Automated Tank Cleaning Myth or Fact - Tankjet

subduedlockMechanics

Nov 5, 2013 (3 years and 11 months ago)

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Automated Tank
Cleaning…

Myth or Fact?

Non
-
Automated Tank Cleaning


Manual Cleaning


Worker safety issues


Time (is money)


Repeatability



Fill & Drain


Large volumes of water/cleaning solution


Sometimes must be heated


Slow


Repeatability



Fully Automated CIP


Completely automated system


Multiple cycles


Spray nozzle or tank cleaning
device


Portable Systems


Simple components


Pump /fluid delivery system


Spray nozzle or tank cleaning
device


Mobile

Automated Tank Cleaning


My tanks are too big (or too small)

for an automated solution”


Myth or Fact?

Tanks of All Sizes Can Be

Automatically Cleaned

Selecting the Right Equipment

Automated Units for Cleaning Tanks with Dia.
Ranging from 2’ to 100’ are Available

High
-
Impact Tank Cleaners
for Tanks Up to 100’ in Dia.

Medium
-
Impact Tank
Cleaners for Tanks Up to

60’ in Dia.

Low
-
Impact Tank Cleaners &
Nozzles for Tanks Up to 25’
in Dia.

Tank Cleaning Nozzles for Rinsing
Tanks with Dia. From 2’ to 16’

“My tanks are too big (or too small)

for an automated solution


Myth or Fact?

“Automated cleaning

won’t really get my tanks clean


Myth or Fact?


Important Selection Criteria


Correct throw distance


Proper impact


Lowest possible flow


Right spray pattern


Complete coverage

of desired surfaces


Repeatability


Proper Specification Ensures Effective
Cleaning

TankJet AA190 Video


AA190 video


“Automated cleaning

won’t really get my tanks clean




Myth or Fact?

“I can’t automate due

to obstructions in my tank”


Myth or Fact?

Preventing “Shadowing”


Account for Internal Obstructions


Carefully select position


Consider multiple units


Use deflected sprays


Other manageable restrictions


Size or location of access ports


Unusual tank shape


Extremely tall or long tanks



I can’t automate due

to obstructions in my tank”



Myth or Fact?

“I’ll still need hot water to remove

residue even with an automated

tank cleaner”


Myth or Fact?

Balancing the Factors Affecting

Cleaning Effectiveness


Decreases the bond between

soil and surface


Decreases soil viscosity


Increases soil solubility


Increases chemical reaction


rate (may allow for shorter


cycle time)


High Temperature


Duration that cleaning solution is
in contact with equipment surface


Factors that influence duration


Chemical concentration


correct
type of cleaner for soil removal


Impact force


Water pressure


Flow rate


Nozzle selection


Temperature
-

to maximize reaction
rate of cleaning solution

Cleaning Time


Varies based on chemical selected,
type of soil and surface to be
cleaned


Concentration normally reduced as
time and temperature increase


Lower concentration means less
chemical is used and cost is reduced

Chemical Concentration


Increasing spray impact

may allow decreases in


Temperature


Chemical concentration


Time


Double spray impact force


by:


Doubling liquid flow rate


Quadrupling liquid pressure


Increasing impact instead of temperature can save thousands
by decreasing energy costs


Spray Impact


An Alternative to High
Temperatures

“I’ll still need hot water to remove

residue even with an automated

tank cleaner”


Myth or Fact?

“The residue in my tank is prone


to sparking so automation is out

of the question”


Myth or Fact?

Tank Cleaning in Explosive Environments


Read the owners manual


Be sure the unit is grounded


Use chemicals compatible with the
unit’s materials of construction


Use explosion
-
proof motors


“The residue in my tank is prone

to sparking so automation is out

of the question”




Myth or Fact?

“I won’t be able to verify that

my tanks are completely clean”


Myth or Fact?


Acoustic sensors can be installed on
tank exterior to detect


Rotation failure


Changes in rotation frequency


Changes in spray pressure


Clogged nozzles


Audible / visual alarms notify
operators when change detected


Swab tests also possible





Monitoring Devices Verify Cleaning

“I won’t be able to verify that

my tanks are completely clean”

Myth or Fact?

“The payback on automated

tank cleaning is too long”


Myth or Fact?


$

Water + energy to heat water


$

Chemicals


$

Labor


$

Disposal


$

Lost Production Time


$

Re
-
cleaning Tanks


$

Scrap Product


=

True cost



The true cost of manual or fill

and drain methods

The Payback for Automated

Tank Cleaning


Cleaner tank


Shorter cycle time


Lower energy costs


Reduced chemical usage


Lower labor costs


Improved worker safety

Payback Example


Chemical Processor


Situation


3200 gallon reactors needed cleaning after every
batch


CIP system failed to clean effectively at 1000 psi


Manual cleaning was required
after

automated
cleaning to ensure cleaning


This combination was expensive, time consuming

and dangerous



Solution


High pressure rotary tank cleaning

nozzle used, operating at 1800 psi


Pneumatic insertion/

retractable device eliminated

any need for personnel to enter

tank


Result


Cleaning time reduced from 2 hrs to 10 min


Additional production time paid for equipment in
just a few months



Payback Example


Chemical Processor

“The payback on automated

tank cleaning is too long”

Myth or Fact?

I can’t automate because…


My tanks are too big (or small)

I can’t automate because…


My tanks are too big (or small)


My tanks won’t get clean

I can’t automate because…


My tanks are too big (or small)


My tanks won’t get clean


I’ve got obstructions in my tank




I can’t automate because…


My tanks are too big (or small)


My tanks won’t get clean


I’ve got obstructions in my tank


I’ll still need hot water to remove re
sidue



I can’t automate because…


My tanks are too big (or small)


My tanks won’t get clean


I’ve got obstructions in my tank


I’ll still need hot water to remove re
sidue


The residue in my tank is prone to sparking



I can’t automate because…


My tanks are too big (or small)


My tanks won’t get clean


I’ve got obstructions in my tank


I’ll still need hot water to remove re
sidue


The residue in my tank is prone to sparking


I won’t be able to verify my tanks are clean



I can’t automate because…


My tanks are too big (or small)


My tanks won’t get clean


I’ve got obstructions in my tank


I’ll still need hot water to remove re
sidue


The residue in my tank is prone to sparking


I won’t be able to verify my tanks are clean


The payback is too long


I can’t automate because…


My tanks are too big (or small)


My tanks won’t get clean


I’ve got obstructions in my tank


I’ll still need hot water to remove re
sidue


The residue in my tank is prone to sparking


I won’t be able to verify my tanks are clean


The payback is too long


FINAL SCORE: 6 “myths”, 1 “maybe”

Questions?