Automated Tank
Cleaning…
Myth or Fact?
Non-Automated Tank Cleaning
• Manual Cleaning
– Worker safety issues
– Time (is money)
– Repeatability
• Fill & Drain
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–
–
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Large volumes of water/cleaning solution
Sometimes must be heated
Slow
Repeatability
Automated Tank Cleaning
• 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
Myth or Fact?
“My tanks are too big (or too small)
for an automated solution”
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
Medium-Impact Tank
Cleaners for Tanks Up to
60’ in Dia.
High-Impact Tank Cleaners
for Tanks Up to 100’ 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’
Myth or Fact?
“My tanks are too big (or too small)
for an automated solution”
Myth or Fact?
“Automated cleaning
won’t really get my tanks clean”
Proper Specification Ensures Effective
Cleaning
• Important Selection Criteria
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–
–
–
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Correct throw distance
Proper impact
Lowest possible flow
Right spray pattern
Complete coverage
of desired surfaces
• Repeatability
TankJet AA190 Video
• AA190 video
Myth or Fact?
“Automated cleaning
won’t really get my tanks clean” “
Myth or Fact?
“I can’t automate due
to obstructions in my tank”
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
Myth or Fact?
“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”
Balancing the Factors Affecting
Cleaning Effectiveness
High Temperature
• Decreases the bond between
soil and surface
• Decreases soil viscosity
• Increases soil solubility
• Increases chemical reaction
rate (may allow for shorter
cycle time)
Cleaning Time
• 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
Chemical Concentration
• 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
Spray Impact – An Alternative to High
Temperatures
• 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
Myth or Fact?
“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”
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
Myth or Fact?
“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”
Monitoring Devices Verify Cleaning
• Acoustic sensors can be installed on
tank exterior to detect
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–
–
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Rotation failure
Changes in rotation frequency
Changes in spray pressure
Clogged nozzles
• Audible / visual alarms notify
operators when change detected
• Swab tests also possible
Myth or Fact?
“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”
The true cost of manual or fill
and drain methods
$
$
$
$
$
$
$
=
Water + energy to heat water
Chemicals
Labor
Disposal
Lost Production Time
Re-cleaning Tanks
Scrap Product
True cost
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
Payback Example – Chemical Processor
• 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
Myth or Fact?
“The payback on automated
tank cleaning is too long”
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?