Solid feeding device for reaction kettle: from unpacking and transportation to monitoring and maintenance

Solid feeding device for reaction kettleIt is an integrated system that integrates storage, transportation, metering, sealing, dust removal, and control, mainly consisting of the following modules:

Storage unit: ton bag unpacking machine, silo, small bag unpacking machine, etc., suitable for ton bag, 25/50kg small bag or bulk material storage, some equipped with pre crushing/screening devices to process agglomerated materials.

Conveyor system: screw conveyor (short distance high viscosity material), vacuum feeder (negative pressure suction, conveying distance 30m/vertical 15m), pneumatic conveying (long-distance conveying, dust capture efficiency>99.9%), as well as vibrating feeder, belt conveyor, etc.

Measurement module: high-precision weighing sensor (accuracy ± 0.1% F.S.), weight loss measuring chamber, twin-screw feeder (anti caking), supporting dynamic error compensation and batch recording (compliant with GMP/FDA requirements).

Sealing and dust removal: Pulse bag filter (emission concentration ≤ 1mg/m ³), sealing cover/glove box (to prevent dust leakage), mechanical/packing/magnetic seal (suitable for different pressure conditions).

Control system: PLC/DCS (Siemens, ABB, etc.) integrated formula management, real-time monitoring (temperature/pressure/flow), fault alarm and remote diagnosis, supporting integration with MES/ERP systems.

The complete process steps of the solid feeding device for the reaction kettle

1. Preliminary preparation and safety inspection

Material inspection: Confirm that the type, purity, and particle size of the material meet the process requirements, and there are no lumps/impurities; Moisture absorbing materials need to be pre dried, and static sensitive materials need to be grounded (resistance ≤ 4 Ω).

Equipment inspection: The sealing gasket/filter bag is intact, the conveying pipeline is unobstructed, the explosion-proof motor (ExdIIBT4) and electrostatic protection device are effective, and the nitrogen inerting system (for flammable materials) is operating normally.

Operation protection: Wear dust masks, goggles, anti-static clothing, clean up debris in the feeding area, and ensure smooth emergency access.

2. Unpacking and transportation start-up

Ton bag unpacking: The ton bag is cut by an automatic unpacking machine, and the material falls into the vacuum feeder or screw conveyor; Manual unpacking should be carried out in a dust-free feeding station to avoid dust dispersion.

Transportation process: The material is transported to the measuring bin through a sealed pipeline, and the pneumatic conveying system generates negative pressure through a Roots blower to ensure continuous and stable transportation of the material; The screw conveyor pushes materials through rotating blades and is suitable for high viscosity or easily clumped materials.

3. Accurate measurement and feeding control

The measuring system monitors the weight of materials in real time through weighing sensors, and the PLC adjusts the conveying rate according to preset parameters (such as feeding amount and speed), with an error controlled within ± 0.1% - ± 0.5%; The weightless measuring chamber eliminates vibration/temperature interference through dynamic compensation algorithms.

When feeding, the material enters the reaction vessel through a double ball valve and butterfly valve seal to prevent dust leakage; For multi-component feeding, the system supports multi formula management and automatically switches the feeding sequence and proportion.

4. Sealing and environmental protection treatment

During the feeding process, the dust removal system continues to operate, and the pulse bag filter collects the scattered dust, with emission concentrations in compliance with OSHA/GB16297 standards; The sealing cover/glove box ensures negative pressure (≥ -5kPa) in the operating area to prevent dust from escaping.

After the feeding is completed, the system automatically cleans the pipeline (CIP/SIP system) to prevent cross contamination; Waste bags should be disposed of according to solid waste regulations, and wet mop (high-pressure water gun is prohibited) should be used for on-site cleaning to ensure no residue.

5. Monitoring and maintenance

Real time monitoring of equipment status by the control system (such as motor current, temperature, vibration), triggering alarms and automatic shutdown in case of abnormalities; Regular maintenance includes filter bag cleaning, sensor calibration, lubricant replenishment, and seal replacement.

For flammable and explosive materials, the system is equipped with overload protection, pressure monitoring, and explosion-proof facilities; Before long-term shutdown, a comprehensive inspection is required to update aging components and record maintenance records.