Installation and Operation of Magnetic Stirring Reactors

Principles of Operation

Step-by-Step Installation Guide

1. Transport & Positioning:
   • Avoid impact to the magnetic stirrer on the reactor cover during handling.
   • Ensure the installation site is level and vibration-free.
2. Environmental Requirements:
   • Operate in a well-ventilated area compliant with explosion-proof standards.
   • Maintain ambient temperature between 10–30°C for optimal performance.
3. Seal Selection:
   • Choose gaskets matching the reaction medium, design pressure (e.g., 1–10 bar), and temperature (-20–200°C).
   • Common materials: PTFE for corrosive media, metal spiral wound gaskets for high pressure.
4. Reducer Lubrication:
   • Fill the reducer oil tank with No.13 compressor oil or No.11 cylinder oil.
   • Maintain oil level at the marked line; replace oil every 6 months or 1,000 operating hours.
5. Cooling System Setup:
   • Connect the magnetic stirrer's cooling jacket to a separate water source (inlet at the bottom, outlet at the top).
   • Ensure cooling water does not flow through the reactor's internal cooling coil into the stirrer jacket.
   • Maintain water pressure at 0.1–0.3 MPa and temperature ≤25°C.
6. Electrical System Placement:
   • Locate the control cabinet and variable frequency drive in a dry, ventilated electrical room.
   • Ensure grounding resistance <4Ω for safety.
7. Valve Operation:
   • Close valves gently to prevent damage to sealing surfaces.
   • Use needle valves for precise flow control; avoid sudden opening/closing of ball valves.

Operational Best Practices

1. Pre-Startup Checks:
   • Verify gasket tightness and stirrer rotation (manually turn the shaft to check for obstructions).
   • Confirm cooling water flow and electrical connections.
2. Startup Sequence:
   • Activate the cooling system first, then power on the reactor.
   • Gradually increase stirring speed (start at 50 RPM, then adjust to target speed ≤1,500 RPM).
   • For heating, set temperature in 10°C increments to avoid thermal shock.
3. Running Monitoring:
   • Track pressure (should not exceed design pressure), temperature (±2°C accuracy), and stirrer noise.
   • Record operational data every 30 minutes for traceability.
4. Shutdown Procedures:
   • Stop heating and allow the reactor to cool to ≤50°C before reducing stirring speed to zero.
   • Turn off the cooling system last to prevent condensation.

Maintenance Tips

• Bearing & Bush Replacement:
  Replace immediately if unusual friction or vibration occurs (indicative of excessive wear clearance).
• Periodic Inspections:
  • Monthly: Check gasket condition and lubricant quality.
  • Quarterly: Calibrate temperature/pressure sensors.
  • Annually: Perform pressure testing (1.25x design pressure for 30 minutes).