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磁力密封在高温易燃易爆反应釜中的应用Magnetic seal in the application of high temperature and flammable and explosive reaction kettle

  在高温、中压、易燃易爆介质反应釜中采用磁力密封技术与采用填料密封、机械密封技术相比具有操作简便、无泄漏、维修简便、降低维修费用、节能降耗、安全可靠、综合效益好等优点,可在老化工装置及新建化工装置上广泛应用。
  原来采用的填料密封反应釜,反应后卸压放掉氢气,用高温多级泵输送至反应器。该工艺流程,存在以下几个问题:

  1、填料密封反应釜密封效果不好,易泄漏,不但造成苯胺等蒸汽泄漏,浪费原材料,而且易燃易爆气体泄漏危及安全生产。

  2、由于制备反应结束后温度仍大于260℃,而高温多级泵许用温度范围要求小于180℃,所以必须降温至180℃,才能启动泵输送,这样,不但要用冷却水冷却导热油,再冷却物料温度,增加了热耗,而且,也增加了每釜生产时间约2小时左右。

  3、冷却后在高温多级泵输送过程中,由于物料中存在铝粉多,原采用反应釜底部出料,所以经常容易堵塞底阀,经常反冲、拆清阀门,即影响生产又容易损伤多级泵叶轮及机械密封。

  由于是间断输送物料,容易造成机械密封泄漏、影响生产、造成环境污染,维修工工作量相当大,平均一星期检修一次,特别是经常发生中班、零点班维修工加班加点,才能维持生产,维修工作环境恶劣,气味扑鼻,造成头昏头疼,而且维修备品配件费用高。

  4、输送至反应釜后,由于介质温度从260℃已降至180℃,在反应釜中,又要用导热油加温至260℃以上才能反应,每釜需多供热量10万大卡。

  5、  由于原工艺从制备釜出料,部分未反应铝粉夹带至泵,使泵无法工作,所以在进泵前增加了进料过滤器,平均每月需清洗一次过滤器。

   由于存在以上诸多缺陷,现采用磁力密封制备釜、带压、输送至反应器。这样的工艺具有以下优点:

  1、制备反应釜时由于磁力密封无泄漏,保证了安全生产,减少了物料的泄漏浪费。

  2、由于无泄漏可控制反应压力3~3.5Mpa下反应提高了制备效果,缩短了制备反应时间。

  3、采用插入管输送,不存在制备釜底部堵塞及铝粉带入问题。

  4、由于利用压差输送,取消了高温多级泵,节省了电,特别是解放了维修工、减少了艰苦的维修工作,节省了昂贵的备品配件的费用。

  5、输送至反应釜由于不用泵也不需降温,直接260℃输送至反应釜,节约了每釜加热量10万大卡,节约了2小时生产时间,提高了生产能力。

    使用磁力密封注意事项:

  1、磁力釜用密封,使动密封转变为静密封,需全封闭密封结构,磁力采用稀土结构钢,稳定性好,不易退磁,使用寿命长。但要注意在运转过程中,隔离套内的内磁转子不断搅动介质,加之涡流等因素,导致隔离套温度上升,一般在超过200℃时,会造成磁力性材料的严重退磁而失效。因此,结构上采用夹套冷却装置,来防止水污结垢堵塞水道,一般采用去离子水冷却,并有明显溢流装置,以防断水,使温度升高失去磁性。

  2、磁力密封带动搅拌器,在联轴器上有一对轴承在釜内,所以必须重视该轴承(一般为滚动轴承)的润滑,在高温下采用高温润滑脂,并采用耐高温耐腐蚀的填料(一般采用柔性石墨),以保证轴承润滑,一般情况每半年检修检查一次。

  3、磁力联轴器在安装过程中,应避免磁转子与其他金属件的剧烈碰撞以免损伤磁转子而影响其传递力矩。

  4、组装时注意内、外磁转子和隔离套的同心度,不允许有接触磨擦。

  5、磁力传动是恒力矩传动,因此在启动运转中不应有过载,并应低负荷起动。

  6、运转中隔离套与内磁转子间应充满介质并循环,否则会迅速升温,出现滑脱现象,应立即停车,避免磁能转变为热能而使磁转子升温而退磁失效。

使用磁力密封的效益和效果明显,使得操作简便,节能降耗,减少了维修工作量及工作难度,减去了两台设备及其备品备件费用,赢得了生产时间,提高了生产装置能力,杜绝了泄漏,减少了物料损失,保证安全,获得了较大的综合效益。

1、操作上减少了启动泵等步骤,使操作更简便可靠。

  2、在维修上可减少两个维修工,每年节约四万元左右。

  3、节省两台设备及备品配件修理费每年节约五万元左右。

  4、每釜生产时间节约约两小时,提高生产装置能力约10%。

  5、减少氢气、苯胺气体泄漏损失,确保了安全生产。

  6、该装置投资5.5万元,约三个月可收回投资,年综合效益约30余万元。

   推广及应用

  釜用机械密封存在价格高,维修频繁,维修费用高及维修难度大等缺点。磁力密封反应釜及类似我公司生产工艺装置可广泛采用此工艺流程,比釜用机械密封有很大的优越性,磁力密封应该是老化工装置改造及新建化工装置的首选技术。

 

At high temperature, medium pressure, flammable and explosive medium in the reaction kettle using magnetic sealing technology compared with using packing seal, mechanical seal technology has simple operation, no leakage, simple maintenance, reduce the maintenance cost, saving energy and reducing consumption, safe and reliable, and the advantages of good comprehensive benefits, but in the old chemical plant and new chemical device is widely used.

