Regular Inspection and Maintenance Guide for Waste Tire Pyrolysis Equipment

Regular Inspection and Maintenance Guide for Waste Tire Pyrolysis Equipment

The regular inspection and maintenance of waste tire pyrolysis equipment follows a standardized mechanism: daily inspection, weekly lubrication, monthly fastening, and annual overhaul. The core maintenance covers seven key systems including the pyrolysis reactor, driving roller, sealing system, condenser, safety instruments, electrical system and environmental protection system, to ensure long-term stable, safe and efficient operation of the equipment.

1. Daily Inspection (Per Shift / Per Day)

Objective: Eliminate potential risks such as leakage, abnormal noise, over-temperature and over-pressure in time.

1.1 Pyrolysis Reactor (Main Furnace)

• Check the furnace body for no deformation, local overheating, cracks or flue leakage; focus on welding seams and flange connections.

• Inspect sealing parts: Ensure graphite packing at the feeding/discharging port and furnace door is intact without oil and gas leakage, and the furnace door is tightly closed.

• Check furnace coking: Clean coking once the thickness exceeds 3-5mm to avoid local overheating and reduced working efficiency.

• Verify instrument status: Pressure gauges, thermometers and safety valves are in good condition and within the calibration period; ensure working pressure ≤0.3MPa and working temperature ≤550℃.

1.2 Driving System (Rollers, Tracks, Reducer)

• Check rollers for flexible rotation without jamming or abnormal noise; fasten all mounting bolts; replenish high-temperature lithium grease every 3-5 days.

• Inspect tracks for no severe wear or deformation and good contact with rollers.

• Check the reducer for normal oil level, clear oil quality, no oil leakage and no abnormal operating noise; tighten fixed bolts regularly.

1.3 Oil-Gas Pipeline & Condenser

• Inspect all pipelines for no cracks, looseness or leakage; ensure flange gaskets are intact.

• Clean carbon black deposits on filters and four-way connectors before and after each production to prevent pipeline blockage.

• Check the condenser for normal inlet and outlet water temperature and good cooling effect; dredge pipe passages regularly.

1.4 Safety & Environmental Protection System

• Maintain normal water level of the water seal tank, replace water every 3-5 days; prevent oil accumulation and peculiar smell.

• Ensure flame arresters and safety valves are sensitive, reliable and unblocked with regular calibration.

• Check fire fighting equipment and gas alarm system (LEL≤25%) for intactness; ensure anti-static grounding is reliable.

1.5 Electrical System

• Check motors and circuits for no overheating, peculiar smell or shell damage; ensure firm wiring and reliable grounding.

• Keep the control cabinet clean and dry with normal indicator lights and no burnt contacts.

2. Weekly Maintenance (Minor Maintenance)

• Full Lubrication: Replenish high-temperature grease for roller bearings, gears and couplings; check and top up reducer gear oil.

• Bolt Fastening: Retighten all connecting bolts of furnace body, rollers, reducer, pipeline flanges and motor base.

• Sealing Inspection: Check wearing conditions of packing and graphite gaskets at furnace door, inlet and outlet; replace aging and worn parts in time.

• Comprehensive Cleaning: Remove dust and oil stains on furnace outer wall, condenser and pipelines; clean the carbon black collection system.

• Cooling System Maintenance: Inspect water pumps, pipelines and valves; clean filter screens to ensure sufficient cooling water and unobstructed circulation.

3. Monthly Maintenance (Medium Maintenance)

• Deep Cleaning: Clean internal coking of the pyrolysis reactor with high-pressure water or mechanical cleaning after shutdown, cooling and ventilation; remove oil dirt and scale on the condenser via chemical cleaning; thoroughly dredge main oil-gas pipelines, gas separators and water seal tanks.

• Wear Parts Replacement: Batch replace aging sealing accessories including packing, graphite rings and flange gaskets; clean or replace oil-gas filters and carbon black filters.

• Electrical & Instrument Calibration: Calibrate pressure gauges, thermometers and safety valves; test motor insulation, check circuit aging and polish contactor contacts.

• Driving System Inspection: Measure wear of rollers and tracks, replace over-worn parts and correct coaxiality; test reducer oil quality and replace gear oil once deteriorated or discolored.

4. Annual Overhaul (Major Maintenance)

Complete a full systematic overhaul with 6-7 days of scheduled shutdown every year.

• Core Component Detection: Conduct thickness measurement and weld flaw detection on the furnace body to check corrosion and deformation, repair or replace damaged parts; inspect heads and flanges for cracks and corrosion to ensure pressure bearing safety.

• Driving System Overhaul: Disassemble, clean and inspect all roller bearings, replace worn accessories and re-level and align the equipment; disassemble the reducer to check gears and bearings, replace gear oil and sealing parts; refuel or replace motor bearings.

• Pipeline & Valve Maintenance: Conduct pressure testing for the whole pipeline system, repair leakage points; grind or replace faulty valves to eliminate internal and external leakage.

• Safety System Full Inspection: Calibrate or replace safety valves, rupture discs and emergency vent valves; clean or replace flame arrester filter elements; fully test gas alarm, fire fighting and anti-static grounding systems.

• Electrical & Automatic Control Inspection: comprehensively inspect control cabinets, PLC systems and sensors, replace aging lines and accessories, and complete linkage debugging of the whole system.

• Anti-corrosion & Heat Preservation: Derust and repaint equipment and pipeline surfaces; repair or replace damaged heat preservation layers to reduce heat loss.

5. Reference Replacement Cycle of Key Wear Parts

6. Standard Safety Management Specifications

• Standard Maintenance Procedure: Shut down the equipment & stop heating → cool down to below 60℃ → release pressure → cut off power and heat source → replace flammable gas with nitrogen → ventilate fully → test and confirm safety before maintenance operation.

• Maintenance Records: Record all inspection, maintenance and repair work in detail, including date, inspection position, faults and processing measures, to establish complete equipment health files.

• Spare Parts Reserve: Stock up commonly used accessories such as sealing parts, bearings, gaskets and filters in advance to shorten downtime.

• Personnel Training: Operators must hold valid certificates, be familiar with equipment structure, operating rules and emergency disposal measures for over-temperature, over-pressure, leakage and fire accidents.

7. Common Faults & Solutions

• Oil-gas Leakage: Replace aging packing; retighten loose bolts; correct deformed flanges or replace gaskets.

• Roller Abnormal Noise & Jamming: Replenish high-temperature grease for lack of lubrication; replace damaged bearings; correct deformed tracks.

• Poor Condenser Oil Discharge: Clean blocked filters; remove scale and dirt on condenser pipes via chemical cleaning.

• Abnormal Pressure Rise: Reduce feeding capacity; clean severe furnace coking; dredge blocked oil-gas pipelines.