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Detect, Measure, Analyze.
Thank You for Attending Today’s Webinar:
Your HostJohn GreivellVP OperationsRAECO-LIC [email protected]
Featured SpeakerPhil KoppenhoferBusiness Development ManagerAlfa [email protected]
Follow the Conversation LIVE @RAECOLIC #RAECOWebinar
Tank Cleaning 101
Optimized tank cleaning
elevates the bottom line
How to clean tanks and confined spaces quickly
and safely, using fewer resources
Phil Koppenhofer, Business Development Manager
www.alfalaval.com© Alfa Laval Slide 2
Today’s topics
Why should optimized tank cleaning be important to you?
Types of tanks and confined spaces
Understanding your true cleaning process
The four factors of cleaning
Common tank cleaning methods, pros and cons
Developing an engineered tank cleaning solution
Benefits of optimized tank cleaning
Real-life case studies
Q & A with our experts Elevate your
bottom line
through tank
cleaning
www.alfalaval.com© Alfa Laval Slide 3
Why should tank cleaning be important to you?
Production & uptime:
Increase uptime by
reducing time spent
cleaning
Health & safety
Eliminate confined
space entry for manual
cleaning
Costs & efficiency:
Clean faster and
better, using fewer
natural resources
Product quality: Avoid
contamination and product
recalls
www.alfalaval.com
Types of tanks and enclosed spaces
© Alfa Laval Slide 4
OTRs
Mash tanks
Spray dryers
400 bbl tanks
Tankers
Wet wells
ISO containers
Kegs
White water chests
Crude carriers
Lift stations
Hot wort receivers
Trailers
Smoke stacks
Tablet coaters
Overflow/surge tanks
Evaporators
Drums
Fryers
Aerators
Malt facilities
Kettles
Mixers
Reactors
Cutting boxes
Wet bulk trailers
Balance tanks
Cheese vats
ISO tanks
Fuel storage tanks
Black liquor chests
DEF tank systems
Silos
MPTs
Dryers
Refineries
Process tanks
Schoene tanks
Stock chests
Manholes
Ribbon blenders
Fluid-bed systems
Exhaust stacks
Collection tanks
Yeast tanks
Machine pits
Broke chests
Fermenters
Blenders
USTs
Frac tanks
Mud tanks
ASTs
Letdown tanks
Totes/IBCs
Portable restrooms
Railcars
Holding tanks
Cookers
Storage tanks
Dry bulk trailers
Barrels
…and many more
www.alfalaval.com© Alfa Laval Slide 5
Ask yourself:
What is your real cleaning process?
Cleaning with the wrong type of device for the application causes
plants to modify methods over time.
Problem products of long-term build-ups:
Manual hose pre-rinse
Extended wash cycles
Additional rinses
Wash failures
Custom-drilled SSB
Post-wash checkup or spot clean
Corrective actions use more cleaning time and labor, which increases costs.
www.alfalaval.com© Alfa Laval Slide 6
Four factors of cleaning
Primary cleaning factors Time
Chemical action
Temperature
Mechanical force
www.alfalaval.com© Alfa Laval Slide 7
Common tank cleaning methods
Boiling out/fill and drain
The process of filling a tank or vessel
with a concentrated chemical solution
then heating the tank to remove
residues.
Time: High
Chemical Action: High
Temperature: High
Mechanical Force: Low
Operating Costs: High
www.alfalaval.com© Alfa Laval Slide 8
Common tank cleaning methods
Manual cleaning
The process of entering the tank and
manually cleaning with a hose,
pressure washer or scrub brush. This
includes a pre-rinse spray down, spot
cleaning, and post wash checkup with
a person entering a tank.
Time: High/Varies
Chemical Action: Low
Temperature: Low
Mechanical Force: High
Operating Costs: High (labor)
www.alfalaval.com© Alfa Laval Slide 9
Common tank cleaning methods
Manual cleaning
problems
Regulations
Cost of labor
Human error
Can never guarantee reliable,
consistent results
Worker safety
Risk of injury by falling
Inhalation of hazardous fumes
www.alfalaval.com© Alfa Laval Slide 10
Common tank cleaning methods
Static spray balls
Static spray balls are designed to
create a “liquid sheet” that erodes
residue while cascading the walls of
the tank interior with chemical cleaning
agents.
