1.Purpose
Ensure the safe, reliable and stable use and operation of the enamel reactor.
2.Scope
It mainly refers to the enamel reactor used in production. R&D enamel reactor and other material reactors, as well as other types of enamel jars, enamel kettles, etc.
3.References
GB 25025-2010 Technical Specifications for Glass-Lined Equipment and its updated and alternative versions.
4.Terminology
4.1. Enamel reactor: a kind of glass-lined steel with glass-lined stirring paddle, which is used as a vessel for various chemical synthesis reactions such as material synthesis;
4.2. Glass-lined: a glass material with special properties of smooth and dense lamination at high temperature on a metal matrix;
4.3. Mechanical failure: the failure behavior of damaging the kettle wall, stirring slurry, temperature sleeve, and glass-lined layer of various sealing surfaces due to mechanical impact, collision, crushing, vibration, wear, bending, and shaking;
4.4. Thermal failure: the failure behavior of the glass-lined layer damaged due to the rapid temperature change process of strong absorption, exothermic (reaction) process, local overheating and subcooling, such as rapid temperature rise and drop, local runaway reaction, welding slag burn, external direct welding, etc.;
4.5. Chemical failure: the failure behavior of the glass-lined layer damaged due to water corrosion, hydrogen acid and fluorine-containing medium corrosion, and hot phosphoric acid hot alkali corrosion;
4.6. Water corrosion: due to the long-term flow of pure water such as cold water and softened water, which stays on the wall for a long time, or is accompanied by heating and high temperature, etc., the corrosion behavior of the glass-lined surface is tarnished and frosted.
5.Responsibilities
5.1. The enamel reactor is a crackable, breakable and fragile device, and the production department, the department or individual who uses the enamel reactor has the responsibility to use it carefully in accordance with this specification and relevant standards and use requirements to ensure the safe, reliable, stable and durable operation of the enamel reaction;
5.2. The departments and personnel who use the enamel reactor in the production have the responsibility to record the problems and problems found in the use process.
Summarize and propose suggestions for modification of this specification to update;
6.Use is prohibited
Enamel reactors are forbidden to be used under the following conditions:
1) Hydrofluoric acid and fluoride-containing media or materials of any concentration and temperature;
2) Alkaline medium or material with pH greater than 12 and temperature higher than 80;
3) Phosphoric acid solution with a concentration of more than 30% and a temperature greater than 180 and equivalent medium;
4) The process of repeated back-and-forth filling and reaction of acidic and alkaline materials, especially the repeated alternate back-and-forth filling and reaction process of concentrated and strong acidic and alkaline materials;
5) Hard blocks, materials with sharp corners, and other materials that can cause damage to the glass-lined layer;
6) It is strictly forbidden to weld directly on the outer wall of the enamel reactor.
7. Precautions for use
1) Working pressure, normal pressure; Operating temperature, 0-200. If you need to expand, you should consult the equipment supplier in advance;
2) Try to avoid rapid alternating impact of cold and hot to prevent the glass-lined layer from falling off due to rapid thermal expansion and contraction;
3) Large materials should be crushed before joining, so as to avoid oversized and heavy materials directly hitting the wall and bottom of the kettle. When it is really necessary to add dry materials directly, the inner extension pipe with deceleration effect should be used to stick to the bottom of the kettle and add it slowly, especially in the early stage of material addition
4) Always pay attention to the firmness of the temperature sleeve (including molybdenum nails), stirring paddle installation and connection, so as to prevent loosening and jumping to the bottom of the kettle and smashing the glass-lined layer; or due to the excessive shaking amplitude of the stirring paddle, it collides with the kettle wall and squeezes the installation connection surface of the stirring paddle, resulting in damage and failure of the glass-lined layer;
5) Always pay attention to the sealing status of the sealing surface (pad) and sealing liquid (grease), and ensure that the sealing surface and sealing liquid (grease) are clean and free of particles and leakage during installation and use;
6) When adding alkaline materials, the inner extension pipe should be used to avoid the alkali solution directly acting on the outer surface of the kettle wall, stirring paddle and temperature casing;
7) It is not allowed to reverse the stirring paddle;
8) In principle, it is not allowed to use manhole feeding, if it must be used, it is necessary to consult the equipment supplier in advance;
9) Set up a permanent and clearly visible emergency information in the equipment or surrounding visible parts (in advance that it does not affect the operation of the equipment), including: the contact information of the equipment supplier, the company's EHS supervisor or the person in charge of the equipment and effective backup***
10) A clear start-up and shutdown should be established, including an emergency start-up and shutdown system or work instructions;
11) Before the reactor operator takes up his post, he must do on-the-job training. The training content includes the operation specification, the reactor instruction manual, etc., and the assessment is passed; and regularly conduct on-the-job practice ability inspections;
12) If the discharge port is blocked, do not use metal tools to shovel, and use wooden sticks or other soft tools;
13) When entering the equipment for installation or maintenance, a soft pad should be laid on the bottom of the kettle to avoid damage caused by the fall of tools and screws. Wear soft-soled shoes such as rubber soles to avoid wear and tear on the bottom of the kettle;
14) It is not allowed to enter the reactor alone without the company and care of others;
15) The work instructions for the use of the reactor should be formulated, and the training should be carried out according to the work instructions before taking up the post.
8. Daily maintenance, maintenance and repair
1) The production and use department or the competent department of equipment shall establish a daily maintenance and maintenance system based on this operation specification and product manual according to the actual use, and strictly implement it;
2) The discharge hole should be equipped with an upper unfolding valve to minimize the material residue;
3) Regularly check the use status of the temperature sleeve and calibrate the error of temperature measurement regularly;
4) Regularly inspect the sugar glass lining, transmission parts, and sealing surfaces (pieces), and if there is any abnormality, it should be dealt with in time or contact the equipment supplier for processing, without delay;
5) Regularly replace the lubricating fluid (grease) in the transmission device and mechanical seal cavity to ensure normal lubrication;
6) Non-metallic appliances such as bamboo, wood, and plastic should be used to clean up the adhesion on the glass-lined surface, and metal appliances should be prohibited;
7) Weakly acidic water (such as dilute sulfuric acid in demineralized water, etc.) should be used for equipment cleaning, especially the cleaning of the dead angle of the stirring paddle, temperature casing, sealing surface interface, feeding hole, discharge hole and observation hole;
8) After cleaning the scale in the jacket, it should be rinsed repeatedly in time to cause the outlet cleaning water to be neutral;
9) In case of damage to the glass-lined layer, it is necessary to contact the equipment supplier or professional repair personnel for maintenance in time, and the applicability assessment should be carried out before use after maintenance;
10) Before long-term shutdown, the reactor and connected pipelines should be purged and dried;
9. Equipment use registration
1) The use of equipment should be registered, especially the time of (emergency) start-up, feeding, discharging, delivery, abnormal state and users; cleaning, maintenance, repair, personnel access, etc.;
2) On-site use and management personnel should apply efficient use registration methods according to the actual use system;
10. Miscellaneous
For matters not covered herein, refer to the relevant standards and systems, as well as the provisions of the equipment use instructions;
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