Comprehensive Guide to Stainless Steel Reactor Maintenance & Repair

Operational Guidelines

1. Safety Protocols:
   • Before Use: Close cold medium inlet valves, drain residual coolant from the reactor and jacket.
   • During Operation: Start the agitator before heating (steam/electric); never exceed rated steam pressure.
   • After Use: Rinse with warm water immediately, then clean with 40–50℃ alkaline water, followed by fresh water.
2. Critical Warning:
   ▪ Do not heat an empty reactor to avoid thermal stress or surface damage.

Routine Maintenance Schedule

Interior Damage Repair

1. Common Damage Causes:

• Mechanical impact, thermal shock, or chemical corrosion leading to:
  ▪ Cracks, chips, or pits in the stainless steel surface.
  ▪ Enamel damage in lined reactors (cracks, bubbles, pores).

2. Polymer Composite Repair Process:

1. Surface Preparation:
   • Sandblast to remove rust (achieve Ra 2.5–5μm roughness).
   • Clean with anhydrous alcohol to eliminate contaminants.
2. Repair Application:
   • Apply base layer of polymer composite primer.
   • Apply top layer mixed with stainless steel/ceramic powder for strength.
   • Cure for 24 hours at room temperature (or as per manufacturer specs).
3. Post-Repair Checks:
   • Visual inspection for uniform finish.
   • Pressure decay test for leak detection in critical applications.

Advanced Maintenance Tips

• Corrosion Prevention:
  ▪ Use citric acid solution for passivation after repairs.
  ▪ Apply protective coatings to high-wear areas (e.g., agitator shafts).
• Thermal Management:
  ▪ Control heating/cooling rates (max 5℃/min) to avoid thermal stress.

Emergency Shutdown Steps

• Unusual noise/vibration: Stop agitator, inspect bearings.
• Leakage: Isolate reactor, depressurize, check seals/gaskets.
• Overheating: Cut heating source, activate emergency cooling, ventilate.