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Repair Technology of Stainless Steel Reactor after Breakage

Release time:

2020-03-02

Stainless steel reactor is an indispensable reaction equipment and storage container for chemical, petroleum, fuel, medicine, fertilizer, rubber, plastic, organic synthesis, food, scientific research and other industries. Its advantages are low cost, corrosion resistance (except hot phosphoric acid, strong alkali), good performance, smooth surface, strong wear resistance and hardness, and wide range of uses. It can be used in various chemical reactions of gaseous, liquid and solid in chemical production, such as evaporation, concentration, distillation, polymerization, chlorination, nitration, saponification, esterification and other technological processes. The disadvantage is that the installation and use should be cautious. Once the glass lining surface is damaged, it becomes an idle equipment that cannot be used, resulting in an increase in the cost of use. Stainless steel reaction kettle porcelain surface damage to stop using, timely repair, otherwise it will make small problems expand into a big problem, bad repair, even if it can be repaired, the repair quality and use cycle will be reduced. In the specific repair, according to different media, different process conditions, different parts of the selection of different repair materials and materials, choose the appropriate repair method.

(1) porcelain surface damage glue repair method. The choice of glue should be considered from the aspects of corrosion resistance, high temperature resistance, bonding firmness, expansion coefficient, etc. The following operation steps shall be strictly followed for glue repair:

① Clean the damaged surface. Before gluing, the damaged surface must be carefully cleaned, and the rust or residue on the damaged surface must be cleaned with an angle grinder, and then use a hand grinder (hand electric drill with a small grinding wheel head) or the iron brush on the angle grinder to make 5mm ~ 10mm wide hemp lines on the edge of the damaged surface, and scrub with ethanol cleaning agent.

② Hang the glue twice. Hang the glue on the damaged surface and fine hemp lines, and hang it evenly at one time, the thinner the better; After that, continue to apply evenly. The glue cannot be too thick. Otherwise, the glue will crack due to temperature rise during use and the repair will fail.

③ Heat and bake the glue hanging part indirectly with a heat source (direct heating is strictly prohibited). Keep the heat source and the glue hanging part above 300mm, or dry naturally for more than 24 hours to ensure the glue surface is solidified.

(2) Equipment perforation repair method. Cover the periphery of the perforated part with wet cloth or wet cotton yarn to prevent the surrounding enamel from being damaged by welding slag. The iron block with the same size and thickness as the perforation part shall be blocked and kept in the same plane, and the spot welding shall be started, and the temperature shall be cooled with water until the welding is completed. Then repair is carried out using method (1).

(3) tantalum nail fixation method. The advantage is that the corrosion resistance is strong, the repair is fast, and the repair is not afraid of bumping. The disadvantage is that it is only suitable for small area repair, not more than 500mm × 500mm. The commonly used tantalum nail is a whole formed by M8 standard tantalum screw and hexagonal plug wrapped with PTFE. There are generally two ways to use:

① Directly fixed with tantalum nails. It is suitable for the parts with less damage to the porcelain surface. Use a Φ6mm/Φ7mm drill bit to drill the center of the damage, tap with an M8 tap, clean the damaged surface and scrub with detergent (ethanol), hang the glue, and screw the tantalum screw on the plug directly into the drill hole until it is tightened.

② Select PTFE material for corrosion-resistant plate fixation, suitable for large damaged surface parts. The specific repair method is to select a 2mm ~ 3mm thick PTFE plate larger than the damaged area according to the damaged area. Use a Φ6mm/Φ7mm drill bit to determine the location and quantity of holes around the damaged area, use M8 tap to tap, then clean the damaged surface and scrub with cleaning agent (ethanol), and then hang the glue. In order to ensure the sealing of the periphery, the PTFE rope is pressed into the glue, the PTFE plate is tightened and then loosened with tantalum nails, the glue is hung under each nail cap, and the PTFE rope is wound and then screwed one by one until the glue is extruded around the repair.

(4) rivet fixing method. Mainly suitable for irregular round and diameter 55mm, not perforated stainless steel reactor. The specific operation steps are:

① Grind the damaged surface and clean it.

② Use Φ3mm drill bit to drill a hole depth of about 8mm at the damaged point.

③ Use the reaming grinding head to expand the inner wall of the hole out of the cross-sectional groove.

④ According to the actual depth of the drilling and the thickness of the tantalum plate, cut the Φ3mm tantalum strip into a section that is about 2mm ~ 3mm longer than the total length of the hole.

⑤ Cut the tantalum plate into a plate about Φ5mm larger than the damaged surface, determine the center position and drill holes.

⑥ Hang glue and PTFE soft tape evenly on the damaged surface (not thick), press the cut tantalum plate on it, insert tantalum strips into the holes, gently hit the tantalum plate with a special small hammer, and then hit the tantalum strips. As the tantalum strips are expanded and fixed in the holes, the exposed tantalum strips are piled up to fix the tantalum plates.

(5) clip repair method. Suitable for corrosion perforated unjacketed glass lined storage tanks. The specific operation steps are to hang glue on the polished and cleaned damaged surface in the tank, press directly on the damaged surface with 2mm ~ 3mm thick PTFE plate with drilled holes as sealing material, then pass tantalum screws through the corrosion holes, and tighten the outside with screws and pads at one time.

All the above repair methods must use repair glue, so the use of glue must refer to the "instructions for use". Repair good stainless steel reaction kettle, it is necessary to ensure that the glue can be used, otherwise even if it is used, the effective use time will not be too long, and even the damaged area will be further expanded. Using the repaired stainless steel reaction kettle, air replacement shall be carried out first when there is no material in the equipment, and special personnel shall be assigned to enter the equipment after passing the inspection by the oxygen detector. Some enterprises in order to increase production in a short period of time to ignore the inspection, resulting in equipment can not be repaired and scrapped. For this reason, the stainless steel reaction kettle used after repair must be checked, and the repair and inspection records must be made.