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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


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


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.


Four factors of cleaning

Primary cleaning factors Time

Chemical action

Temperature

Mechanical force


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



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)



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



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


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.



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


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


Simple customer conversion No need to change fittings, pressure, or flow

Installs easily on existing sanitary tube fittings

www.alfalaval.com


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.



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


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


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


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


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


Liquid

Food

Lotion

Gel

www.alfalaval.com


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


www.alfalaval.com


Wash fluid

Water, caustic, solvent, diesel

Available pressure and flow

29 – 1000 psi (2 – 69 bar)

3 GPM – 160 GPM


www.alfalaval.com


Obstructions

Mixers and agitators


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


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


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



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


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


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


Certificates of completion available

upon request.

Phil KoppenhoferBusiness Development

Manager

http://www.gamajet.com/


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Upcoming Webinar:

Best Practices in Maintaining Gas Detection SystemsThursday, December 1 1pm CST

Webinar invitation e-mail coming soon…

Featured SpeakerJohn GreivellVP OperationsRAECO-LIC LLC

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