Instructions for Use of Magnetic Driven Stirring Reactor

1End face magnetic drive stirring reactorCharacteristics and Applications:

A stirred reaction device for gas-liquid, liquid-liquid, and two-phase chemical reactions in a reactor system, which can fully stir various chemical materials at high pressure and temperature to enhance mass and heat transfer processes.

The main feature of this device is the use of a static sealing structure, and a magnetic coupling is used to connect the agitator and motor drive. Due to its non-contact torque transmission, static sealing replaces dynamic sealing, which can solve the leakage problem that previous mechanical seals and packing seals could not solve. The entire mixing component of the medium can work in a sealed state. Therefore, it is more suitable for reactions of various flammable, explosive, highly toxic, valuable media and other permeable chemical media. It is a leak free reaction equipment for sulfurization, fluorination, hydrogenation, oxidation and other reactions in petroleum, chemical, organic synthesis, food and other processes.

According to the corrosion performance of the material, various grades of stainless steel, titanium, nickel, zirconium, tantalum, PTFE lining, and other metal materials can be selected for the contact material of the reactor body to prevent corrosion of the main body by the reaction material.

2、 Main technical parameters:

1. Main technical parameters:

indicator project	Nominal volume L
	0.1~0.5	1	2	3
Work pressure Mpa	≤35.0Mpa
Operating Temperature℃	≤450℃
Heating method	Electricity, steam, thermal oil, far-infrared, water circulation, etc
Heating power KW	1	1.5	1.5	2
Mixing speed r/min	Adjustable from 20 to 1500r/min
Motor power w	80
Main material selection	Various grades of stainless steel such as 321, 304, 316L, titanium, nickel, zirconium, tantalum, Hastelloy, etc
control instrument	Equipped with PID automatic temperature regulator, it has speed display and stepless speed regulation function. The heating voltage can be adjusted to achieve automatic constant temperature. It is also equipped with heating voltmeter, motor ammeter, and working time display.
The working environment of the controller	Environmental temperature 0~50℃, relative humidity of 30~85%, the surrounding medium does not contain conductive dust, Egyptian corrosive gas

Note:0.1~0.25L without internal cooling coil, 0.1~0.5L without solid feeding port. The operating pressure of a conventional kettle is 9.8Mpa, the stirring speed is adjustable from 20 to 1500r/min, and the working temperature is 300 ° C℃The main contact material is 1Gr18Ni9Ti stainless steel; Conventional kettle lid openings: gas phase port with needle valve, liquid phase port with needle valve and bottom tube inserted into the kettle, solid feeding port with screw plug, temperature measurement and control port with platinum resistor, pressure gauge with safety explosion port with pressure gauge and safety explosion-proof device, inlet and outlet water nozzles for cooling coil in the kettle; If the user has special requirements for the kettle cover, kettle body opening, internal structure, pressure level, stirring blade, and other auxiliary devices (such as condensation reflux device, constant pressure feeding tank, receiving device, condenser, etc.), they can be processed and manufactured according to the user's requirements; For reaction vessels with special requirements from users, the technical specifications shall be based on the label of the purchased equipment. If there are special supporting requirements, they shall be in accordance with the contract agreement.

3、 Structure Introduction and Working Principle:

1. It mainly consists of the kettle body, kettle cover, magnetic driven stirrer, heater, valve, solid feeding port, internal cooling coil, safety blasting device, pressure gauge, control instrument, and lifting device.

(1) The kettle body and kettle cover are made of stainless steel or other metal materials, and the kettle body and flange are connected by threads or directly welded. The kettle cover is a single flat or convex cover, and the sealing between the kettle body and the kettle cover is achieved by gaskets or the sealing of the cone surface of the kettle body and the spherical line of the kettle cover. The two are sealed by tightening the nut with the main bolts evenly distributed in the circumferential direction of the flange, and the sealing is reliable and leak free.

（2）、Magnetic StirrerIt is driven by a servo motor to rotate the outer magnetic steel body, which drives the inner magnetic steel body, stirring shaft, and stirring blade to rotate through magnetic lines, thus achieving the purpose of stirring. In order to ensure the normal operation of the magnetic stirrer, it is equipped with a cooling water jacket. When the operating temperature exceeds 100 degrees, cooling water needs to be introduced between the cooling water jackets to reduce the temperature and ensure that the magnetic material of the magnetic stirrer does not demagnetize.

