure, leakage of materials, equipment wear and tear of moving parts.
(4) change the kettle body thin jacket or heat transfer plates, especially the high price of stainless steel, this great danger. Kettle body compressive strength and stiffness degradation, the device can cause an explosion accidents.
(5) gear rack is too short, no adjustment of mechanical seals and Cowper wheel space, replace the mechanical seal wearing parts, reducer and motor to be demolished, very inconvenient. The deceleration frame is long enough, only decomposition Cowper wheel, the other does not have to move. Although the short-rack manufacturer or user to save manufacturing costs a little, but later consumed by the user equipment maintenance time charge is usually much higher than the cost of a little saving. At least for the user, reckoning or long-term accounts and uneconomical.
(6) for the material saving, head does not push the straight edge, head stiffness degradation, reduce equipment capacity.
(7) an intermediate gear rack without locating bearing. Oscillating agitator shaft is too large, resulting in seal failure.
(8) to change the thin flange material, while not reaching the rated load deformation, resulting in flange seal failure. Even innocuous medium high pressure at high temperatures, sudden failure will have serious consequences, even more harmful media.
(9) bottom rack bearing and deceleration different axes, or stirring shaft and reducer shaft misalignment, resulting in another stirring shaft stiffness swing bottom bearing life and reduce wear and tear due to seal failure.
(10) and the inner wall of the reactor vessel internal parts are not polished, kettle rough wall, rust, scale, cleaning or replacement of the initial difficulties when using the product.
(11) In order to ensure that the equipment strength, corrosion resistance and clean barrel and flanges, etc. in the autoclave should be double welded inside and outside, are often simplified to the outer side welding. After the inside of the small welding, the user is not easy to see the appearance of it, but less reliable equipment, the inside is not welded to the formation of cracks, easy to penetrate the autoclave, and difficult to clean, ingredients infiltrate usually uncertain, can be both long stay caught deep corrosion of equipment, and then fall off may contaminate the product.
 Stainless steel reactor maintenance must be done regularly, but also in maintenance when there are a few very important details, let's look at a few details of it.
 
1. Removal ago, the first magnetic reactor should be drained within the autoclave reaction mass, and with a harmless gas and liquid media clean, so as not to dismantle the autoclave personnel injury.
 
2, magnetic reactor under stirring shaft to check the amount of rocking on a regular basis, if we find a large amount of swing should immediately open the structure according to FIG replace the bearings and bushings. The magnetic stirrer composite bushings or graphite sleeve design life of 1 to 2 years, to ensure the normal operation of equipment replacement is recommended once a year. To replace the blades within the maintenance tank, baffle, draft tube and other components, be sure to loosen the main bolt, nut Lord, lift the tank cover and disassemble piece by piece.
 
3, repair magnetic stirrer, you do not need to open the tank cover, as long as the lid was loosened and the coupling nut, to lifting the drive, then remove the screw connection with the inner magnet, still stirring shaft into the autoclave . Removal should be avoided and the magnetic impurities such as iron into the gap inside and outside the magnet, the magnet and to ensure concentricity of the inner and outer sealing cap to be avoided in the inner and outer rotor caused by wear and tear. When you install the bolts tightened bolts evenly symmetrical, and 2 to 3 times tighten the bolt to prevent partial damage to the gasket sealing effect impact.
 
4, high temperature and high speed magnetic stirrer, an upper left hole injection, is injected in the parking of the bearing grease settings, it can be used after only unload pressure in the autoclave until each addition 30-50C.C, with a syringe. Overhaul the entire process: in any case, should not use any hammer beat the parts, so as not to affect the installation accuracy.
 Reactor commonly used in petrochemical, rubber, pesticides, dyes, pharmaceuticals and other industries, to complete the sulfonation, nitration, hydrogenation, alkylation, polymerization, condensation and other processes, as well as many other process organic dyes and intermediates
 The reaction process equipment. Due to the different conditions and media, material selection and structure of the reactor are not the same, but the basic composition is the same, including the transmission, heat transfer and a stirring device, the kettle (cover, cylinder, bottoms) process to take over. Reactor body is usually made of stainless steel, non-ferrous metals (or composite board) reactor of the most common material is stainless steel autoclave 304,321 or 316L, a common non-ferrous materials are Hastelloy, titanium, nickel, zirconium, Monel Wait.
 Reactor structure is basically the same, but the chemical reaction required under certain temperature conditions can be carried out, mostly intermittent operation. Its both under pressure and withstand temperature, the majority reactor pressure vessel maintenance and safety.
1, should be strictly in accordance with the calibration on the product nameplate working pressure and temperature operational use, in order to avoid danger.
2, reactor transmission. Reactor with a stirrer, has a certain speed requirements. Common motor drives the reactor agitator running through reducer. Reactor reducer for the vertical mount, oiled, no vibration, no leakage, long-term stable operation.
3, agitator reactor. Stirrer reactor is the main part, to strictly abide by the provisions on product instruction cooling, oiling, etc., good equipment maintenance and repair. In normal operation should always check the shaft radial wobble amount is greater than a predetermined value, the blender can not be reversed, and the autoclave coil, discharge pipe, to maintain a certain distance between thermowell and prevent collisions. Periodic inspection for corrosion reactor stirrer, cracks, deformation and loose.
4. To check for corrosion reactor casing (or liner) regularly.
5, when all valves used, should be slowly turning the stem (needle), close the cover of the pressure to achieve sealing effect. Close difficult when too much force, so as not to damage the sealing surface.
6, electrical control instruments by hand operation, according to the provisions set overload protection facilities.
 
