Stainless Steel Reactor Maintenance & Repair Guide

Core Maintenance Principles

Routine Operational Protocols

1. Process Safety Steps:
   • Before Operation:
     ▪ Close cold medium inlet valves.
     ▪ Drain residual cold medium from the reactor and 夹套 (jacket).
   • During Operation:
     ▪ Start agitator before heating (steam/electric).
     ▪ Maintain steam pressure below rated working pressure.
   • After Operation:
     ▪ Rinse immediately with warm water to remove sticky materials.
     ▪ Perform 40–50℃ alkaline water cleaning, followed by fresh water flushing.
2. Critical Warning:
   ▪ Never heat an empty reactor (risk of thermal stress and surface damage).

System-Wide Maintenance Schedule

Surface Damage Repair Solutions

1. Common Damage Types:

• Cracks/Chips: Caused by mechanical impact or thermal shock.
• Corrosion Pits: Result from prolonged exposure to aggressive media.
• Coating Failure: Occurs in lined reactors due to chemical degradation.

2. Polymer Composite Repair Process:

1. Surface Preparation:
   • Sandblast damaged area to remove rust and contaminants (Ra 2.5–5μm roughness).
   • Clean with anhydrous alcohol to eliminate oil residues.
2. Repair Application:
   • Base Layer: Apply polymer composite primer, ensuring full coverage.
   • Top Layer: Apply filler mixed with stainless steel powder for strength.
   • Curing: Allow 24 hours at room temperature (or accelerated curing per manufacturer specs).
3. Post-Repair Checks:
   • Visual inspection for uniform finish.
   • Leak test (pressure decay method) for critical applications.

Advanced Maintenance Tips

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

Emergency Shutdown Protocols

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