(3) Heater: The exterior of the kettle is equipped with a barrel shaped silicon carbide furnace core, and heating resistance wires are connected in series, which has the characteristics of uniform thermal conductivity and fast heating speed. The outgoing line is connected to the control instrument through a terminal block and cable. Alternatively, to heat the heat transfer oil of the electric heating tube, a jacket is welded to the flange outside the kettle, and the heat transfer oil of the electric heating tube is inserted into the jacket to achieve heating through the heating tube. Or use far-infrared heaters for direct heating, steam heating, water bath heating, etc.

(4) On the upper or side of the kettle cover, there are air inlet valves, sampling valves, temperature measurement and control devices, safety blasting devices, and cooling coils. External valves, pressure gauges, etc. are connected by circular arc and circular arc lines or directly connected through card sleeves. They are sealed by tightening positive and negative nuts or welded directly with pipe fittings; The valve is a needle valve or ball valve, matched according to user requirements; The sampling valve discharges the material inside the kettle through the bottom tube inserted into the kettle and the pressure inside the kettle; The cooling coil is directly connected to the kettle cover, and the water nozzle on the kettle cover is used to circulate water for cooling. The cooling coil is a serpentine or U-shaped tube.

(5) The safety blasting device is a pressure relief safety device composed of a blasting disc clamp or a safety valve assembly. When the pressure difference inside the blasting disc reaches a predetermined pressure value at a predetermined temperature, the blasting disc or safety valve can be activated to release the pressure medium.

(6) Use of solid feeding port: Use a wrench to unscrew the plug. After loading, rinse the port with reaction liquid first. After there are no metal particles, tighten the plug. Pay special attention to keeping the sealing line of the feeding port clean.

(7) The lifting device consists of a base, support rod, lifting square iron, screw, lifting handwheel and other components. When the work is completed, unscrew the nut between the kettle body and kettle cover, and rotate the handwheel to lift the lifting square iron and kettle cover through the screw; When working, turn the handwheel to lower the square iron and kettle cover through the screw, and then tighten the nut to start working. If it is a flange quick opening reaction kettle, please loosen the bolts on the upper part of the flange, open the flange, turn the handwheel to lift the lifting square iron and kettle cover through the screw, then pull out the fixed pin on the left, turn the flipping handle at the rear to flip the kettle body to the appropriate position, and pour out the materials in the kettle.

2. Conventional controller

The control instrument adopts a finished chassis shell, and all electrical components are assembled into the panel and bottom platform for easy maintenance and repair. The panel is equipped with a main power switch, a finished PID temperature control meter, and a mixing speed adjustment button; Equipped with motor ammeter, heating voltmeter, working time display meter, stirring speed display meter, etc. The back of the box is equipped with terminals and sockets for power supply, heating device, motor, temperature probe, speed measuring element, etc., as well as power supply fuse, heating fuse, motor fuse, etc.

3. Control principle:

(1) Automatic temperature control part of electric heating:

Platinum resistors or thermocouples are installed on the reaction vessel to generate different amounts of electricity using temperature differences, which are converted into electrical signals and transmitted to the temperature indicator regulator. The heating circuit uses a solid-state voltage regulator to adjust the voltage, and the size of the potentiometer is adjusted to change the heating output voltage to achieve stepless voltage regulation. If adjusted appropriately, it can meet the purpose of heating speed and constant temperature.

(2) Mixing speed control section:

The stirring drive motor is a DC servo motor, and its excitation coil voltage is supplied by diode full wave rectification, while the armature voltage is supplied by thyristor bridge rectification. The conduction angle of the thyristor rectifier element is adjusted based on the corresponding movement size of the trigger circuit output pulse to achieve the goal of stepless rotation stirring. An induction speed measuring component is installed on the upper part of the isolation sleeve. When the mixer rotates, the induction component generates an induced electromotive force, which corresponds to the mixing speed. The electric potential is transmitted to the tachometer, which displays the mixing speed of the mixer.

