Common Faults and Troubleshooting Methods of the Main Reactor for Batch-Type Pyrolysis Equipment

Common Faults and Troubleshooting Methods of the Main Reactor for Batch-Type Pyrolysis Equipment

The main reactor serves as the core unit of batch-type pyrolysis equipment. Its operation is susceptible to malfunctions caused by factors such as raw material properties, operating parameters, and equipment wear. Timely troubleshooting and rectification are essential to ensure the stable operation of the production line. Common faults and corresponding solutions are as follows:

I. Reactor Door Seal Failure with Air Leakage into the Reactor

Common Causes

The sealing gasket is aged, cracked or deformed;

Uneven stress on the reactor door locking bolts leads to poor fit between the reactor door and the reactor body;

The sealing surface is contaminated with carbon black, coke residue and other impurities, impairing the sealing performance.

Solutions

Inspect the gasket condition before each feeding batch. Immediately replace aged or damaged gaskets with high-temperature-resistant graphite packing or metal spiral wound gaskets of the same model;

Tighten the bolts diagonally and evenly to ensure balanced stress on the reactor door and a tight fit with the reactor body;

Regularly clean impurities off the sealing surface and apply a layer of high-temperature-resistant sealant to enhance sealing performance.

II. Excessive Temperature Fluctuation in the Reactor with Unstable Temperature Control

Common Causes

Abnormal fire power adjustment of the burner and unstable fuel supply;

Falling-off or damage of the insulation layer resulting in massive heat loss inside the reactor;

Malfunction or installation position deviation of the temperature sensor, causing distorted monitoring data.

Solutions

Check the fuel supply pipeline of the burner, clear blockages in the nozzle, and recalibrate the fire power adjustment program to ensure stable fire power output;

Repair the fallen insulation layer after shutdown, and replace severely damaged parts with aluminum silicate refractory fiber cotton or lightweight refractory castable;

Calibrate the accuracy of the temperature sensor, adjust its installation position to the area with uniform temperature inside the reactor, and avoid direct contact with the reactor wall to prevent monitoring errors.

III. Rotation Jamming of Horizontal Main Reactor with Abnormal Operation

Common Causes

Severe wear on the contact surface between rolling rings and supporting rollers, or foreign matter jamming;

Lack of lubrication, corrosion or damage of bearings in the rotation system;

Coke accumulation of raw materials inside the reactor, leading to excessive load on the reactor body.

Solutions

Clear foreign matter between rolling rings and supporting rollers, grind and repair worn contact surfaces, and regularly add high-temperature-resistant lubricating grease to reduce component wear;

Replace damaged bearings, check the meshing state of transmission chains or gears, and timely adjust the tightness to ensure smooth transmission;

Manually clear large coke residues inside the reactor after shutdown and cooling, optimize the raw material particle size and single-batch feeding volume to avoid overload operation of the reactor body.

IV. Abnormal Pressure Rise in the Reactor with Frequent Pressure Relief of Safety Valve

Common Causes

Blockage of the oil-gas outlet pipeline or filter screen, preventing timely discharge of oil gas;

Malfunction of the pressure relief valve that fails to open normally for pressure relief;

Excessively high pyrolysis temperature accelerating the raw material cracking rate and causing instantaneous accumulation of oil gas inside the reactor.

Solutions

Timely clear tar deposits in the oil-gas outlet pipeline, inspect and replace clogged filter screens to ensure unobstructed oil-gas flow;

Dismantle and overhaul the pressure relief valve, clear impurities inside the valve body, calibrate its sensitivity, and replace it directly if the fault is severe;

Adjust the burner fire power to control the reactor temperature within the set range, avoiding excessive oil-gas accumulation caused by over-high temperature.

V. Corrosion and Thinning of Reactor Inner Wall with Leakage Risks

Common Causes

High sulfur and chlorine content in raw materials resulting in highly corrosive pyrolysis gas;

Long-term failure to clean the reactor inner wall, leading to corrosion of the steel plate under the coke layer;

Improper selection of inner layer materials that cannot withstand corrosive working conditions.

Solutions

Preprocess high-corrosion raw materials to reduce sulfur and chlorine content, or replace the inner layer with more corrosion-resistant 310S heat-resistant stainless steel;

Thoroughly clean the coke on the reactor inner wall after each batch discharge to prevent long-term corrosion of the steel plate under the coke layer by corrosive gas;

Regularly test the thickness of the steel plate, and timely perform weld repair or replacement for parts where corrosion-induced thinning exceeds 10% of the original thickness.