Safety Operation Procedures for Oil Sludge Pyrolysis Equipment

1. Safety Inspection Before Startup

1. Check the pyrolysis reactor, flanges, and door seals for integrity: no cracks, deformation, or leakage.

2. Verify pressure gauges, temperature meters, safety valves, and rupture discs are valid and within calibration period.

3. Check nitrogen system pressure to ensure normal purging function.

4. Confirm cooling system (cooling water, condensers, oil pumps) is unobstructed and tight.

5. Check flue, desulfurization, dust removal, and induced draft system for normal operation.

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7. Ensure fire extinguishers, emergency sand, and fire-fighting equipment are available and effective.

8. Clear combustible materials; keep passages clear; unauthorized personnel prohibited.

   
   

2. Feeding and Nitrogen Purging (Critical Safety Step)

1. Oil sludge feed shall NOT contain volatile solvents, sealed containers, explosives, hard metals.

2. Loading volume shall not exceed 80% of reactor volume to prevent overflow.

3. Securely close and lock the reactor door; nitrogen purging is mandatory to eliminate air and ensure oxygen-free environment.

4. Heating without nitrogen purging is strictly prohibited to prevent explosion.

   
   

3. Heating and Pyrolysis Operation

1. Heat slowly and evenly; rapid high-temperature heating is forbidden.

2. Strictly control temperature and pressure: maintain slight negative or low positive pressure; no over-temperature or over-pressure.

3. Monitor oil output continuously; immediately stop heating if abnormal oil-gas, pressure surge, odor, or smoke occurs.

4. Do NOT open reactor door, remove flanges, or loosen gauges during operation.

5. Cooling system must run continuously; stop heating immediately if water supply fails.

   
   

4. Non-Condensable Gas and Exhaust Safety

1. Non-condensable gas must pass through water seal before burning; direct discharge is prohibited.

2. No leakage in gas pipelines and gas holder; open flames and smoking forbidden nearby.

3. Desulfurization and dust removal systems must operate synchronously; environmental equipment cannot be shut down.

   
   

5. Cooling and Discharging Residue

1. After pyrolysis, cool naturally to below 80°C before opening the door.

2. High-temperature door opening is strictly prohibited to prevent backfire, deflagration, burns.

3. Avoid contact with hot residue to prevent scalding and fire.

4. Residue must be fully cooled and confirmed fire-free before transportation.

   
   

6. Equipment Maintenance Safety

1. Maintenance allowed only after full cooling, pressure release, and ventilation.

2. Electrical equipment must be explosion-proof and moisture-proof; no unauthorized wiring.

3. Regularly inspect gaskets, safety valves, rupture discs, temperature and pressure sensors.

4. Shut down immediately for abnormal noise, vibration, oil or gas leakage.

   
   

7. Emergency Handling

1. Sudden pressure surge: stop heating, increase negative pressure, check blockage.

2. Oil-gas leakage: stop heating, cut power, prohibit ignition, ventilate, evacuate.

3. Fire: use dry chemical fire extinguisher; do NOT use water on hot oil fire.

4. Burns or gas exposure: evacuate to safe area and provide first aid.

   
   

8. Personnel Requirements

1. Operators must be trained and qualified before operation.

2. Mandatory PPE: work clothes, safety shoes, gloves, goggles.

3. Drunk, fatigued, unattended, and illegal operations are strictly forbidden.