4、 Installation and use:

1autoclaveInstallation and use:

(1) Location of installation:high-pressure reactorIt should be installed in a high-voltage operating room that meets explosion-proof requirements and equipped with multiple unitsautoclaveWhen there is an explosive medium present, it should be placed separately and separated by a safe explosion-proof wall between every two units. Each operating room should have a passage and outlet leading to the outside, and good ventilation of the equipment should be ensured.

(2) After opening the packaging, check for any damage to the equipment. Install the equipment according to the structural diagram below based on the device model. If the heating method is thermal oil electric heating, please purchase the corresponding model of thermal oil according to the operating temperature (note: thermal oil is not allowed to contain moisture) and add it. When adding, open the oil filling port on the upper part of the jacket and the oil level port on the upper part of the jacket. Add oil through the oil filling port until the oil level port flows, and then tighten the oil level port. Do not tighten the oil filling port to avoid pressure. Check the equipped parts according to the packing list.

(3) Installation and sealing of kettle body and kettle cover: The kettle body and kettle cover are in line contact with the circular arc surface using gaskets or conical surfaces. They are tightly pressed against each other by tightening the main nut to achieve a good sealing effect. When tightening the nut, it must be diagonally symmetrical and gradually tightened with force, evenly applied. It is not allowed for the kettle cover to tilt to one side to achieve a good sealing effect. When tightening the main nut, it should not exceed the specified tightening torque of 40-120N. M Scope: To prevent the sealing surface from being crushed or worn out under overload, special care should be taken for the sealing surface. Before each installation, use a relatively soft paper or cloth to wipe the upper and lower sealing surfaces clean. Pay special attention not to touch scars on the sealing surface of the kettle body and lid. If operated reasonably, it can be used more than tens of thousands of times. After the sealing surface is damaged, it needs to be reprocessed and repaired to achieve good sealing performance. When disassembling the kettle lid, the lid should be slowly lifted up and down to prevent the sealing surfaces between the kettle body and lid from colliding with each other. If gasket sealing is used (PTFE, aluminum gasket, copper gasket, asbestos gasket, etc.), a good sealing effect can be achieved by tightening the main nut.

(4) The installation of valves, pressure gauges, and safety valves achieves a sealing effect by tightening the positive and negative nuts. The circular sealing surfaces at both ends of the connection must not rotate relative to each other. When assembling all screw connections, lubricant or graphite mixed with oil must be applied to prevent them from biting. The use of valves: Needle valves are line sealed, and good sealing performance can be achieved by gently rotating the valve needle and compressing the sealing surface. Excessive force is prohibited to avoid damaging the sealing surface.

(5) After the equipment is installed, introduce a certain amount of nitrogen and maintain pressure for 30 minutes to check for any leaks. If any leaks are found, use soap foam to locate the leakage points in the pipeline or pipe opening, release the gas and tighten it, then conduct a nitrogen pressure test again to ensure there are no leaks before starting normal operation.

(6) When heating up, the heating rate should not exceed 100%℃/h， The heating power should be slowly increased from low voltage. When cooling down, water can be used for internal cooling through the cooling coil. Rapid cooling is prohibited to prevent excessive temperature stress from causing cracks in the cooling coil and kettle body. When the temperature inside the kettle exceeds 100 degrees Celsius during workAt ℃,Magnetic StirrerThe water jacket between the kettle cover should be filled with cooling water to ensure that the water temperature is less than 35 ℃, in order to prevent demagnetization of the magnetic steel.

(7) Safety device: It adopts a positive arch type metal blasting disc made of stainless steel and manufactured according to the national standard GB567-89 "Technical Conditions for Arch Type Metal Blasting". It has been tested before leaving the factory and cannot be adjusted arbitrarily. If it has already exploded, it needs to be replaced again. The replacement period is determined by the using unit according to the actual situation of the unit. For those that exceed the calibrated bursting pressure of the bursting disc but have not exploded, they should be replaced. If they are frequently used, they should not exceed 80% of the lower limit pressure of the bursting disc. When replacing, attention should be paid to the convex surface of the bursting disc facing upwards.

(8) After the reaction is complete, first cool down and release the gas inside the kettle through the pipeline to reduce the pressure inside the kettle to atmospheric pressure. It is strictly prohibited to disassemble under pressure. Then, symmetrically loosen and remove the main bolts and nuts, and carefully remove the kettle cover (or lift the kettle cover) and place it on the bracket. During the disassembly process, special attention should be paid to protecting the sealing surface.