Time: High
Chemical Action: High
Temperature: Varies
Mechanical Force: Low
Operating Costs: High
www.alfalaval.com© Alfa Laval Slide 11
Static spray ball
Cleaning methods:
Cleans in spots (small
footprint)
Cascading flow
(Undeveloped falling film)
Pressure:
25 PSI
Benefits:
Low cost
Ideal for easy-to-clean
residues
Photo taken at very low PSI
www.alfalaval.com
ASME BPE-2014 Guideline for
Static Sprayball Usage
2.5 -3.0 GPM X
Circumference of
Tank/Vessel
Not recommended for
vessels above 8-10 ft in
diameter
Recommended flow rate increased quickly as the tank diameter
increases.
www.alfalaval.com© Alfa Laval Slide 13
Common tank cleaning methods
Rotary sprayheads
Cleaning methods: Revolving flat fan spray effect
Repeated moderate impact
Penetrates films
Dislodges soils
Water consumption: Medium (70%)
Mechanical impact: Medium
Pressure: 15 to 40 PSI
www.alfalaval.com© Alfa Laval Slide 14
Rotary spray heads
The flow of cleaning media causes the
head of the spray head to rotate on a
liquid film with fans of water laid out in a
swirling pattern on the entire perimeter
within the spray pattern.
This generates a vibrating impact in the
impact zone and a dynamic cascading
flow that covers all internal surfaces of the
tank, vessel or reactor. Fully developed falling film
www.alfalaval.com© Alfa Laval Slide 15
Simple customer conversion No need to change fittings, pressure, or flow
Installs easily on existing sanitary tube fittings
www.alfalaval.com
ASME BPE-2014 Guideline for
Rotary Sprayball Usage
1.9 - 2.3 GPM X
circumference of
tank/vessel
Not recommended for
vessels above 8-10 ft in
diameter
Recommended flow rate increased quickly as the tank diameter
increases.
www.alfalaval.com© Alfa Laval Slide 17
Common tank cleaning methods
Rotary impingement device:
An automated, fluid-driven device that optimizes the
pressure and flow to create high impact cleaning jets
producing mechanical force
IMPINGEMENT
www.alfalaval.com
Rotary impingement tank cleaning
© Alfa Laval Slide 18
1 cycle 2 cycles 8 cycles
Full pattern
Combines pressure and flow to create high impact cleaning jets
Impact and resulting tangential force blast contaminants from the surface
Devices rotate in a repeatable, reliable 360 degree pattern for whole tank coverage
Impact is a one-time investment, whereas chemicals, temperature, water, and time are continual expenditures
www.alfalaval.com© Alfa Laval Slide 19
Maximum savings with
rotary impingement Time: Reduces cleaning times
by 90%
Chemical Action: Savings up
to 75%
Mechanical Force: High
Pressure: 30-800+ PSI
Water consumption:
30-160 GPM
Water and wash fluid
savings up to 90%
Tangential
force
demonstration
www.alfalaval.com
IMPACT: Mass at a Velocity
Normal and Sheer Force
Theoretical Impact = 0.0526 x (GPM) x √(PSI)
20
Notice that the equation uses the square root
of the pressure. For this reason doubling the
pressure will not double the impact at the
same flow rate. If you double the flow rate
and maintain the same pressure, the impact
will double.
www.alfalaval.com
ASME BPE-2014 Guideline for
Rotary Jet Head Usage
1.3 – 1.5 GPM X
circumference of
tank/vessel
Can easily clean up to
100+ ft in diameter.
50+% water savings are
possible
www.alfalaval.com
When rotary impingement is
NOT the best choice:
Easy-to-clean residues
Wash fluid usage is not an issue
Appropriate pressure not available
Budgetary constraints/ROI payback > 2 years
© Alfa Laval Slide 22
www.alfalaval.com
Developing an engineered solution
Industrial or Sanitary design
Industrial design: Often grease-lubricated for optimal
running time, designed to handle the toughest
environments
Sanitary design: Self-lubricating, self-flushing, self-
cleaning, made of FDA-compliant materials
Type of tank residue
Chemicals
Powder
Sludge
© Alfa Laval Slide 23
Liquid
Food
Lotion
Gel
www.alfalaval.com
Developing an engineered solution
Tank size and dimensions
2.5 – 100’ radius tanks (.76 – 30.5 m)
Tank opening
Range includes machines that can fit
through a 2” opening and larger
© Alfa Laval Slide 24
www.alfalaval.com
Developing an engineered solution
Wash fluid
Water, caustic, solvent, diesel
Available pressure and flow
29 – 1000 psi (2 – 69 bar)
3 GPM – 160 GPM
© Alfa Laval Slide 25
www.alfalaval.com
Developing an engineered solution
Obstructions
Mixers and agitators
© Alfa Laval Slide 26
Hi
land
sea
Tank configuration
Downward directional devices
www.alfalaval.com
Completing the engineered solution
How can I tell if my tank is
being cleaned?
