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 BeAutomatically Cleaned

Selecting the Right EquipmentAutomated 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 removeresidue 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 shortercycle 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 forceby: – 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 removeresidue 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 proneto 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 residue

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 residue• 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 residue• 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 residue• 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 residue• 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?