(9) Cleaning inside the kettle: After each operation, use cleaning solution (be careful not to corrode the main material when using cleaning solution) to remove the residue on the kettle body and sealing surface. It should be cleaned regularly and kept clean. Hard substances or rough surfaces are not allowed to be used for cleaning.

2. Installation and use of control instrument:

(1) After opening the packaging box, the controller should be visually inspected for any damage or rust caused by poor transportation and storage. The support legs should be opened to check if the controller is level, and the movement of the movable parts should be checked for flexibility.

(2) Connect the wires according to the wiring names on the back panel of the controller, and install grounding wires for each device.

(3) After each operation, adjust the stirring speed to zero to prevent the fuse from being burned out due to the motor being too large during the next startup.

(4) Heating operation of heater: Please operate according to the user manual of the configured finished temperature gauge.

(5) Speed regulation:When in use, simply press the up arrow on the controller and adjust the displayed number to achieve the desired speed; After setting the speed, the motor and magnetic stirrer start running,While stirring, the speed is measured by the induced magnetic field of the Hall element on the upper part of the kettle,The tachometer displays the actual speed up to the set speed.

(6) Maintenance and upkeep of control instruments: Before normal operation, it is necessary to carefully check for any abnormalities. During operation, the back door must not be opened to prevent electric shock hazards. The measuring instruments should be calibrated regularly to ensure accurate and reliable operation. The working environment of the equipment should meet safety technical requirements. Instruments that are not used for a long time or those that work in humid environments should have their overall insulation resistance measured irregularly, and the overall resistance value should not be less than 10 Μ Ω.

5、 Attention:

1. InReaction kettleWhen conducting reactions in different media, the first step is to investigate whether the media corrode the main material. Special orders are required for chemical reactions that cause rapid reactions, generate large amounts of gas, or are flammable and explosive at high temperatures, as well as reactions that cause severe corrosion to stainless steel due to ultra-high pressure, ultra-high temperature, or chloride ions, fluoride ions, etc. in the medium!

2. When loading the reaction medium, it should not exceed 2/3 of the liquid level of the kettle body!

3. It is strictly prohibited to disassemble under pressure during work or at the end!

4. CleaningautoclaveSpecial attention should be paid not to pour water or other liquids into the heating furnace to prevent the heating furnace wire from burning out. If heating the jacket heat transfer oil, be careful not to mix water or other liquids into it when adding heat transfer oil. The oil level of the heat transfer oil should be checked periodically!

5. If there is abnormal noise inside the isolation sleeve during operation, the machine should be stopped to release pressure and the mixing system should be checked for any abnormal conditions. Regularly check the swing amount of the mixing shaft. If the swing amount is too large, the bearing or sliding shaft sleeve should be replaced in a timely manner!

6. Connect the corresponding voltage according to the operating voltage of the controller, single-phase 220V, three-phase 380V. Do not connect the live and neutral wires of the controller in reverse; Wiring work should not be carried out during power transmission to prevent electric shock! To ensure the normal operation of the controller and the personal safety of the staff, it is necessary to connect the grounding wire! The controller itself is not explosion-proof, so it should avoid flammable and explosive environments such as oil and gas!

7. After the final reaction temperature is determined, it is not allowed to change the temperature setting value during the heating process to avoid significant temperature overshoot!

8. Under the premise of connecting the power supply, even if the heating and stirring switches are not turned on, the output terminals on the back panel of the controller are still live. It is not allowed to pull or touch any plugs during operation!

9. The working time display is based on the internal microcontroller 8031, which accumulates the internal frequency division for timing. Each power on/off will cause the internal accumulated data to disappear. During operation, it should be noted that the working time display is in minutes, and the maximum working time is 9999 minutes (166.5 hours)!

10. The correct detection position of the speed display is crucial for the stable display of the speed. This position has been adjusted at the factory and should not be adjusted arbitrarily!

11. Every time the machine is turned on, it is required that any button should be in its initial state. This requires the operator to develop good working habits and turn the knob back to the smallest position after each operation to prevent excessive current from causing significant damage to the controller during the next startup!

12. Regularly inspect various instruments and blasting relief devices to ensure their accurate and reliable operation. The working environment of the equipment should comply with safety technical specifications!

