Glass lined reactor operating procedures

1、Operation of the reaction kettle:

1.1, the preparation before driving:

1.1.1 determine to drive personnel, drive personnel for professional training, glass-lined products, the use of precautions training, production procedures training, printing equipment operation records; prepare the necessary driving tools, such as spanners, pipe wrenches and so on;

1.1.2, check the speed reducer (according to the instruction manual specified lubricant varieties filled with the required amount of oil), seat bearings, kettle seals oil box lubricant amount; check the cooling water system in all parts, to meet the operating requirements; check the reactor card, manhole, test mirror, pressure gauge, the process of the pipeline mouth connection is installed in place, whether the pressure gauge in the validity of the period.

1.1.3 After checking and confirming that the transmission part is intact, start the circulating oil pump and check whether the oil pump rotates clockwise; start the motor and check whether the stirring shaft rotates in clockwise direction, and it is forbidden to reverse the rotation;

1.1.4, when in use, at room temperature, kettle water instead of material test run: through the process pipeline injection of clean tap water and reach the required level height or quantity of process, send power to start the stirrer operation, while the kettle pressure to achieve the required process pressure, check the kettle import and export valves for leakage, if there is leakage should be well labelled, to be adjusted to sealing after the pressure is removed. If there is any leakage, mark it and adjust it to sealing after pressure relief. If there is any leakage in the relevant dynamic and static sealing points, use the direct venting valve to release pressure and see whether the pressure can be drained off quickly;

1.1.5 Confirm whether the corresponding valve is in the controlled position according to the valve confirmation table for opening and stopping.

1.2 Requirements when driving:

1.2.1, according to the process operating procedures into the material, start mixing operation; if you need to open the post of feeding, the operator must be in the tank mouth of the side of the back of the operation, not directly facing the mouth of the tank, in order to prevent the material hurt people; prohibit the direct kettle without liquid material into the conditions of the particles of solid material, in order to prevent hard objects touching the anticorrosion layer.

1.2.2, the reaction kettle in operation should strictly implement the process operating procedures, is strictly prohibited over-temperature, over-pressure, overloading operation; where there is over-temperature, over-pressure, overloading and other abnormalities, and immediately according to the provisions of the process to take appropriate measures. Prohibit the reaction kettle to exceed the specified liquid level reaction;

1.2.3 Add (input) materials strictly according to the material proportion stipulated in the process, and control the speed of adding and warming in a balanced way, so as to prevent equipment accidents caused by incorrect proportion or adding (input) materials too fast, which will lead to violent reaction in the kettle, and abnormal situations such as over-temperature, over-pressure, and over-loading.

1.2.4 When the equipment is warming up or cooling down, it must be carried out slowly to avoid the sudden superposition of thermal stress and pressure, resulting in localised exceeding the adhesion strength that the porcelain layer can withstand and resulting in broken porcelain leading to equipment damage.

1.2.5 Strictly implement the shift management system, truthfully fill in the equipment operation records, the operation and integrity of the equipment included in the contents of the shift, in order to prevent the emergence of abnormalities and equipment accidents due to unclear shift handover.

1.3 Requirements when stopping:

1.3.1 according to the process operating procedures to deal with the kettle material to stop the stirrer, according to the requirements of the production process to reduce pressure, temperature, discharge, clean up the kettle residue, blowing kettle wall dirt, check the equipment intactness; open the jacket sewage valves, will be jacket water discharge, in order to prevent in the next cycle cycle through the steam when the production of water hammer and damage to the equipment, according to the process operating procedures, to confirm that qualified to prepare for the next cycle of the operation.

2, daily inspection and maintenance:

2.1, ear reducer and motor sound is normal, hand touch perception reducer, motor, seat bearings and other parts of the driving temperature: general temperature ≤ 40 ℃, temperature ≤ 60 ℃ (the back of the hand on the can stay for more than 8 seconds for normal).

2.2 Check whether there is any oil leakage in the reducer, whether the shaft seal is intact, whether the oil pump is oiled, whether the oil level and oil quality change in the reducer box, whether there is any lack of oil in the oil box of the kettle seal, and make up or update the corresponding lubricating oil if necessary;

2.3 Check whether the explosion-proof membrane, pressure gauge, thermometer and other devices are accurate and sensitive, whether the pressure gauge has been calibrated and sealed intact, whether the red line of the pressure gauge is drawn correctly and whether the explosion-proof membrane is leaking internally;

2.4, always listen to the reaction kettle for abnormal vibration and rattling;

2.5, keep the stirring shaft clean and see the light, to the round nut connection of the shaft, check the direction of rotation of the stirring shaft is rotating in the clockwise direction, it is strictly prohibited to reverse;

2.6 Regularly check the condition of stirring, serpentine tube and other kettle accessories, and tighten the loose bolts, and replace the relevant parts when necessary;

2.7 Check whether all import and export valves of reaction kettle are intact, if there is any problem, it must be dealt with in time;

2.8 Check whether the flange and seat of kettle have loose bolts, and whether the shroud of transmission parts is intact and reliable;

2.9 Check whether the effective surface of enamel of reaction kettle loses light, cracks, bursts porcelain, perforation, whether the iron base of kettle body has corrosion, pockmarks, and whether the sealing surface of each interface has leakage. Insulation, paint and so on is complete, there is no shedding, burnt situation;

2.10, do a good job of equipment health, to ensure that no oil, equipment to see the original colour;

2.11, in the maintenance must be disconnected from the power, and hang the power failure sign;

2.12, into the reactor maintenance, must be strictly enforced into the restricted space operation standards

3, enamelled tank precautions

3.1 The inner and outer surfaces of the tank are not allowed to knock, collision, in order to prevent the glass enamel from falling off;

3.2 Do not allow the use of electric and gas welding in the tank and glass-lined walls. In the outer jacket for welding and cutting, must be filled with water inside the tank before (in principle, glass-lined pressure vessels are not allowed to modify private);

3.3 The filling coefficient of the reactor is subject to the drawing.

3.4 When placed in the open mouth, prevent hard objects from falling in to avoid damage to the glass-lined;

3.5 When the tank card is loose or fall off, it should be tightened in time;

3.6 When the outdoor temperature is below 0℃, the water must be drained;

3.7. reaction kettle body temperature of 110 ℃ need to cool, the jacket should first open cooling water, to be cooled to 50 ℃ below the contents of the jacket can be changed to ice brine, not directly with ice brine cooling, so as to avoid the temperature difference is too large, caused by the glass lining cracking.

