CHEMICAL

REACTOR
(MAINTENANCE DEPT)
 WHAT IS A
CHEMICAL
REACTOR?
A chemical reactor is a vessel
or device used to carry out
chemical reactions. These
reactions can be used for
various purposes, including
the production of chemicals,
pharmaceuticals, and more.
 HOW MANY
TYPE OF
REACTOR?
IN OUR FACTORY THERE
ARE FOUR TYPE OF
GLASS LINED REACTOR (GLR) STAINLESS STEEL REACTOR (SSR)
REACTOR
1. GLASS LINED
REACTOR (GLR)
2. STAINLESS STEEL
REACTOR (SSR)
3. MILD STEEL REACTOR
(MS)
4. MILD STEEL LEAD
BOUNDED REACTOR
(MSLB)

MILD STEEL REACTOR (MS) MILD STEEL LEAD BOUNDED REACTOR (MSLB)
 DESCRIBE EACH TYPE OF REACTOR
1. GLR (GLASS-LINED REACTOR)
 A glass-lined reactor is a type of vessel used in the chemical and pharmaceutical
industries for various chemical processes.
 It consists of a steel shell with a lining made of glass.
 The glass lining is typically applied to the internal surfaces of the reactor,
including the walls and often the agitator, providing a protective barrier between
the reactive contents of the vessel and the steel shell.
THE KEY FEATURES OF A GLR INCLUDE:
 CORROSION RESISTANCE
 TRANSPARENCY
 CLENABILITY
 PRODUCT PURITY
 MECHANICAL DURABILITY
 THERMAL SHOCK
 LIMITED OPERQATING TEMP & PRESSURE
 2. (SSR) STAINLESS STEEL REACTOR
 A stainless steel reactor is a type of vessel used in various industries, including
chemical, pharmaceutical, and food processing, for a wide range of chemical
processes.
 It is constructed primarily from stainless steel, a corrosion-resistant alloy.

THE KEY FEATURES OF A STAINLESS STEEL REACTOR INCLUDE:

 CORROSION RESISTANCE
 STRENGTH AND DURABILITY
 TEMPERATURE RESISTANCE
 HYGIENIC AND EASY TO CLEAN
 CUSTOMIZABLE
 RESISTANCE TO CONTAMINATION
 VERSATILITY
 3. (MS) MILD STEEL REACTOR
 A mild steel reactor is a type of vessel used in various industrial applications, particularly in the
chemical and process industries.
 It is constructed primarily from mild steel, which is a type of carbon steel.

 Surface Coating: To mitigate corrosion, mild steel reactors are often coated or lined with materials
like glass or specific protective coatings.

THE KEY FEATURES OF A STAINLESS STEEL REACTOR INCLUDE:

 Cost-Effectiveness
 Good Mechanical Strength
 Weldability
 Versatility
MILD STEEL REACTORS ALSO HAVE SOME LIMITATIONS:

 Corrosion Susceptibility
 Limited Temperature and Chemical Compatibility
 Surface Coating
 4. LEAD LINED REACTOR
 A lead lined reactor is a type of vessel used in various industrial applications, particularly in the

chemical and process industries.

 It is constructed primarily from mild steel, which is a type of carbon steel and lined with lead.

 Surface Coating: To mitigate corrosion, lead lined reactors are coated or lined with materials like

lead or specific protective coatings (furan resin).

THE KEY FEATURES OF A STAINLESS STEEL REACTOR INCLUDE:

 Cost-Effectiveness
 Good Mechanical Strength
 Weldability
 Versatility
SCHEMATIC
DIAGRAM OF
GLR (GAS-
LIQUID
REACTOR)
SCHEMATIC
DIAGRAM OF
REACTOR
 WORKING PRINCIPLE OF REACTOR
Chemical reactors are designed to facilitate chemical
reactions. The working principle involves:
 Mixing: Reactants are brought into contact and thoroughly mixed to enhance
collision between molecules.
 Reaction: Chemical bonds are broken and new ones are formed, leading to
the desired chemical transformation.
 Control: Reactor conditions (temperature, pressure, concentration) are
controlled to optimize the reaction.
 Separation: The product is separated from unreacted materials.
Reactors can vary in design and operation, including batch reactors,
continuous flow reactors, and more, depending on the specific requirements of
the chemical process.
 MAINTENANCE PROCEDURE THAT OCCURE IN REACTOR, WHAT TYPE OF
PROBLEM HAVE FACED SO FAR, AND HOW DO YOU FIX THEM?
Maintenance procedures for chemical reactors are crucial to ensure safe and efficient operation. Here's a general overview of common maintenance steps:
 1. Regular Inspections: Routine inspections are conducted to identify signs of corrosion, leaks, wear, or other issues. Inspect critical components, such as
the reactor vessel, agitators, valves, and instrumentation.
 2. Cleaning: Remove any residue or fouling that may have built up on the reactor internals. This can be done through methods like chemical cleaning or
mechanical cleaning, depending on the nature of the fouling.
 3. Replacing Mech. Seals and Gaskets: Gaskets, O-rings, and seals should be checked and replaced if they are damaged or deteriorated to prevent leaks.

