High-pressure reactors are vital reaction vessels in chemical production, providing the necessary space and conditions for chemical reactions. The following points should be observed during installation prior to use:
1. Installation and Sealing of the Reactor Lid
If the reactor body and lid utilize a line-contact seal (involving conical and arc surfaces), the main bolts must be tightened to press the surfaces firmly together for an effective seal. However, the tightening torque must remain within the 80–120 Nm range to prevent crushing or excessive wear on the sealing surfaces; special care must be taken to protect these surfaces. When installing the lid, move it slowly to avoid collisions between the sealing surfaces of the body and the lid, which could cause damage. When tightening the main nuts, apply force symmetrically and gradually in multiple stages, ensuring even pressure to guarantee a secure seal.
2. Connection Points for Right- and Left-Hand Threaded Nuts
At the connection point for right- and left-hand threaded nuts, only the nuts themselves should be rotated; the two arc-shaped contact surfaces must not rotate against each other. All threaded fasteners should be coated with oil or a mixture of oil and graphite during assembly to prevent seizing.
3. Valve Usage
Needle valves utilize a line-contact seal; a gentle turn of the valve stem to press against the sealing surface is sufficient to achieve a good seal. Excessive force must be avoided to prevent damaging the sealing surface.
4. High-Pressure Reactor Controller
The controller should be placed flat on the operating bench. The operating environment temperature should be between 10°C and 40°C, and the relative humidity should be below 85%. Ensure that the surrounding atmosphere is free from conductive dust and corrosive gases.
5. Inspection of Fixed Contacts
Before use, inspect the moving parts and fixed contacts on the front and rear panels to ensure they are in proper condition. You may remove the top cover to check for loose connectors or any damage or corrosion resulting from transport or improper storage.
6. Connecting Wires
Connect all wires, including the power cord, the electric furnace cable (connecting the controller to the reactor vessel), the motor cable, and the leads for the temperature sensor and tachometer. Before connecting to the power supply, verify that the wires are intact and observe electrical safety precautions.
7. Safety Devices
For units equipped with rupture discs, do not disassemble or test them casually; once a disc has ruptured, it must be replaced—this is critical. Rupture discs that fail to burst despite exceeding their rated bursting pressure must also be replaced immediately to ensure safe operation.
8. Preventing Excessive Temperature Differentials
Avoid rapid heating or cooling during the operation of the high-pressure reactor to prevent cracks in the vessel body caused by excessive temperature differentials, which could compromise safety. Additionally, circulating water must flow through the water jacket between the magnetic stirrer and the reactor lid to prevent the magnetic components from losing their magnetism, which would impair performance.
9. Use of Newly Installed Reactors
Newly installed (or repaired) high-pressure reactors must undergo an airtightness test before being put into normal service. Nitrogen or other inert gases are recommended as the test medium; the use of flammable or explosive gases is strictly prohibited. The test pressure should be 1 to 1.05 times the working pressure. Pressure must be increased in stages—ideally in increments of 0.25 times the working pressure. Hold the pressure for 5 minutes at each stage and for 30 minutes upon reaching the final test pressure. If a leak is detected, depressurize the system before attempting repairs; for safety reasons, do not perform maintenance while the vessel is pressurized.