How to Judge the Wear Degree of the Main Reactor of Batch-Type Pyrolysis Equipment

How to Judge the Wear Degree of the Main Reactor of Batch-Type Pyrolysis Equipment

To judge the wear degree of the main reactor of batch-type pyrolysis equipment, it is necessary to comprehensively evaluate from three dimensions: reactor structure, operation status and key components by combining three methods: visual inspection, parameter monitoring and component testing. The specific steps are as follows:

Judgment of Wear and Corrosion Degree of Reactor Inner Wall

Direct Visual Inspection

After shutting down the equipment and cooling it to room temperature, open the

 reactor door and check whether the inner wall has obvious corrosion spots, pits, cracks or thickness reduction. If the inner wall has large-area rust, local steel plate depression, or the steel plate surface exposed under the coking layer is rough with the risk of perforation, it indicates that the wear and corrosion are relatively severe.

Thickness Measurement

Use an ultrasonic thickness gauge to evenly select 10–15 detection points on the inner wall of the reactor (focus on the area near the oil-gas outlet and the area of the reactor bottom with frequent raw material contact) to measure the actual thickness of the steel plate. Compare it with the original thickness of the equipment when it leaves the factory: if the thickness reduction exceeds 10%, it is judged as moderate wear; if the thickness reduction exceeds 20%, it is judged as severe wear, and the inner steel plate must be repaired by welding or replaced immediately.

Corrosion Product Analysis

If the inner wall is attached with dark brown, loose corrosion products that reappear soon after cleaning, it indicates that the pyrolysis gas of raw materials has strong corrosivity and the reactor is in a state of continuous corrosion.

Judgment of Wear of Reactor Door and Sealing Components

Sealing Gasket Inspection

Check whether the sealing gasket is aged and hardened, cracked, deformed or insufficient in compression. If the gasket surface loses elasticity, has gaps, or gaps are still visible after the reactor door is locked tightly, it indicates that the gasket is worn and invalid and needs to be replaced.

Sealing Surface Flatness Detection

Attach a straightedge to the sealing surface of the reactor door and body. If the gap exceeds 0.5mm, or the sealing surface has obvious scratches and pits, it indicates that the sealing surface is worn and needs to be polished and repaired; otherwise, air leakage will occur.

Locking Bolt Status Check

Check whether the bolts are stripped, deformed or broken. If the sealing effect cannot be guaranteed even after the bolts are tightened, it indicates that the bolts are worn and invalid.

Judgment of Wear of Rotating Components of Horizontal Main Reactor

Contact Status Check of Rolling Rings and Supporting Rollers

Observe the contact position between rolling rings and supporting rollers during operation. If there are local bright spots, grooves or uneven wear, it indicates that the contact surface is severely worn. After shutting down the equipment, push the reactor body by hand; if the rotation resistance is large, there is jamming or abnormal noise occurs, further inspection is required.

Bearing Wear Detection

Monitor the operation sound of the rotating system. If there is a "rustling" abnormal noise or increased vibration, it indicates that the bearing is short of lubricating oil or worn. After disassembling the bearing, if pitting, corrosion or excessive clearance is found on the surface of the balls, the bearing is judged to be worn and invalid.

Transmission Component Inspection

Check the meshing state of transmission components such as gears and chains. If there is peeling on the gear tooth surface or the chain is loose and elongated, it indicates that the transmission components are worn, which will cause unstable rotation speed of the reactor body.

Operation Parameter Abnormality Monitoring (Indirect Judgment of Wear)

Temperature Fluctuation Monitoring

If the temperature fluctuation range inside the reactor exceeds ±20℃ and cannot be stabilized even after eliminating the burner fault, it may be caused by insulation layer falling off or reactor wall thinning leading to increased heat loss, which is an indirect manifestation of reactor structure wear.

Pressure Abnormality Judgment

If the slight positive pressure inside the reactor is difficult to maintain or the pressure relief frequency increases abnormally, and the pipeline blockage factor is ruled out, it is highly probable that the sealing components of the reactor are worn, resulting in air leakage.

Energy Consumption Change Comparison

If the fuel consumption per batch of raw materials increases by more than 15% compared with the initial stage, and there is no obvious damage to the insulation layer, it indicates that the inner wall of the reactor is thinned and the thermal insulation performance is reduced, which is an important signal of reactor wear.