 4. Pressure Relief Device Inspection: Safety relief valves and rupture discs must be inspected and tested to ensure they function properly in case of
overpressure situations.
 5. Instrument Calibration: Calibrate and test instruments, sensors, and control systems to maintain accurate process control.

 6. Agitator Maintenance: Inspect and service agitators and mixing devices to ensure proper mixing and heat transfer.

 7. Reactor Vessel Integrity: Periodic inspections of the reactor vessel are essential to check for any signs of corrosion, erosion, or stress-related issues.

 8. Piping and Valve Maintenance: Check and maintain the piping system, valves, and fittings to prevent leaks or blockages.

 9. Heat Exchanger Maintenance: If the reactor has heat exchangers, clean and inspect them to ensure efficient heat transfer.

 10. Safety System Checks: Ensure that safety systems, including emergency shutdown systems, are functioning correctly.

 11. Material Testing: Periodically test the reactor materials to assess their integrity and structural soundness.

 12. Control System Check: Inspect and maintain the control systems to ensure they operate correctly and are up to date.

 13. Documentation: Keep detailed records of all maintenance activities, inspections, and repairs.

 14. Training: Ensure that personnel responsible for reactor maintenance are properly trained in safety procedures and best practices.

 15. Emergency Response Planning: Have a plan in place for responding to emergencies, such as leaks, fires, or other safety incidents.

Remember that the specific maintenance procedures can vary based on the type of reactor, the materials involved, and the nature of the chemical processes
taking place.
WHAT TYPE OF PROBLEM HAVE FACED? HOW DO YOU FIX THEM?

MECHANICAL SEAL PROBLEM REPLACING SEAL DAMAGED PARTS

JACKET & COIL LEAKAGE PROBLEM PATCH WELDING/JACKET REPLACEMENT
PATCH WELDING/IN GLR PTFE PATCH
SHELL LEAKAGE PROBLRM
FITTING
GEAR BOX BEARING & OIL SEAL DAMAGED
BEARING AND OIL SEAL REPLACE
PROBLEM
STIRRER REPAIRING WITH FABRICATION
REACTOR STIRRER BLADE DAMAGE OR
TEAM AND BEARING REPLACEMENT WITH
BEARING DAMAGE
MECH.TEAM
NEW NOZZLE FABRICATION AND GRAFITE
REACTOR NOZZLE DAMAGE PROBLEM
TILES COATING

THERMOWELL LEAKAGE PROBLEM THERMOWELL REPAIRING OR REPLACEMENT

 WHAT MODIFICATION HAVE YOU MADE TO
THE REACTOR SO FAR?
 WE HAVE REPLACED GEAR REDUCER WITH HIGH TORQUE AND HEAVY LOAD GEAR REDUCER TO

ENHANCE ITS LOAD BEARING CAPACITY AS PER REQUIREMENT.

 WE HAVE REPLACED GLASS LINED Y-TYPE FLUSH BOTTOM VALVE WITH PTFE BALL VALVE.(TO

REDUCE MAINTENANCE COST)

 LIMPET COIL REPLACED WITH MS CONVENTIONAL JACKET FOR INCREASING RATE OF HEAT & COLD

EXCHANGE IN REACTOR

 ADDITIONAL NOZZLE IS FABRICATED AS PER REQUIREMENT FOR PRODUCT INGREDIENTS FEEDING

 WE HAVE ASLO INSTALLED HIGH PRESSURE AND TEMPERATURE ALARM SENSOR

 IN LEAD LINED REACTOR WE ADD ANOTHER LINED OF FURAN RESIN COATED AFTER LEAD TO

INCREASE ITS COROSION RESISTIVITY

 WHAT IS THE LOCKING SYSTEM OF REACTOR
STIRRER WOOD? AND WHY DO THEY DO IT?
Here are some common methods for locking the stirrer in place
during transportation:
Locking Mechanism: Many reactors come with built-in locking mechanisms or
clamps designed specifically for immobilizing the stirrer during transportation.
Ensure these are securely fastened before moving the reactor.
Use Supporting Structures: Some reactors have supporting structures or
brackets to hold the stirrer in place during transport. These structures are
designed to prevent the stirrer from moving or vibrating.
Padding and Restraints: Use padding materials such as foam or rubber to
cushion and secure the stirrer in place. You can also use straps or restraints to
prevent any movement.

It's important to ensure that the stirrer is immobilized securely to avoid

any damage during transportation.
 ANY OTHER INPUT
 REACTOR INRTER-LOCK -REACTOR VENT LINE SHOULD BE OPEN
ALWAYS
 WE HAVE INSTALLED SCRUBBER SYSTEM FOR PREVENT GASES.
THANK YOU