As a core equipment in the fields of chemistry, materials, etc., the daily maintenance and troubleshooting of laboratory reactors are directly related to experimental safety and data reliability. The following will explain from two aspects: maintenance points and fault handling:
1、 Core points of daily maintenance
Check before use
Confirm that the blasting vent is connected to the outside to avoid pressure accumulation and potential hazards.
Check the calibration marks of pressure gauges, thermometers, safety valves, and other instruments to ensure accurate data. For example, the pressure gauge should be used with a pressure within 1/2 of its nominal value and regularly compared and calibrated with a standard pressure gauge.
Manually rotate the mixing shaft to confirm that there is no jamming or abnormal noise, in order to avoid mechanical failure causing uncontrolled reaction.
Operating Specifications
Strictly follow the rated pressure and temperature indicated on the kettle nameplate, and it is strictly prohibited to operate beyond the limit. For example, glass lined reaction vessels need to control the temperature difference between cold and hot shocks (cold shock<110 ℃, hot shock<120 ℃) to prevent cracking of the ceramic surface.
When feeding, first add solid material, then slowly inject liquid, and start stirring to promote uniform mixing, avoiding local overheating or violent reactions.
After the reaction is complete, cool down to a safe range before venting to prevent the kettle from deforming due to sudden pressure changes.
Cleaning and anti-corrosion
Clean the kettle body after each use to avoid residue corroding the inner wall or affecting the next experiment. For example, media containing chloride ions and fluoride ions require special customized kettle body materials.
The metal kettle body should be regularly coated with anti-corrosion paint, and the enamel kettle should be checked for bulging or micro holes on the porcelain surface, and repaired or replaced in a timely manner.
2、 Common faults and troubleshooting methods
Sealing leakage
Phenomenon: Leakage at the sealing surface or valve.
Reason: Loose screw, damaged sealing surface, aging packing.
Solution: Tighten the screw and re polish the sealing surface; Mechanical seals need to be checked for deformation of the dynamic and static ring end faces or whether the selection of sealing ring materials is reasonable.
Temperature/pressure out of control
Phenomenon: Temperature overshoot or abnormal pressure.
Reason: Temperature control system malfunction, instrument failure, intake valve sticking.
Handling: Check the connection between the thermocouple and the controller, calibrate the instrument; Clean the blockage of the intake valve and repair the heat transfer efficiency of the mixer.
Mixing failure
Phenomenon: The mixing shaft does not rotate or makes abnormal noises.
Reason: Bearing wear, motor reversal, demagnetization of internal magnetic steel (magnetic coupling transmission).
Solution: Replace bearings or internal magnetic steel; Confirm that the motor direction is clockwise and reverse rotation is strictly prohibited.
Damaged kettle body
Phenomenon: Cracks, corrosion perforation.
Reason: Corrosion of the medium, thermal stress cracks, and uniform wear.
Treatment: Local welding repair or re lining with corrosion-resistant materials; If the thickness is lower than the design lower limit, the kettle body needs to be replaced.
3、 Suggested maintenance cycle
Daily: Check instrument readings, sealing, and mixing flexibility.
Weekly: Clean the kettle body, lubricate mechanical components such as mixing shaft bearings and valve stems.
Monthly: Calibrate pressure gauges and thermometers, and detect the popping pressure of safety valves.
Every year: Conduct a comprehensive inspection of the thickness of the kettle body, the performance of the magnetic coupling, and replace aging seals.
By standardizing operations and regular maintenance, the service life of the reactor can be significantly extended, the failure rate can be reduced, and the safety and accuracy of experimental data can be guaranteed.