Stirrer Failure in Reactor (fertilizer industry)

Issue reported with SAM GUARD®

•SAM GUARD® detected a problem with the stirrer in a reactor when the RPM value change from 37rpm to 21rpm. •The alert was generated on 04.09.21 and, although there was no change in motor behavior, the maximum rpm was not reached.

•The issue was very prominent and clear on SAM GUARD®  for the production engineers to take further action.


If the issue had been left undetected, the stirrer could have failed during a running batch process causing product quality issues for the entire batch due to uneven mixing and failed temperature regulation.


The plant engineers analyzed the alerts and told maintenance to check the stirrer.

It was found upon inspection that the disc on the stirrer was displaced.


Production loss and product loss was prevented.