4、Operating procedure of heating up and cooling down unit

4.1 Procedure of heating up

4.1.1 Check whether the valves of the reaction kettle are in the correct state, and confirm that the reaction kettle forms a closed system;

4.1.2 Open the reactor jacket pouring valve, drain the condensate in the jacket (in order to prevent water hammer phenomenon when warming up); close the pouring valve and open the jacket trap.

4.1.3 Open the primary and secondary doors of the steam valve group, and contact DCS to open the steam valve slowly;

4.1.4 The opening degree of steam valve is 20% at the beginning, first give the jacket preheating, and then gradually increase the opening degree according to the requirements of reaction temperature. Reactor jacket pressure can not exceed the working pressure marked on the equipment drawings;

4.1.5 After reaching the specified temperature, enter the heat preservation stage. Observe the pressure and temperature in the jacket and kettle at regular intervals and make records; check whether there is any leakage point of steam;

4.1.6 After use, contact DCS to close the steam regulating valve, and the reactor can be cooled down slowly; if it is necessary to speed up the cooling speed, after exhausting the residual gas, then open the inverted shower valve, and cool down to the required temperature according to the cooling procedure;

4.2 Cooling down procedure

4.2.1 Check the steam valve, inverted shower valve and trap closed, open the return valve; slowly open the water inlet valve to control the reactor jacket pressure shall not be greater than the working pressure marked on the equipment drawings;

4.2.2 jacket medium temperature and the kettle medium temperature difference shall not exceed 90 degrees, to avoid cold shock damage to the kettle

4.2.3 After the completion of cooling, the first closed water inlet valve, and then close the return valve; infrequent use of the equipment must be jacketed water discharge, brine pressure back to the brine pool, to avoid corrosion of the jacket;

4.2.4 The temperature that can be reached by using circulating water is 10℃ (winter), and the temperature that can be reached by using brine is -19℃;

5, glass lining equipment installation precautions

5.1 before unloading and lifting should carefully check the glass-lined surface for damage; into the tank must wear rubber-soled shoes, so as not to damage the porcelain surface; lifting with rubber sheet pads and other soft cushions to protect the porcelain surface, do not touch or collide with the porcelain surface; handling of unpackaged equipment can only be used to make the equipment tank lugs, bearings force, do not allow the receiver, clamps and other fragile force, should not be rolled or prying pry bar.    

5.2 tighten the card, according to the symmetry of tightening in turn, the force can not be uniformly tightened at once, so as not to seal poorly, in order to obtain a good seal, should be slowly passed into the equipment into the steam, to be the pressure up to 0.1Mpa, and then tighten the valve, to wait for the pad to become soft and then open the valve to remove the pressure, and then tighten the card.

5.3 it is forbidden to apply welding directly on the outer wall of glass-lined equipment.

5.4 Where the glass lining parts of the seal, should be based on the reaction medium, temperature, select the gasket material (factory products are configured according to the general conditions of the gasket).

5.5 When installing the stirrer, the radial runout at the shaft seal is adjusted to a small gap to ensure the sealing, and the stirrer can not be reversed to avoid the stirrer falling and smashing the enamel surface.

5.6 Glass enamelled equipment should not be used in the following media reaction and storage, otherwise it will be damaged faster due to corrosion.

5.6.1 Hydrofluoric acid of any concentration and temperature;

5.6.2 Alkaline media with PH ≥ 12 and temperature ≥ 100 °C;

5.6.3 Phosphoric acid in concentrations of 30% or more and at temperatures ≥180°C;

5.6.4 The reaction of alternating acid and alkali;

5.6.5 Other media containing fluoride ions.

5.7 The use process should be slowly warming and cooling, because the sudden heat and cooling of the stress generated by the glass-lined equipment will affect the service life and damage to the porcelain surface.

5.8 Pay attention to the sealing condition of each flange connection in the process of use, if leakage is found, measures should be taken, such as in the case of acid, quick use of lye neutralisation and water washing.

5.9 When entering the equipment for installation or maintenance, the bottom of the tank should be laid on a soft cushion, so as not to fall into the tools, and must wear rubber-soled shoes, so as not to damage the glass surface. In case of clogging of the outlet, metal tools shall not be used for shovelling and beating, and wooden sticks or other soft objects may be used for unblocking.

5.10 the use of the process should be regularly checked, such as the release of materials found within the glass enamel debris, should be immediately checked, found that there are burst parts should be dealt with in a timely manner.

5.11 Precautions for storage of equipment

5.11.1 In the case of conditions, equipment indoor storage.

5.11.2 equipment in outdoor storage, should pay attention to cover, to avoid people knocking objects, sun and rain.

5.11.3 When stored in winter, special attention should be paid to check whether water accumulates in the tank and thermometer casing to avoid damage due to freezing.

5.11.4 For the reaction tank or polymerisation kettle assembled with mechanical seals, protect the sealing parts and keep them clean.