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The introduction for cladding plate reactor (1/3)

By WHGCM September 28th, 2023 80 views

Definition
Cladding plate refers to a layer of metal covered with another metal plate, that has achieved the effect of saving resources and reducing costs without reducing the use of the effect (corrosion resistance, mechanical strength, etc.) under the premise of saving resources and reducing costs. 

It mainly explains nine aspects of this reactor, including characteristics, application scope, working principle, selection, customization standards, precautions during production, installation procedures, usage rules, cleaning, maintenance, and troubleshooting.
structure of cladding plate Common cladding plates are stainless steel cladding plates, titanium steel cladding plates, nickel aluminum cladding plates, and so on. Due to its relatively low cost, this material is widely used in the manufacture of reactors and pressure vessels.


Features of Cladding Plate Reactor
Cladding plate reactor has the characteristics of rapid heating, high-temperature resistance, corrosion resistance, hygiene, no environmental pollution, automatic heating without a boiler, and convenient use.
Applications
It is widely used in the petroleum, chemical industry, rubber, pesticide, dyestuff, medicine, and food, to complete vulcanization, nitration, hydrogenation, alkylation, polymerization, condensation, and other processes. 
On the premise of complete mixing the reacting substances, such as reactor, reaction pot, decomposition pot, polymerization kettle, etc., materials generally include carbon-manganese steel, stainless steel, zirconium, nickel-based Hastelloy, Monel, Inconel alloy, and other composite materials. 
For physical changes such as heating, cooling, liquid extraction, and gas absorption, stirring devices that required to obtain good results. It is the ideal equipment for chemical, pharmaceutical, and other industries.
Working principle of cladding plate reactor
Structure of the reactor: 
It contains a kettle body, a kettle cover, a jacket, a stirrer, a transmission device, a shaft seal device, and support. 
The mixing forms generally include anchor type, paddle type, turbine type, pusher type or frame type, etc. 
When the height and diameter of the stirring device are relatively large, it requires multi-layer stirring blades. And they can also be optionally selected according to user requirements. 
And a jacket is a component outside the kettle wall. Or a heat exchange surface to install inside the vessel. The heat exchange realizes through external circulation. 
Heating methods include electric heating, hot water heating, thermal oil circulation heating, far-infrared heating reaction kettle, external and internal coil heating, etc. However, cooling methods include jacket cooling and kettle inner coil cooling, stirring blades, etc. 
The support seat has a support type or an ear type support, etc.
The gear reducer can be applied when the speed exceeds 160 rpm. The number of openings, specifications, or other requirements can be designed and produced according to user requirements.
Usually, the packing seal utilizes under normal pressure or low-pressure conditions, and the general working pressure is less than 2 kg. In normal medium pressure or vacuum conditions, mechanical seals are enough to be used, and the pressure is negative pressure or 40kgs.
When in high pressure or high volatility, the magnetic seal works well, and the pressure exceeds 14 kgs. In addition to the magnetic seals that use water to cool down, other seal forms will increase the cooling water jacket when the temperature exceeds 120 degrees.

Standards of selecting and customing the cladding plate reactor: 
The cladding plate reactor is chosen according to the stirring purpose of the cladding plate reactor and the flow state to determine the slurry type and baffle conditions. The determination of the flow state is affected by the viscosity of the stirring medium.
The use conditions of the cladding plate reactor are relatively specific, not only for slurry type and stirring but also for the viscosity range of the propulsion medium, stirring speed, and the capacity range of the tank.
Many cladding plate reactor applications are specific and detailed according to the purpose of stirring and the flow state during the stirring when the list of cladding plate reactor types is confirmed.
The advantage of the selection of cladding plate reactors is that the scope of use of the slurry type is divided according to the characteristics of different stirring processes, making the selection more specific.

WHGCM is a high-quality manufacturer of magnetic cladding plate reactors. Our magnetic cladding plate reactors are high in quality, low in price, and welcomed by customers. To facilitate customers interested in the magnetic cladding plate reactor, I will briefly introduce the usage of the magnetic cladding plate reactor below.
The magnetic cladding plate reactor is suitable for the continuous hydrogenation method to produce sorbitol, xylitol, maltitol, furfuryl alcohol, and other products. It is the equipment for the continued hydrogenation reactions of sorbitol, xylitol, maltitol, etc. device of.
We are a company of full vitality, innovation ability, and team spirit. We focus on providing customers with reliable, and comprehensive hydrogenation cladding plate reactors. It is precisely because of customer satisfaction that we have more and more long-term cooperation customers.
The electric heating of the cladding plate reactor winds the resistance wire around the insulating layer of the cladding plate reactor or installs it on the insulator at a certain distance from the cladding plate reactor.
Therefore, the cladding plate reactor forms a small space gap between the resistance wire and the cladding plate reactor body.
The first three methods need to add a jacket on the cladding plate reactor to obtain high -temperature. Due to the extreme temperature change, the jacket and shell of the cladding plate reactor are subjected to temperature changes to generate temperature difference pressure. When using electric heating, the equipment is lighter and simple, the temperature is easier to adjust, and there is no need for pumps, stoves, chimneys, and other facilities. It is also easy to start, the risk is not high, and the cost is low, but the operating cost is higher than other heating methods, and the thermal efficiency is higher. It is below 85%, so the cladding plate reactor is suitable for places where the heating temperature is below 400°C and the price of electricity is low.
Things to pay attention to when making cladding plate reactors:
1. The cladding plates used for the stainless steel polymerization reactor body should be inspected macroscopically one by one, and there must be no harmful appearance defects in processing and use, and even ultrasonic flaw detection one by one. When welding the transition layer.
It is necessary to consider the dilution on the base layer to avoid the formation of a martensitic structure.
In the past, to prevent this phenomenon, the compound layer on the edge of the groove was planned off by 5~10mm when planning the groove design.
Clean up, this approach also causes an increase in surfacing, wasting expensive stainless steel electrodes.
In the welding process of stainless steel polymerization reactors, the Submerged-Arc-Automatic-Welding is suitable for inner and outer base welds (except the last ring weld).
 For submerged arc automatic welding, the three factors of welding current, welding voltage, and welding speed are the main process specifications, and the regulations for welding cladding plates of stainless steel polymerization reactors play an outstanding role in ensuring welding quality, shortening the production period, and improving the qualified rate of flaw detection.
The correct cleaning method can promise quality and improve efficiency, but many customers choose not to do any cleaning.

2. The cladding plate reactor should strictly prevent the carbon steel welding wire from being welded on the cladding layer or the excessive layer welding wire welding on the cladding layer, and the cladding layer should not be damaged when welded for the base layer.
Cladding plate reactor When assembling composite steel plate butt joints, the reference plane is the stainless steel cladding layer to prevent the misalignment from being too large and affecting the cladding welding quality.
During assembly and welding, strictly avoid mechanical damage and arc burns on the surface of the stainless steel clad layer.
When the spatter of carbon steel welding falls on the cladding layer, it requires carefully removed. When welding the excessive layer, reduce the dilution to ensure penetration rate, a tiny specification should be adopted as much as possible.
The welding materials used in the reactor must have valid and corresponding material approval certificates. All welders who participate in welding must have a qualification certificate and have passed the mechanical examination and approval before they can work on the job.

To be continued.
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