Hydrogenation high-pressure reactorUsing hydrogen as the reaction medium, hydrogen has the characteristics of flammability and explosiveness (explosion limit 4.0% -75.6%), strong diffusion, and the equipment operates under high-pressure conditions. This guideline must be strictly followed, and operators must undergo special explosion-proof safety training and pass the assessment before taking up their posts.
1、 Hydrogen pretreatment and system explosion-proof adaptation
Hydrogen purity and impurity control: Industrial hydrogen with a purity of ≥ 99.99% is used, and the pre filter needs to be replaced regularly (every 300 hours) to remove impurities such as moisture and sulfides, and to avoid the reaction of impurities with the kettle material to produce flammable and explosive by-products; Hydrogen storage tanks should be kept away from open flames and heat sources, with a distance of ≥ 5m from equipment, and equipped with anti-static grounding (grounding resistance ≤ 10 Ω).
Explosion proof system inspection: The equipment must be equipped with intrinsic safety explosion-proof components, including explosion-proof motors, explosion-proof pressure gauges (with a range of 1.5-2 times the working pressure), and explosion-proof solenoid valves; Before starting up, check the hydrogen pipeline, valves, and sealing surface of the kettle body with soapy water to ensure no leakage (leakage rate ≤ 0.005MPa/h); The ventilation system needs to be turned on for 30 minutes to ensure that the hydrogen concentration in the operating area is ≤ 0.4% (lower explosive limit 1/10).
2、 Safety regulations for the entire process of hydrogen operation
Hydrogen charging operation: First, turn on the nitrogen to replace the air inside the kettle (replace 3 times, each time with a nitrogen pressure of 0.2MPa, maintain the pressure for 5 minutes), and then charge hydrogen after detecting that the oxygen content is ≤ 0.5%; Slowly open the valve during hydrogen charging, control the pressure rise rate to ≤ 0.1MPa/min, and avoid static electricity caused by too fast flow rate; After charging to the working pressure, close the hydrogen valve and maintain the pressure for 10 minutes to confirm no leakage.
Reaction process monitoring: Real time monitoring of the pressure (fluctuation range ≤± 0.05MPa), temperature (deviation from the set value ≤± 2 ℃), and hydrogen flow rate inside the reactor. Overpressure (working pressure ≤ 80% of rated pressure) and over temperature operation are strictly prohibited; The use of non explosion proof tools, mobile phones, and other electronic devices is prohibited in the operation area. Personnel should wear anti-static work clothes and insulated shoes, and it is forbidden to wear synthetic jewelry.
Hydrogen exhaust operation: After the reaction is complete, first cool down to below 50 ℃, then slowly open the exhaust valve and control the pressure reduction rate to ≤ 0.1MPa/min. When the hydrogen exhaust reaches 0.1MPa, switch to nitrogen replacement (replacement 3 times) to ensure that the hydrogen concentration in the kettle is ≤ 0.4% before opening the kettle cover.
3、 Explosion proof emergency response and daily maintenance
Leakage emergency: Upon discovering a hydrogen leak, immediately initiate emergency procedures, close the hydrogen main valve, turn on the explosion-proof exhaust fan, and evacuate personnel to the upwind direction; If the leakage is large, dilute with nitrogen and strictly prohibit turning on or off any electrical equipment. When calling 119, it indicates "hydrogen leakage".
Fire emergency: In case of a fire, immediately turn off the hydrogen source and use dry powder fire extinguishers or carbon dioxide fire extinguishers to extinguish the fire. It is strictly prohibited to spray water directly onto the kettle body; If the kettle body is overpressure, open the safety valve to release the pressure and evacuate personnel to a safe area.
Regular maintenance: Check the sealing of explosion-proof components weekly, calibrate pressure gauges and safety valves monthly, conduct pressure tests on hydrogen pipelines quarterly (test pressure is 1.25 times the working pressure), and archive all maintenance records for at least one year.