Store time and pressure data,
automatically calculate cleaning process
feedback
Light indication integrated into the field
housing offering the visual feedback to
operators and maintenance staff on-site
Perfect solution for verifying your tank
cleaning device is working at maximum
capacity
3-A 74-05 and EHEDG compliant
© Alfa Laval Slide 27
www.alfalaval.com
Results of optimized tank cleaning
Cleaning standard
Repeatable, reliable results
Volume of water, waste and detergents
Flow can be reduced by +50%
Consumption of water can be reduced by 75%
Consumption of detergent can be reduced by 75%
Time
Cleaning times can be reduced by +50%
Allows for more production
Safety
Eliminate manual cleaning
© Alfa Laval Slide 28
Less than
1 year
payback
www.alfalaval.com
Case Study: Money in the Bank
Situation: At a Georgia chemical company, totes are
used for shipping finished goods and receiving the
company’s raw materials.
Problem: Outsourcing cleaning was expensive and
in-house manual cleaning was ineffective and
time-consuming.
Solution: Alfa Laval GJ Tote Blast Station with a
GJ 9 tank cleaning device
Results: The company brought entire tote cleaning process in-house, completely eliminating costs of
outsourcing
Device cleans their totes 40-60% faster than manual cleaning
The totes are 100% clean, every time
The AL GJ Tote Blast Station with AL GJ 9 paid for itself in six weeks
© Alfa Laval Slide 29
www.alfalaval.com© Alfa Laval Slide 30
Situation: A chemical manufacturer has large tanks with agitators mixing batch chemicals on
a daily basis.
Tank Cleaning Process: Running static spray balls for an hour plus everyday, plus manual
tank entry for secondary cleaning
Problem: A ‘near miss’ situation occurred
Solution: The company purchased a rotary impingement tank cleaning device from Alfa
Laval.
Results:
Manual tank cleaning eliminated
Added Bonuses! Tank cleaning times were reduced by 73%
Wash fluid usage was reduced by 82%
Case Study:
A Near Miss Sparks Change
www.alfalaval.com
Case Study:
A Need for Speed
© Alfa Laval Slide 31
Situation: A water-based adhesives manufacturer needs to increase production to meet market
demands
Tank Cleaning method: Manual cleaning, using a combination of hoses and brushes. Cleaning is
necessary 3 times per day, for each vessel. Each cleaning takes 60 – 90 minutes.
Solution: 2 Alfa Laval rotary impingement devices
New tank cleaning process: Each cleaning is reduced to 16 minutes, with repeatable, reliable results
every cleaning.
Results: Savings of approximately 18 hours of cleaning time every day
Allowed for 12% increase in production
Rotary impingement devices paid for themselves in under 6 months
The manufacturer met the increased needs of their customers and gained market share in
their industry.
www.alfalaval.com
Optimized tank cleaning
Installing the correct method of tank
cleaning:
Ideally starts in the design process
Offers big gains in existing processes, too
Begins with a site visit
Considers all the variables of your true cleaning
process
Reliable solution that includes post-sale technical
service
www.alfalaval.com© Alfa Laval Slide 33
The impact of optimized tank cleaning
Production & uptime:
Increase uptime by
reducing time spent
cleaning
Health & Safety:
Eliminate confined
space entry for manual
cleaning
Costs & efficiency:
Clean faster and
better, using fewer
natural resources
Product quality: Avoid
contamination and quality
issues
www.alfalaval.com
Thanks for your time. Visit www.gamajet.com for more information
© Alfa Laval Slide 34
Certificates of completion available
upon request.
Phil KoppenhoferBusiness Development
Manager
Detect, Measure, Analyze.
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Detect, Measure, Analyze.
Upcoming Webinar:
Best Practices in Maintaining Gas Detection SystemsThursday, December 1 1pm CST
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Featured SpeakerJohn GreivellVP OperationsRAECO-LIC LLC