Prevention of Sludge Formation

[Budb]

Trying to get information or ideas on eliminating, reducing, and/or handling sludges formed in 1000 gal. chemical reactors and piping. The chemicals are diispropylcarbamide (DIC) and/or dicyclohexylcarbamide stabilized phosphorous compounds (similar to pesticides) being hydrolyzed with a mixture of water and NaOH at ~ 170 degrees F. The mixture is constantly stirred at a high shear rate, and at times seems to be an emulsion, but isn't. For additional shear the equipment contains staic mixing elements in the recirculation loop. It appears that a urea containg substance forms as a separate phase, coats the vessel inside surface, then collects at the bottom of the reactor as a sludge. Thank you.