Reactor rules
1, the reaction vessel before driving
1) Check the kettle, blender, rotating parts, ancillary equipment, indicating instrument, safety valves, piping and valves compliance with safety requirements.
2) Check the water, electricity, gas and compliance with safety requirements.
2, reactor start -
1) feeding should be preceded by opening the autoclave stirrer, and when no noise is normal, the material is added to the reaction vessel, addition shall not exceed process requirements.
2) Before opening the steam valve, the first valve open back after Inlet Valve. Open the steam valve should be slow, so that the preheating of the jacket, and gradually boost, jacket pressure may not exceed a predetermined value.
3) steam valve and cooling valve can not start, hammering and allowed collision steam pipe passing gas.
4) When the cooling water valve open, the first valve open back, after entered the valve. Cooling water pressure of not less than 0.1 MPa, and allowed more than 0.2 MPa.
5) water ring vacuum pump, after the first open water pump, when the pump stops, first stop the pump without water, and the water pump should be excluded.
6) Always check the functioning of the reactor, abnormal should be shut down for maintenance.
7) cleaning titanium epoxy (enamel) reactor, the reactor allowed to use alkaline brush, careful not to damage the enamel.
3, the reactor after stopping
1) stirring was stopped, turn off the power all kinds of valves.
2) must cut off the power when the reactor clean-up mixer, hanging signs, and set guardianship.
3) must reactor pressure vessel requirements for regular technical inspection, test failed, he shall not run.
 Common Faults and Causes of reactor
1. Symptom: sealing surface leakage. Cause: Loose screw thread; sealing surface damage. Remedy: Re-tighten the screw; re-grinding polished sealing surface.
2. Symptom: at the valve leaks. Cause: stem (needle), the valve port sealing surface damage. Remedy: Repair, replace the stem (needle), the valve port.
3. Symptom: outside the magnet rotates within the magnet does not turn, the motor current is reduced. Cause: autoclave temperature is too high, poor cooling cycle, the magnet inside the magnetic fade due to high temperature. Hydrogenation reaction, the magnet inside the sleeve for cracks, swelling within the magnet. Remedy: inform supplier, to replace the internal magnet.
4. Symptom: friction noise within the magnetic coupling actuator. Cause: bushings, bearing wear, the gap is too large, the inner magnet rotating appear jerky. Remedy: replace bearings, bushings.
 
Chemical production requirements and trends of the reactor
1, a large volume of which is to increase production, reduce production errors between quality, effective way to reduce product costs and trends. Dye used mostly for domestic reactor 6000L or less, and some other sectors of 30m3; abroad in the dye industry 20000 ~ 40000L, and other industries up to 120 m3.
2, reactor agitator, depending on the reaction conditions required, by a variety of supporting the use of a combination of blades, to increase the reaction effect. Abroad, in addition equipped with a stirrer, still make the kettle body is rotated along the horizontal line, thereby increasing the reaction rate.
3, production automation and continuous instead of the cumbersome manual clearance operations, such as the use of process control, can ensure stable production, improve product quality, increase revenue, reduce manual labor, but also to eliminate pollution of the environment.
4, the rational use of energy, the process to select the best operating conditions and strengthen the insulation measures to improve the heat transfer efficiency, minimize heat losses, thermal energy or heat after the reaction is sufficiently comprehensive utilization. Application of heat pipe technology, will be the direction of future development.