13. Connect the blasting vent to the outside through a pipeline during installation!

14. When the kettle is not in use for a long time, the inside and outside of the kettle should be cleaned and wiped clean without water or other materials, and stored in a clean, dry, and non corrosive place.

VIcontrol instrumentCommon faults and troubleshooting methods:

Preface number	Fault phenomenon	Possible reasons	exclusion method
1	The power switch was not turned on when the power was turned on, but the heating voltmeter indicated and was not adjustable.	1. Loose or poorly connected terminals. 2. The heating furnace wire is burnt out or there is poor contact at the porcelain joint. 3. The solid-state regulator inside the controller is damaged. 4. The heating fuse is damaged.	1. Tighten the terminal block. 2. Use a multimeter to measure for resistance on the terminal block (cut off power). 3. Replace the solid-state regulator by model. 4. Replace the fuse.
2	Turn on the power switch but there is no indication.	1. The main power fuse is damaged. 2. Poor internal contact of the power switch. 3. Incorrect power supply connection.	1. Replace the fuse. 2. Replace the rotary switch. 3. Measure the power supply voltage using a meter and make corrections.
3	No temperature display or negative values.	1. The thermocouple wiring is open and in contact with each other, but there is poor contact with the socket of the control instrument that can be plugged in. 2. The thermocouple is damaged and disconnected. 3. The thermometer is damaged.	1. Open the thermocouple connector, re weld the wire end or switch the wiring position, and re plug the thermocouple socket. 2. Replace the thermocouple. 3. Replace the temperature gauge.
4	Turn on the mixing adjustment potentiometer, but the motor does not turn.	1. The mixing fuse is damaged. 2. The thyristor is damaged. 3. The motor terminal is disconnected. 4. The potentiometer switch on the panel is damaged. 5. There are damaged components in the overall circuit board.	1. Replace the fuse. 2. Use a multimeter RX1 to measure the resistance between the cathode of the thyristor and the control electrode, with a forward resistance of 30-40 Ω and a reverse resistance of 60-80 Ω. Then use a circuit to determine whether the performance of the thyristor has deteriorated. If the light bulb lights up at a touch, disconnect the control electrode, and the light bulb illuminates to prove that the thyristor is not damaged. 3. Measure with a multimeter according to the circuit diagram, identify the fault and correct it. 4. Remove the potentiometer and slowly adjust it by touching the two feet of the potentiometer with a gauge to see if there is any disconnection. Otherwise, replace it. 5. Starting from the power supply voltage of the circuit, check whether the transformer has a voltage output of 55V and 20V, and sequentially check Q1Q2, BT33, A940, 10K potentiometer, pulse transformer, etc.
5	Turn on the mixing switch to burn the fuse or replace the fuse immediately.	1. The motor wiring is short circuited. 2. There is a diode burnt out in the thyristor terminal block. 3. Silicon controlled breakdown. 4. The excitation coil of the motor is short circuited.	1. Correct the wiring. 2. Measure the diode with a multimeter, and the forward resistance should be 15-20 Ω, and the reverse resistance should be infinite. 3. Measure the resistance between 3CTA and K using a 10K gauge, which should be infinite, otherwise it will be damaged. 4. Replace the electric motor Normal resistance: 123W (1.9K)） 185W(1.5K) 355W(1.5K)
6	The speed is running normally, but the stirring speed is not displayed.	1. Check for damage to the wires of the speed measuring plug and the Hall element. 2. The upper speed measuring sleeve of the magnetic stirrer has shifted. 3. Invert the position of the Hall element during your maintenance. 4. The internal speed measuring magnetic steel of the device has fallen off or demagnetized.	1. Measure with a multimeter to see if there is any poor contact or open soldering of the speed measuring wire. 2. Move the speed measuring sleeve slightly up, down, left, and right, and tighten it after the speed stabilizes. 3. Hall elements have NS poles, and this controller uses N poles for speed measurement. 4. The speed measuring magnetic steel body is sensitive to hydrogen gas. If it is broken by hydrogen gas, please contact the manufacturer.
7	The temperature cannot be controlled in automatic control mode.	1. The solid-state regulator is burnt out.	1. Replace the solid-state regulator with the original model