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In general, there are usually four main factors that can cause the stainless steel reactor to stick to the wall. Understanding these issues is crucial for maintaining smooth and efficient production processes.
1. Raw Material Issues: One of the primary causes is related to the quality of the raw materials used. For instance, if the urea contains a high level of sulfate, adding it during the later stage of the polycondensation reaction can act like a curing agent, accelerating the crosslinking of the resin into a network structure. If this isn't addressed in time, the resin can solidify inside the reactor, leading to sticking. To prevent this, it's essential to use standard industrial-grade urea with sulfate content limited to 0.01% or less.
2. Operational Imbalance: Another common issue arises when the operating conditions are not well-controlled. Fluctuations in temperature, pressure, or other key process parameters can lead to uneven polycondensation reactions, increasing the risk of material sticking to the reactor walls. During operation, it's important to gradually increase pressure and temperature. A typical practice is to introduce steam at around 0.15 MPa for 2-3 minutes before slowly raising the pressure. The pressure should be increased at a rate of 0.1–0.15 MPa per minute to ensure stability.
3. Temperature Gradient Issues: A significant temperature difference between the reactor wall and the material inside can also contribute to sticking. This often happens when the cooling medium is too cold, causing a large temperature differential that leads to localized solidification or adhesion of the resin to the stainless steel surface. Maintaining consistent temperatures throughout the reactor is key to preventing this problem.
4. Reaction Conditions: The temperature and duration of the polycondensation reaction play a critical role as well. If the reaction temperature drops below 80°C and chlorination is used with ammonia as a catalyst, the reaction can proceed too quickly without an immediate pH change. As the temperature rises, the pH drops rapidly, which accelerates the reaction and may lead to gelation and sticking. Additionally, prolonged reaction times can result in higher molecular weight resins with increased viscosity, making them more prone to sticking. To avoid these issues, the reaction temperature should be carefully controlled, typically kept within 95°C, and the process should be stopped promptly once the desired degree of polymerization is achieved.
By addressing these four factors—raw material quality, operational stability, temperature control, and reaction timing—manufacturers can significantly reduce the risk of material sticking to the reactor walls, ensuring smoother and more reliable production outcomes.