Fault Cause Analysis and Corresponding Solutions for Far-Infrared Reactors

I. Fault Phenomenon: Shell Damage (Corrosion, Cracks, Perforation)

1. Attack by process media (crevice corrosion, intergranular corrosion);
2. Cracks or caustic embrittlement induced by internal stress;
3. Thinning due to abrasion or uniform corrosion.

1. For shells lined with corrosion-resistant materials, re-line or carry out partial welding repair;
2. Relieve stress after welding; repair cracks once found;
3. Replace the shell if its thickness is below the minimum allowable design thickness.

II. Fault Phenomenon: Overheating and Overpressure

1. Instrument failure and inadequate control;
2. Operational error or improper material proportioning, resulting in violent reaction;
3. Adverse side reactions caused by poor heat transfer or stirring performance;
4. Bypass valve failure and excessive inlet pressure.

1. Inspect and restore the automatic control system; strictly follow safety operating procedures;
2. Implement emergency pressure relief in accordance with operating specifications, feed materials quantitatively and on schedule, and strictly prevent misoperation;
3. Increase heat transfer area or remove scale deposits to improve heat transfer effect; restore the agitator and enhance stirring efficiency;
4. Close the main steam valve and cut off steam for valve maintenance.