The mobile reactor cleaning machine is a compact, highly flexible, and portable device capable of deep cleaning. Its operating principle is to utilize a high-pressure pump to generate high-pressure water, coupled with the combined motion of a three-dimensional rotating nozzle and a telescopic rod, to achieve 360° cleaning of the reactor. This equipment completely resolves the issues of existing cleaning methods, such as low automation, time-consuming and labor-intensive processes, and the risk of personal injury.
Design Requirements
Because reactors are closed vessels equipped with internal agitators, automated three-dimensional high-pressure water cleaning is increasingly being adopted to improve cleaning quality and efficiency, replacing manual and chemical cleaning. However, due to limitations in the reactor's building height, reactor layout, and the diverse cleaning equipment, installing a suspended three-dimensional cleaning system is not feasible. Manual cleaning is the only option, which is time-consuming and ineffective.
To address the cleaning challenges associated with the reactor layout, STD developed a mobile automated reactor cleaning trolley. This system incorporates a high-pressure water three-dimensional cleaning machine mounted on a mobile lift. This single trolley can clean reactors at varying heights. The self-propelled trolley is controlled by a remote control. This mobile design eliminates the need for individual reactor cleaning equipment, significantly reducing costs.
Difficulties
Because the interior of the reactor has various complex structures such as the stirring shaft, achieving dead-angle cleaning has always been a difficult problem in the industry.
The interior of a reactor, with its complex structures, including agitator shafts, has always been a particularly challenging task in the industry. Manual cleaning has numerous drawbacks, making it difficult to achieve satisfactory cleaning results. Firstly, manual cleaning requires access to the reactor and the use of handheld tools, which is not only labor-intensive and time-consuming, but also creates an extremely harsh working environment. Secondly, due to various production processes, toxic or harmful gases may exist inside the reactor, which can be harmful to the human body. Even with cleaning fluids, this can still have some adverse effects. Furthermore, the interior of a reactor can be a flammable and explosive working environment, making manual cleaning highly dangerous. Furthermore, since cleaning relies on manual operation, cleaning results are significantly affected by human factors. Every year, there are reports of injuries and fatalities related to manual cleaning. This not only negatively impacts a company's social image but also poses significant safety risks. Furthermore, reactors are typically equipped with agitator shafts, impellers, coils, reinforcing ribs, and other heterogeneous components, further complicating manual cleaning. Furthermore, some materials within the reactor can easily dry and form a film, making cleaning difficult. Therefore, choosing the right time to clean after emptying the reactor is crucial.
In response to the shortcomings of existing technologies, STD has independently developed and put into use a series of automatic reactor cleaning solutions, including: hoisting automatic cleaning devices, mobile reactor automatic cleaning devices, etc. Among them, the ARM-W500EA-800EX mobile reactor automatic cleaning machine is simple and easy to operate. It is suitable for reactor working scenarios where hoisting automatic cleaning devices cannot be installed. It can achieve 360° cleaning of the inside of the reactor without dead angles, without excessive manual intervention, and the cleaning is thorough and convenient, saving time and effort.
Working Principle
This system features one-touch operation and a high degree of automation. This automated reactor cleaning system can clean difficult-to-clean areas of the reactor, such as the back, bottom, and upper head of the agitator shaft. Using a high-pressure, three-dimensional cleaning nozzle, it sprays high-pressure water jets to achieve this cleaning. Typically, two to four cleaning points are set on the agitator shaft (configurable and adjustable). After cleaning one side of the agitator shaft, the hose reel returns to its starting point and swings to the other side of the shaft. The cleaning process is similar to the left. Depending on the specific cleaning point, the reel automatically cleans the reactor. The cleaning time for each cleaning point can be set as needed.
Because reactors often contain various components such as the agitator shaft, impellers, and coils, targeted cleaning is essential to ensure seamless cleaning.
The mobile reactor high-pressure cleaning system activates the high-pressure pump at the designated cleaning point, using the high-pressure, rotating three-dimensional cleaning nozzle. Cleaning begins at the first cleaning point. For typical reactors, four to six cleaning points are typically targeted (the number of points can be adjusted via the PLC to accommodate different reactor types).
Cleaning
Mobile Reactor Cleaning Machines: Manual and Chemical Cleaning
Manual cleaning involves working in confined spaces and toxic gases are present within the reactor, making it difficult to operate for extended periods. This poses significant safety risks and results in low cleaning efficiency. Chemical cleaning, however, can easily cause varying degrees of corrosion to metal equipment, and the resulting cleaning solution is difficult to handle, which is environmentally unfriendly. When the physical and chemical materials within the reactor reach a certain hardness and thickness, manual and chemical cleaning are generally inefficient and yield suboptimal cleaning results. For years, industrial enterprises across various sectors have been deeply influenced by traditional reactor cleaning methods.
When preparing for cleaning operations, thorough inspection is essential. Prior to cleaning, ensure that all components of the mobile reactor cleaning machine are functioning properly. Carefully inspect key areas such as the nozzle, cleaning arm, and high-pressure pump to avoid malfunctions during the cleaning process. If necessary, select the appropriate chemical cleaning agent based on the nature of the residue within the reactor. Acidic or alkaline cleaning agents are generally suitable for removing grease, polymer residue, and other residues. When starting a cleaning operation, first set the parameters: appropriate water pressure, flow rate, and cleaning time based on the level of contamination within the reactor. High-pressure water jets are often used to remove stubborn dirt. Next, adjust the nozzle angle and rotation speed to ensure coverage throughout the reactor, avoiding blind spots. The cleaning process is then divided into multiple stages: pre-rinse, main wash, rinse, and disinfection. Each stage should be optimized based on the specific situation. For difficult-to-clean residues, consider using a circulating cleaning method, where the cleaning agent is repeatedly circulated within the reactor until the dirt is completely removed. Regarding cleaning techniques, choosing a highly effective cleaning agent based on the nature of the contaminants can significantly improve cleaning efficiency. High-pressure water jets should be used appropriately; appropriate water pressure can remove stubborn dirt, but excessive pressure should be avoided, as it can damage the reactor. Furthermore, regular inspection and maintenance of the cleaning equipment is essential to ensure optimal working condition and extend its service life.
Automatic reactor cleaning machines are compact, small, easy to move, and highly flexible, making them suitable for use in space-constrained environments. They can also be designed to explosion-proof standards according to customer requirements, ensuring safety and reliability, suitable for use in explosion-proof environments. Suitable for regular or irregular cleaning of reactors (residual materials such as styrene-butadiene latex, nitrile rubber, acrylic emulsion, construction adhesive, carpet adhesive, etc.). The mobile automatic reactor cleaning machine features a compact structure, small size, easy mobility, and high flexibility, making it suitable for use in space-constrained environments. Its multi-point positioning mechanism allows for multi-point positioning not only in the reactor's depth but also in its radial direction. One-touch operation provides a high degree of automation. A program can be set for each reactor size, allowing cleaning of different reactor models by simply selecting the appropriate cleaning program. This one-touch operation significantly reduces cleaning time.
