The broad understanding of the
Reactor is that there is a physical or chemical reaction container. Through the structural design and parameter configuration of the container, the heating, evaporation, cooling and low-speed mixing functions required by the process are realized. It is widely used in medicine, food, chemical industry, rubber, pesticides, dyes, and is a pressure vessel used to complete processes such as vulcanization, nitration, hydrogenation, alkylation, polymerization, and condensation.
1. Failure phenomenon: shell damage (corrosion, cracks, through holes) Causes of failure: 1. Radiation from the medium (pitting corrosion, intergranular corrosion); 2. Cracks or alkali embrittlement due to thermal stress; 3. Wear thinning or Uniform corrosion.
Treatment methods: 1. The shell lined with corrosion-resistant materials needs to be relined or partially repaired; 2. After welding, stress should be eliminated, and cracks should be repaired; 3. If the thickness exceeds the minimum design allowable thickness, the body needs to be replaced.
2. Failure phenomenon: over-temperature and over-pressure failure reasons: 1. The instrument fails and the control is not strict; 2. Misoperation; improper raw material ratio; violent reaction; 3. Side reaction occurs due to poor heat transfer or stirring performance; 4. The intake valve fails and the intake pressure is too large and the pressure is high.
Treatment methods: 1. Check and repair the automatic control system, and strictly implement the operating procedures; 2. According to the operation method, take emergency pressure relief, and feed materials regularly and quantitatively according to the regulations to strictly prevent misoperation; 3. Increase the heat transfer area or remove the scale to improve the transmission The agitator is repaired by thermal effect to improve the stirring efficiency; 4. Close the main steam valve, and repair the valve when the steam is cut off.
3. Failure phenomenon: seal leakage failure reasons: packing seal 1. The stirring shaft is worn or corroded at the packing, causing the gap to be too large; 2. The oil ring cannot be formed due to improper position of the oil ring or the oil circuit is blocked; 3. The gland is not pressed tightly. The packing quality is poor, or it has been used for a long time; 4. The stuffing box is corroded.
Mechanical seal 1. The end faces of the dynamic and static rings are deformed and bruised; 2. The end face specific pressure is too large, and the friction pair is thermally deformed; 3. The sealing ring is selected incorrectly, the pressing force is not enough, or the V-shaped sealing ring is installed reversely, and the sealing performance is lost; 4. The vertical error between the axis and the end face of the static ring is too large; 5. The operating pressure and temperature are unstable, and hard particles enter the friction pair; .
Treatment method: packing seal 1. Replace or repair the stirring shaft, and process it on the machine tool to ensure the roughness; 2. Adjust the position of the oil ring and clean the oil circuit; 3. Press the packing or replace the packing; 4. Repair or replace; Mechanical seal 1. Replace the friction pair or re-grind; 2. Adjust the specific pressure appropriately, strengthen the cooling system, and take away the heat in time; 3. The material of the sealing ring should be selected, the installation should be reasonable, and there should be enough pressing force; 4. Shutdown, Re-align to ensure that the non-perpendicularity is less than 0.5mm; 5. Strictly control the process indicators, particles and crystals cannot enter the friction pair; 6. Adjust and overhaul to make the shaft channeling meet the standard; 7. Improve the installation process, or interference The amount should be appropriate, or the adhesive should be easy to use and firm.
4. Failure phenomenon: there is abnormal noise in the kettle. Reasons for the failure: 1. The accessories (coiled tube, thermometer tube, etc.) in the agitator friction kettle or scraping the wall; 2. The agitator is loose; 3. The lining is bulging and collides with the agitator; 4. The stirrer is bent or the bearing is damaged.
Treatment methods: 1. Stop for inspection and align, so that there is a certain distance between the agitator and the accessories; 2. Stop for inspection and fasten the bolts; 3. Repair the bubbling or replace the lining; 4. Overhaul or replace the shaft and bearing.
5. Failure phenomenon: The enamel mixer falls off. Reasons for failure: 1. Corrosion and fracture by the medium; 2. The motor rotates in the opposite direction.
Treatment methods: 1. Replace the enamel shaft or repair it with FRP; 2. Stop the machine to change the steering.
6. Failure phenomenon: Enamel kettle flange leakage failure reasons: 1. The flange porcelain surface is damaged; 2. The material of the gasket is unreasonable, the installation joints are incorrect, vacant, and misplaced; 3. The clips are loose or insufficient.
Treatment methods: 1. Repair, apply anti-corrosion paint or resin; 2. According to the process requirements, select the gasket material, the gasket interface should be close together, and the position should be uniform; 3. According to the design requirements, there should be a sufficient number of clips, and they should be fastened.
7. Failure phenomenon: Scale explosion and micro-holes occur on the porcelain surface. Reasons for the failure: 1. Acidic impurities enter the jacket or stirring shaft tube, resulting in hydrogen embrittlement; 2. The porcelain layer is not dense, and there are hidden dangers of micro-holes.
Treatment methods: 1. After neutralization with sodium carbonate, rinse with water or repair, and the ones with serious corrosion need to be replaced; 2. The ones with a small number of micropores can be repaired, and the ones with serious renewing can be repaired.
8. Fault phenomenon: The motor current exceeds the rated value. Fault reasons: 1. The bearing is damaged; 2. The temperature in the kettle is low and the material is viscous; 3. The spindle speed is fast; 4. The diameter of the agitator is too large.
Treatment methods: 1. Replace the bearing; 2. Adjust the temperature according to the operating rules, and the viscosity of the material should not be too large; 3. Control the spindle speed within a certain range; 4. Adjust it appropriately.
