Release time：2025-02-25 popularity：407
As the core equipment of chemical, pharmaceutical, food and other industries, the performance of reaction kettle is directly related to production efficiency and product quality. However, the reactor is not permanent equipment, with the use of time increases, its performance and safety will gradually decline. In order to ensure production safety and efficiency, enterprises need to clarify the reactor scrapping standards, timely replacement of aging or damaged equipment. In this article, we will discuss the scrapping standard of reactor in detail to help enterprises make scientific decisions.
1.Ensure production safety
Aging or damaged reactor may have leakage, explosion and other potential safety hazards, timely scrapping can avoid accidents.
2.Improve production efficiency
Decreased performance of the reactor will affect the reaction efficiency, increase energy consumption and production costs.
3.Ensure product quality
Corrosion and contamination of the reactor may lead to substandard product quality and affect the reputation of the company.
4.Comply with regulatory requirements
Many industries have clear regulations on the service life and safety of equipment, and timely scrapping can avoid legal risks.
1. Service life
Design life: the design life of the reactor is usually 10-15 years, more than the design life, equipment performance will be significantly reduced.
Actual use: If the equipment is used for a long time in poor environment (such as high temperature, high pressure, strong corrosion), the actual life may be shorter than the design life.
2. Material corrosion
Degree of corrosion: serious corrosion of the inner wall of the reactor or key components (e.g., wall thickness thinning more than 20% of the original thickness), which may lead to leakage or rupture.
Corrosion type: uniform corrosion, pitting corrosion, stress corrosion, etc. need to be assessed, especially pitting corrosion and stress corrosion may cause sudden accidents.
3. Cracks and damages
Surface cracks: Cracks visible to the naked eye appear on the surface of the reactor, especially in stress concentration areas (such as welds, openings).
Internal damage: internal cracks or defects are found through non-destructive testing (e.g. ultrasonic testing, ray testing).
4. Deterioration of sealing performance
Leakage problem: the seals of the reactor (e.g. gaskets, mechanical seals) are aging or damaged, resulting in media leakage.
Failure of pressure test: In the pressure test, the kettle can not maintain the specified pressure, indicating that the sealing performance has been seriously degraded.
5. Failure of performance indexes
Heat transfer efficiency decreases: due to scaling, corrosion or coating shedding, the heat transfer efficiency of the reactor is significantly reduced.
Deterioration of stirring effect: the stirrer is worn or deformed, resulting in uneven mixing of materials and affecting the reaction effect.
6. Failure of safety accessories
Failure of safety valve: The safety valve cannot open or close properly, which may lead to overpressure or insufficient pressure relief.
Failure of pressure gauge and thermometer: the monitoring instrument fails to accurately reflect the operating status of the equipment.
7. Economic Assessment
Excessive maintenance costs: If the maintenance cost of the reactor is close to or exceeds the cost of replacing the equipment with a new one, it should be considered for scrapping.
Increase in energy consumption: the energy consumption of aging equipment increases significantly, making long-term operation uneconomical.
1.Visual inspection
Check the internal and external surfaces of the reactor kettle for corrosion, cracks, deformation and other problems.
2.Non-destructive testing
Use ultrasonic testing, ray testing, magnetic particle testing and other methods to assess the internal damage of the equipment.
3.Pressure test
Carry out hydraulic test or pneumatic test to check the sealing and pressure-bearing capacity of the reaction kettle.
4.Material Analysis
Perform material analysis on severely corroded parts to assess remaining life.
5.Performance Test
Test the heat transfer efficiency, stirring effect and other performance indexes of the reactor.
1.Regular maintenance
Develop and implement a regular maintenance programme, including cleaning, lubrication and tightening.
2.Anti-corrosion measures
Use anti-corrosion coating, cathodic protection and other techniques to retard corrosion.
3.Operation standardisation
Train operators to ensure that the equipment operates within the specified temperature and pressure ranges.
4.Timely maintenance
Discover small problems and deal with them in time to avoid enlargement of the problem.
The scrapping standard of reaction kettle is an important basis for ensuring production safety, efficiency and product quality. Enterprises should scientifically assess the status of reaction kettle according to the service life of the equipment, corrosion degree, performance indicators and other factors, and scrap the aging or damaged equipment in time. At the same time, through regular maintenance and standardised operation, to extend the service life of the reactor, reduce production costs. Only in every aspect of equipment management to achieve refinement, enterprises can be invincible in the fierce market competition.
