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The introduction of cladding plate reactor (2/3)

By WHGCM September 28th, 2023 101 views

Cladding plate reactor installation procedures:

1. The reaction kettle shall run in a high-pressure operation room that meets the explosion-proof requirements. If there are several reaction kettles, they should be layout separately, and every two sets should be divided by an explosion-proof wall.
All of the operation rooms should have a door leading to the outside. The passages and outlets of the equipment should be well-ventilated when there is an explosive medium.
After the package is unclosed, check whether the equipment is damaged, install the equipment according to the structure diagram according to the equipment model, and check the accessories according to the packing list.
If the heating method is heat conduction oil electric heating, please purchase the corresponding type of heat conduction oil according to the operating temperature Note:
The heat transfer oil is not allowed to contain water.  If adds the oil, open the oil filling port on the upper part of the jacket and the oil level port on the middle and upper parts of the jacket also.
Fill in the oil through the oil filling port and wait until the oil level port flows out. Please do not screw the filler port to avoid pressure.

2. Kettle cover is installed on the cladding plate reactor.
If you use it, the kettle cover between the concave and convex sealing should seal. The kettle cover on the kettle body is carefully sealed according to the fixed position.
Make sure the nut is tightened.  The nut needs to be diagonal and symmetrical. Tight them more gradually. Once it is in use, the stress is uniform, and the cover is not allowed to tilt to one side, so that a good sealing effect can be achieved.
There are only positive and negative connecting nuts, and the two round sealing surfaces can rotate relative to each other. They should be coated with lubricating oil.
The needle and thread of the kettle are sealed. When the reactor is running, you only need to turn the valve needle slightly to effectively compress the sealing cover so that it can achieve a good sealing effect, and effectively use the hand plate of the rotating mechanism to execute the kettle to check whether it operation is flexible.
3. Kettle body and cover are in line contact with the gasket or the conical surface and the arc surface. 
Tighten the main nut, they are pressed against each other to achieve a good sealing effect. When tightening the nut, it must be tightened diagonally and symmetrically several times.
The force is uniform, and the lid of the kettle is not allowed to tilt to one side to achieve a good sealing effect. When tightening the main nut, the specified tightening torque must not exceed the range of 40-120 N.M. to prevent the sealing surface from being squeezed or overloaded.
Special care should be taken. Before each installation, wipe the upper and lower sealing surfaces with soft paper or cloth. Pay special attention not to touch the sealing surfaces of the kettle body and lid.
After the damage, it needs to be reprocessed and repaired to achieve good sealing performance.
When disassembling the kettle cover, the kettle cover needs to be mentally lifted up and down to prevent the sealing surfaces between the kettle body and the kettle cover from colliding with each other.
When the seal is a  gasket, tighten the main nut good sealing effect can be achieved. Pressure gauges and safety valves are set by tightening the positive and negative nuts to complete the sealing. Arc-sealing surfaces at the two ends of the connection must not rotate relative to each other. When assembling all screw connections, lubricants or oils must be blended. Graphite, so as not to bite to death.
4. After the reaction is completed, cool down first, and then release the gas in the kettle to the outside through the pipeline to reduce the pressure in the kettle to normal pressure.
It is strictly forbidden to disassemble under pressure, and then loosen the main bolts and nuts symmetrically. Then carefully remove the kettle cover or raise the kettle cover and place it on the support. Please pay attention to protecting the sealing surface during the cover removal.
5. After the equipment finishes the installation, inject a certain amount of nitrogen gas to keep the pressure for half an hour.
Check whether there is any leakage. If leakage occurs, please use soap foam to find the leakage point of the pipeline and nozzle.
If the leakage happens, release the gas and tighten it, then pass it again. Inject the nitrogen pressure holding test to ensure it has no leakage and start to work.
To cool down, we can use water for internal cooling through the cooling coil, and rapid cooling is prohibited to prevent excessive temperature difference stress from causing cracks in the cooling coil and the kettle body. When the temperature in the kettle exceeds 100°C during operation, the water jacket between the magnetic stirrer and the lid of the kettle should be filled with cooling water to ensure that the water temperature is less than 35°C to avoid demagnetization of the magnetic steel.
Safety fittings:
It adopts positive arched metal bursting disc, made of stainless steel, manufactured according to the national standard GB567-89 "Technical Conditions for Arched Metal Blasting". 
The reactor has been tested before leaving the factory and don't spoil at your will. If blasting happens, replace it. You can determine the replacement period as per the actual situation.
For those that exceed the bursting pressure of the bursting disc but have not burst, it also needs replacing.   Use frequency should not exceed 80% of the lower limit pressure of the bursting disc.
At last, you shall pay attention to the convex side of the bursting disc upwards.

