Weixian Technology has improved ultra-large sulphonators (178-240 tubes) and achieved successful operation and wide deployment:   1.Screw Head: As shown in Fig.1, gaskets (Items 1–3) block SO₃, preventing rust or seizure between Tube plate 1 and the screw. Item 5 is a one-way gasket, needing under half the torque of imported equipment, significantly reducing tube plate 1 deformation.   （Fig 1:WEIXIAN Sulphonator head diagram） （Fig 2: Imported / Copy Sulphonator Head Diagram）   2. Increased Distribution Chamber Height: With the improved screw head sealing, the organic chamber height can be increased by 25% or more, minimizing the flow pressure difference between center and edge for uniform distribution, especially in ultra-large sulphonators with 178/192 tubes or more. Imported sulphonators, limited by the dual-direction gasket (Item 5, Fig.2), are fixed at 32 mm, causing higher pressure differences as size increases.   3. Pressurized Water Return: Improved screw head sealing increases clamping force on sealing ring (Item 9, Fig.1), allowing shell-side cooling water above 0.5 MPa and enabling pressurized water return, eliminating a high-power circulation pump. Imported design (Fig.2, Item 9) has a limiting block, restricting shell-side pressure to ≤0.15 MPa and preventing pressurized return.   Weixian Sulphonator Assembly and Disassembly Guidelines   (A) tube plate Removal Precautions 1.      Loosen screw heads (Item 4, Fig.1) after slightly loosening the pressure ring (Item 1), then remove all screw heads. 2.      Once screw heads are removed, tube plate 1’s reaction force is gone; central locating rods (1–3) can be lightly unscrewed and removed. 3.      Normally, tube plate 1 is removed every 1–2 years. To clean the feed chamber or nozzles, remove only the screws; debris can be vacuumed out. 4.      Screw head seals (Items 1–3) can be reused; no replacement needed every time.   (B) tube plate 1 and screw head Installation 1.      Position the tube plates 1 and 2 using the three locating tie rods per tube layout; tighten nuts. 2.      Install central rods (1–3) with a 400 mm (16”) torque wrench, max 80 kN, tightening evenly; do not use extra leverage. 3.      Tighten other tie rod bolts sequentially, finishing diagonally to avoid uneven stress and edge leaks. Check central rods lightly. 4.      Install screw heads: loosen pressure ring slightly, tighten screws with torque wrench (35–45 kN, click indicates correct), ensure even load, then tighten compression ring.   (C) Leak and Pressure Test 1.      Do not test shell-side leaks with screw heads loose; fully tighten tie rods and screw heads first. 2.      During LAB circulation, vent tube plate 1 chamber, check each screw’s PTFE gasket (Item 5) and ring with flashlight or dry paper; ensure no leaks.        

  1. The sealing type of compression nut on reactor tube sheet 1:  increasing one V type Teflon gasket and Fluororubber O ring to isolate the leakage of SO3 and organic acid, so that no rust or leakage happen. The reliability is better than Italy reactor.(as below photo No.1 and 2) 2. The No.3 of photo change to flat Teflon gasket(Italy is two way gasket): This will bring better seal performance and can reduce 50% force to tube sheet 1, so that the transformation would greatly reduced and the organic material would not leak into reactor tube. The reactor washing times and operation period is highly improved.   3. Compared with Italian reactor, the thickness of WEIXIAN tube sheet 1/2/3 is 16% more and organic material chamber is 25% higher, that can make the transformation of tube sheet close to zero and distribution of organic material becomes more equal, this makes big capacity reactor be possible.   4. The welding point between reactor tube and distributor move up to avoid reaction segment and change from butt welding to fillet welding, so that there is no welding joint in reactor tube inside, compared with Italy reactor, WEIXIAN will not have leakage in this part, the reliability improved greatly.   5. The size and angle optimation of reactor tube, distributor and nozzle, make sure the organic material pressure drop 13% more when passing through gap , so the self balance performance is improved accordingly compared with Italy reactor, especially for α-olefin sulfonation.   6. The special manufacture process of reactor tube (without polishing) ,that can make sure the rough degree of tube inside and outside and each tube are highly consistency( Ra0.4), so the dioxane content will significantly superior to Italy’s when produce SLES.   7. One Fluororubber O ring and three Teflon gaskets were adopted between shell side and tube side of tube sheet 3, so WEIXIAN reactor will never leakage, and the cooling water can recycle under 0.5mpa pressure(pressure test is under 0.6mpa)   8. The material of reactor tube, distributor and nozzle are all booked from Bao steel (The biggest and best steel factory in china) and we ordered at least 5 tons one batch, so that the material source can traceable and the quality can be guaranteed.   9. WEIXIAN engineer will full time supervise the testing and assemble of reactor and its components. That will guarantee the fabrication and manufacturing quality.   Equipment Link: https://www.njweixian.com/sulphonationsulphation-reactor