Simplified Maintenance Method for Cracking Reactors

Simplified Maintenance Method for Cracking Reactors

1. Daily Maintenance (After Each Production Batch / Daily)

Cleaning: Promptly remove carbon black and waste residue from the reactor, and check the inner wall for corrosion or cracks.

Sealing & Lubrication: Inspect sealing gaskets for leaks, and apply high-temperature grease to moving parts such as the feeding screw.

Safety Accessories: Verify that pressure gauges, safety valves, and temperature sensors are functioning normally and responsive.

2. Regular Maintenance (Weekly / Monthly / Quarterly)

Weekly: Remove carbon deposits from the heating system, and check that the discharge hopper opens and closes smoothly.

Monthly: Test the reactor wall thickness, and inspect the jacket for corrosion.

Quarterly: Clean and descale the cooling coils, then passivate them; conduct a hydrostatic test to verify pressure resistance.

3. Annual Overhaul

Internal Component Inspection: Dismantle parts like the feeding screw and replace them if wear exceeds 20%; check the lining for peeling or cracking.

Safety Calibration: Send safety valves and other accessories to a third party for calibration, and organize maintenance records for archiving.

4. Key Precautions

Before entering the reactor for maintenance, obtain a work permit, purge the gas, and test for flammable gas concentrations.

Allow the reactor to cool completely before maintenance to prevent burns.

For long-term shutdowns, dry the reactor and apply rust inhibitor.