What are the reasons for slow reaction in a single-reactor system?
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This post was last edited by fdhg on 2016-2-24 at 20:32. One of the reactor vessels in our production line operates very slowly; even with 10% more initiator added compared to the other vessels, its reaction speed remains low. Please offer some advice, experts. It has been confirmed that the terminator from other reactors was not added to this reactor.
Is it the case that this polymerization reactor has a slow reaction rate, or are many reactors like this? What size are your polymerization reactors, and is the amount of monomer added different from that in other reactors? Is there any difference in the control of the kettle temperature for circulating water? Is it still overheating and overpressure in the polymerization reactor? When the polymerization reactor starts reacting, are its temperature and pressure curves consistent with those of the other reactors?
OP, please upload the reaction curve of this reactor along with those of other reactors for comparison!
For several months now, Reactor 70 has shown slow reaction rates; the amount of monomer added is the same as in other reactors, and the temperature, pressure, and reaction curves are all normal. The reason for the slow reaction is that the volume of water used in the reaction cycle is low.
Slow reaction rate and low circulation water volume indicate that not much heat is released during the reaction. Even with an increased amount of initiator, the reaction remains slow. This indicates that the initiator has been consumed or leaked! If there is a leak, check whether the associated valves are leaking internally; if it has been consumed, check whether other additives that can consume the initiator have reacted with it!
Is this polymerization reactor located at the front or the back? Also, disconnect the initiator pipeline of the reactor and connect it to the tank using a hose (calculate the required amount in advance); set up a separate program to inject the initiator once, and then weigh it to see if it corresponds to the actual value； Next, analyze whether the reactive oxygen species generated by the initiator are at the expected concentration, and then identify the cause.
Perhaps no overall distribution station was set up for the pipe used to add the initiator; as a result, the initiator added to this reactor remained in the pipes leading to other reactors, or insufficient flushing occurred during addition, which led to an amount of initiator actually added to this reactor that was less than that in the other reactors.
Check whether the terminator control valve has internal leakage
Check whether the terminator control valve has internal leakage
If only this one unit is slow while the others are working normally, insufficient initiator dosage is not considered a possible cause. If the water flow rate is low but the reaction time remains the same, consider a leak in the circulating water control valve