Maintenance Key Points of the Main Reactor

Maintenance Key Points of the Main Reactor

The stable operation of the main reactor directly affects equipment productivity and oil product quality. Daily maintenance shall follow the principle of regular inspection and timely servicing. The specific key points are as follows:

I. Daily Operation Maintenance

Before each feeding batch, inspect the sealing gasket of the reactor door for damage. Replace it promptly if aging or cracking is found, to prevent air from leaking into the reactor.

Monitor the reactor temperature and pressure at regular intervals during operation. If local overheating occurs, check whether the insulation layer has fallen off and repair it in a timely manner.

For horizontal rotary main reactors, regularly inspect the contact condition between the rolling rings and supporting rollers. Keep the contact surfaces clean, and apply high-temperature-resistant lubricating grease on a regular basis to prevent wear and jamming.

II. Inter-Batch Maintenance

After discharging each batch, clean the residual carbon black and coke deposits on the inner wall of the reactor. Avoid excessive thickness of the coking layer, which would affect the heat transfer efficiency of the next batch. Do not use sharp tools to scrape the reactor wall during cleaning, to prevent damage to the inner steel plate.

Check whether the oil-gas outlet pipeline on the top of the reactor is clogged, and clean the tar deposits in a timely manner to ensure the smooth discharge of oil gas.

III. Regular Shutdown Maintenance

Every 3–6 months of operation, shut down the equipment for a comprehensive inspection of the reactor:

Test the thickness of the inner steel plate. If the corrosion-induced thickness reduction exceeds 10% of the original thickness, repair by welding or replace the plate.

Check whether the insulation layer is loose, and refill it if necessary.

Derust and lubricate components such as the reactor door locking bolts and bearings of the rotation system, and replace any damaged fasteners.

Check the sensitivity of safety accessories such as safety valves and pressure gauges, and send them to the quality supervision department for calibration on a regular basis to ensure their reliable operation.

IV. Maintenance Precautions

All maintenance operations must be carried out after the reactor cools down to room temperature and the internal pressure drops to normal pressure. Never open the reactor door when it is still at high temperature and under pressure.

Wear a dust mask and protective gloves when cleaning carbon black, to avoid inhaling carbon black dust.

When welding and repairing the reactor, use welding electrodes matching the material of the inner layer. Conduct a flaw detection test after welding to ensure no defects exist in the weld seams.