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reactorgb [2026/03/20 16:07] – [Replacement of the reactor loading] administratorreactorgb [2026/03/24 17:57] (aktuell) – [Replacement of the reactor loading] administrator
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 To detach the cable first remove the cover by loosening the two screws ({{ref>cable_a}}, red arrows). Now you can see the two powerlines (blue and brown) connected to the heater element and the ground (yellowgreen) connected to the reactor housing ({{ref>cable_b}}). These unprotected contacts are the main reason why you disconnect the entire system from the power grid. To remove the cable unscrew the washers so the entire contact housing can be detached ({{ref>cable_c}}). To detach the cable first remove the cover by loosening the two screws ({{ref>cable_a}}, red arrows). Now you can see the two powerlines (blue and brown) connected to the heater element and the ground (yellowgreen) connected to the reactor housing ({{ref>cable_b}}). These unprotected contacts are the main reason why you disconnect the entire system from the power grid. To remove the cable unscrew the washers so the entire contact housing can be detached ({{ref>cable_c}}).
 +
 +<figure center|fumehood>
 +<subfigure|fumehood_a>
 +{{:wartung:kat:20260202_161521.jpg?direct&200 |title}}
 +<caption></caption>
 +</subfigure>
 +<subfigure|mask>
 +{{:wartung:kat:20260202_161556.jpg?direct&200 | title}}
 +<caption></caption>
 +</subfigure>
 +<caption>The reactor inside a fume hood (left) and respiratory protection gear (right).</caption>
 +</figure>
 +
 +The dust created by pouring out the reactor loading is harmful so the reactor needs to be moved to a well ventilated area, preferably a fume hood or outside ({{ref>fumehood_a}}). Additionally wear respiratory protection gear (e. g. FFP2 mask, {{ref>mask}}). **Important:** Provide a heat resistant container to pour the reactor loading into (e. g. metal container / buckets, {{ref>fumehood_a}}). Never dispose of it directly into the trash because the will be a fire hazard! Depending on the residual activity the reactor loading can generate quite a lot of heat when in contact with air. Thus the usage of a metal container.
 +
 +<figure center|pour>
 +<subfigure|pour_a>
 +{{:wartung:kat:20260202_162240.jpg?direct&200 |pour_a}}
 +<caption></caption>
 +</subfigure>
 +<subfigure| pour_b>
 +{{:wartung:kat:20260202_162244.jpg?direct&200 | pour_b}}
 +<caption></caption>
 +</subfigure>
 +<subfigure|pour_c>
 +{{:wartung:kat:20260202_162249.jpg?direct&200 | pour_c}}
 +<caption></caption>
 +</subfigure>
 +<caption>Pouring out the reactor loading.</caption>
 +</figure>
 +
 +Remove the meshed sealing rings ({{ref>pour_a}}) from the flanges of the reactor ({{ref>pour_b}}) and empty it into the container ({{ref>pour_c}}). The black pellets are the copper-based catalyst while the white ones are molecular sieves. For reasons mentioned before leave the old reactor loading to sit for a few days before you dispose of it.
 +
 +<figure center|refill>
 +<subfigure|refill_a>
 +{{:wartung:kat:20260202_162652.jpg?direct&200 |pour_a}}
 +<caption></caption>
 +</subfigure>
 +<subfigure| refill_b>
 +{{:wartung:kat:20260202_162742.jpg?direct&200 | pour_b}}
 +<caption></caption>
 +</subfigure>
 +<subfigure|refill_c>
 +{{:wartung:kat:20260202_162319.jpg?direct&200 | pour_c}}
 +<caption></caption>
 +</subfigure>
 +<caption>Replacement of the loading.</caption>
 +</figure>
 +
 +After this prepare the new reactor loading. Usually the manufacturers of the boxes will provide refill sets for your specific systems ({{ref>refill_a}}). In this case there are two bags of molecular sieves, one bag of catalyst and two rubber gaskets for the meshed sealing rings ({{ref>refill_b}}). Replace the gaskets. To refill the reactor a suitable funnel is needed. For this purpose I 3D-printed a funnel with a KF40 flange which can be directly mounted onto the reactor ({{ref>refill_c}}). The model is provided [[https://www.thingiverse.com/thing:7319176|here (external link)]]. Mount the funnel on the same flange where the old loading came out. Refill the reactor in a specific order: First a bag of molecular sieves, then the bag with the catalyst and lastly the second bag with molecular sieves. The reason for this order is that the catalyst would be packed between the molecular sieves and therefore additionally protected. Now that the loading is replaced everything needs to be put together in reversed order.