6. After the reactor is installed, fill the water jacket with engine oil. Cooling and lubricating mechanical seal to prolong service life. Turn the fan fins of the reactor motor by hand, no abnormal noise, the rotation is flexible, and the oil does not leak.
When refueling the reactor, add refueling from the refueling cup, and you can see that there is oil in the oil cup. When the reactor reducer is approved, it is necessary to add 46# steam engine oil for lubrication.
After the reducer runs for 20 days, the oil should be renewed for the first time. After that, the oil should be renewed every six months. Just open the oil drain nut when changing the oil.
The use of cladding plate reactor
1. Site requirements:
The cladding plate reactor cannot be used just by putting it in the room.
In the process of using the equipment, it needs to be placed separately. Each operating room should have an outlet directly into the outdoor passage or equipment.
It is necessary to ensure that the site is well-ventilated. Installed the kettle cover of the cladding plate reactor, the kettle cover between the concave and convex sealing surfaces should tip during use.
The kettle cover on the reactor body is carefully laid out according to the fixed position.
Tightening the main nut is effective, and it needs to be diagonal and symmetrical. Gradually tighten.
When it is in use, the stress is uniform, and the cover is not allowed to tilt to one side, so that a good sealing effect can be achieved.
Conductive dust and corrosive gases cannot exist in the medium surrounding the product.

2. The use of the valve: the needle valve is fastened with a thread. It only needs to turn the valve needle slightly to press the tight surface to achieve good sealing performance. Excessive force is prohibited to avoid damage to the sealing surface.

3. Pay attention to safety:
1) When using the cladding plate reactor, you should not relax: Generally, the reaction runs under normal pressure or with an open lid, and the still is generally operated under normal or negative pressure. Some people think that operation under normal pressure, exposure, or negative pressure is not very dangerous. However,  signs of accidents cannot be seen and dealt with in time, thus causing accidents.
The pressure on the reactor wall of the normal pressure or the open reactor is greater than that of the reactor with pressure inside the reactor, and the danger is also greater. For the distillation kettle, if the operator makes mistakes in operation and the reaction is out of control, the pipeline valve system will be blocked, and the normal pressure and vacuum state under normal conditions will become positive pressure.
If it cannot be found and disposed of in time, and there is no emergency pressure relief device, it is easy to cause a fire Explosion accident.

For example, the explosion accident of a diazotization reactor in a company was because the steam valve of the diazotization reactor was not closed, and a large amount of steam still entered the jacket of the reactor during the heat preservation stage, causing the temperature in the reactor to rise rapidly, and the diazotization salt was violently discharged.
Decompose, and then explode. The operator on duty did not monitor the temperature of the kettle in place and failed to discover the abnormal temperature in the kettle in time, which delayed the appropriate time to deal with the abnormal situation.

Reactors and stills should have a complete temperature, pressure, flow, and other instrumentation devices. The vacuum pump for vacuum distillation should be equipped with a one-way check valve to prevent air from entering the system when suddenly stopping.

A one-way check valve should also be installed at the connection between the low-pressure system and the high-pressure system to prevent the materials in the high-pressure container from entering the low-pressure system and causing an explosion.
For reaction kettles and distillation kettles that may be overpressured, emergency pressure relief devices must be installed. Generally, safety valves are installed on the equipment, and bursting discs can be installed for equipment that is not suitable for the installation of safety valves or with relatively dangerous processes.

To be continued.
The introduction for cladding plate reactor (1/3)
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The introduction of cladding plate reactor (3/3)
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