After the original packing seal reaction kettle, release the pressure relief of hydrogen, using high temperature multistage pump to the reactor. The technological process, the following problems:

 

1, packing seal reaction kettle sealing effect is not good, easy to leak, causing aniline steam leak, such as waste of raw materials, and flammable and explosive gas leak endanger the safety in production.

 

2, due to the preparation of end of the reaction temperature is still greater than 260 ℃, and the high temperature multistage pump allowable temperature range for less than 180 ℃, so must be cooled to 180 ℃, to start the pump, so, not only should in cooling water cooling heat conduction oil, then cool material temperature, increase the heat loss, and also increased every kettle production time about 2 hours or so.

 

3, after cooling at high temperature in the process of the multistage pump, because the material of aluminum powder, used in the bottom of the reaction kettle discharging, so often easy to block bottom valve, often recoil, tear open the valve, which affect production and easy damage multistage pump impeller and mechanical seal.

 

Is due to the continuous conveying material, easy to cause mechanical seal leakage, affect production, environmental pollution, maintenance workload is quite large, the average maintenance once a week, especially frequent GSM, zero class mechanic work overtime, to maintain production, repair bad work environment, smell fragrant, cause dizziness have a headache, and the high cost of maintenance spare parts.

 

After 4, conveying to the reaction kettle, due to the medium temperature from 260 ℃ to 180 ℃, in the reaction kettle, and to the use of heat conduction oil heating to 260 ℃ or more to get response, must more heat quantity 100000 calories per kettle.

 

5, because the preparation tank discharging from the original process, reaction of aluminium with not to pump, the pump will not work, so before entering the pump increased feed filter, need to clean the filter once a month on average.

 

Due to the defects of these, we use magnetic seal preparation kettle, with pressure, to the reactor. This process has the following advantages:

 

1, the preparation of the reaction kettle due to the magnetic seal leakage and to ensure the safety in production, reduce the leakage of waste material.

 

2, because there is no leakage control reaction under 3 ~ 3.5 Mpa pressure improves the preparation effect, shorten the reaction time of preparation.

 

3, the insert pipe, there is no preparation jams at the bottom of the kettle and aluminum powder into the problem.

 

4, due to the use of the differential transmission, cancel the high temperature multistage pump, save electricity, especially the liberated the bunkers, reduced the hard maintenance, saving the cost of expensive spare parts.

 

5, delivery to the reaction kettle due to no pump do not have to be cool, 260 ℃ delivery directly to the reaction kettle, save every kettle plus 100000 calories quantity of heat, save 2 hours of production time, improve the production capacity.

 

Using magnetic seal note:

 

1, magnetic kettle with seal, dynamic seal into static seal, need to be fully sealed structure, magnetic using rare earth structural steel, good stability, not easy demagnetization, long service life. But should pay attention to in the process of operation, the media stir the inner magnetic rotor of sleeve, together with factors such as eddy current, cause temperature rise of sleeve, generally in more than 200 ℃, can cause serious demagnetization, magnetic materials and failure. As a result, the jacketed cooling device is used on structure, to prevent water scale fouling and plugging in the waterway, generally using deionized water cooling, and have obvious overflow device, in case of water cost temperature magnetic.

 

2, magnetic drive agitator seal, has a pair of bearings on the coupling within the kettle, so must pay attention to the bearing lubrication (generally for the rolling bearing), at high temperatures using high temperature lubricating grease, and USES the high temperature corrosion of packing (generally adopt flexible graphite), to ensure the bearing lubrication, in general, maintenance inspection once every six months.

 

3, magnetic coupling in the process of installation, should avoid magnetic rotor so as to avoid damage to violent collisions with other metal parts of the magnetic rotor and influence the transmission torque.

 

4, the assembly when the note inside and outside magnetic rotor and isolation sets of concentricity, are not allowed to have contact with friction.

 

5, magnetic transmission is the constant torque transmission, therefore should not be in the start-up running overloaded, and should be starting under low load.

 

6, running in the isolation between the inner magnetic rotor and should be filled with medium and circulation, can rapid heating up, otherwise appear slippage phenomenon, should immediately stop, avoid magnetic energy into heat energy and disable magnetic rotor temperature and demagnetization.

 

Using magnetic sealing performance and obvious effect, simple operation, saving energy and reducing consumption, reduce the maintenance workload and work harder, minus the two sets of equipment and spare parts cost, won the production time, improve the ability of production equipment, to eliminate the leakage and reduce the material loss, ensure safety, large comprehensive benefits are obtained.

 

1, operation steps, such as reduced to start the pump on the operation more convenient and reliable.

 

2, can reduce two mechanic in the maintenance, save about forty thousand yuan a year.

 

3, save two sets of equipment and spare parts for repairs to save fifty thousand yuan each year.

 

4, save every kettle production time about two hours, improve production equipment capacity by about 10%.

 

5, reducing the loss of hydrogen gas leak, aniline, ensure the safety in production.

 

6, the equipment investment of 55000 yuan RMB, the investment can be returned for about three months, comprehensive benefit of about 30 RMB ten thousand per year.

 

Promotion and application

 

Kettle with mechanical seal price is high, frequent maintenance, the high maintenance cost and maintenance is difficult. Magnetic sealing reaction kettle and similar to my company's production process device can be widely used in the process, than the kettle with mechanical seal has great superiority, magnetic seal should be old chemical plant modification and new technology of choice for chemical plant.