The Power of in-place cleaning tools Tank Cleaning Technology

By Ren Elgaard Alfa Laval Tank Equipment A/S

Tank Cleaning Technology

Introduction to Tank Cleaning Technology Cleaning methods and parameters

Cleaning Technology AL Portfolio overview Static Spray Ball vs. Rotary Jet Head - Coverage comparison - How soil is attacked - Self cleaning & Hygienic design

Process Analytical Technology (Validation) Saving examples

www.alfalaval.com

Reasons to Clean

Guarantee Product Integrity (Re-use Equipment) Risk Management, stay in control - prevent cross contamination, adulteration and avoidable carryover - removal of bio-film, dried foam, precipitate or sludge/ sediment

Comply with Legal Requirements Prepare Tank for Human Entry i.e. during Maintenance and/or Inspection Remove Hazardous or Explosive Atmospheres Protect the Equipment against Corrosion
www.alfalaval.com

The Optimal Cleaning Operation.

From a customer prospective, the optimal cleaning operation is to turn the tank around as quickly as possible. Using a minimum of water, chemicals, energy and producing a minimum of waste water. Be able to validate the process.

www.alfalaval.com

The environmental impact of cleaning.

By optimizing the CIP process

we reduce the cleaning time we reduce the energy consumption we reduce the waste water created we reduce the chemical used

All of it helping to protect our environment and safeguarding our resources

www.alfalaval.com

Q : Is cleaning the first or last process step ? Cleaning should be an integrated part of the process.

www.alfalaval.com

Cleaning Methods

Cleaning out of place (COP) Manual cleaning (Brush and bucket) Washing Stations (removable pieces) Cleaning lances

Cleaning in place (CIP) Vaporizing solvents Fill boil dump (fill and soak/agitate) CIP plant & cleaning machine

www.alfalaval.com

Cleaning Parameters
T A C C T
Time Brush Water (solvent) Access ability Chemical concentration Temperature Action (mechanical force and heat and mass transfer)

Coverage

T
www.alfalaval.com

TACT Cleaning Parameters - Using Static Spray Balls

Cleaning Philosophy: (Sinner 1960) Cleaning is a matter of applying chemical detergent at a certain temperature for the time necessary to dissolve or loosen the residues so the mechanical action of the falling film can remove the residues

SinnersCircle"TACT"
Temperature Chemical Time

Cascading High-flow low-pressure relying on chemistry, temperature and time.

ActionFlow
www.alfalaval.com

TACT Cleaning Parameters

- Using Rotary Jet Head
Traditional TACT Action (Cascading Flow and Chemistry)

Impactcleaning
Cleaning coverage
Action Coverage Time ActionFlow Chemical Temperature

Improving Action and Coverage: Reduce Cleaning Time Water Consumption Chemical consumption Power Consumption and dont forget the amount of Waste Water Produced

Cleaning Impact (impingement)

Action Impact

Pocket the Money

www.alfalaval.com

Cleaning Equipment

Static Cleaning Devices Static Spray Ball (SSB)

Dynamic Cleaning Devices Rotary Spray Head (RSH) Rotary Jet Head (RJH)

www.alfalaval.com

Static Spray Ball

- Minimum flow rate required
Static Spray Head / vertically tanks
80 70 60 50 40 30 20 10 0 0 5 10 Tank Height [m] 15

100%
Dia. 10m Dia. 9m Dia. 8m Dia. 7m

Flow rate [m/hr]

Dia. 6m Dia. 5m Dia. 4m Dia. 3m Dia. 2m Dia. 1m

20 www.alfalaval.com

Rotary Spray Head

- Minimum flow rate required
Rotary Spray Heads / vertical tanks
60

70%
Dia. 10m

50

Dia. 9m Dia. 8m

40 Flow rate [m/hr]

Dia. 7m Dia. 6m

30 21 20

Dia. 5m Dia. 4m Dia. 3m

10

Dia. 2m Dia. 1m

0 0 5 10 Tank Height [m] 15 20 www.alfalaval.com

Rotary Jet Head

- Minimum flow rate required
Rotary Jet Head / vertical tanks
40 35 30 25 20 15 10 5 0 0 5 10 Tank Height [m] 15

50%
Dia. 10m Dia. 9m Dia. 8m Dia. 7m

Flow rate [m/hr]

Dia. 6m Dia. 5m Dia. 4m Dia. 3m Dia. 2m Dia. 1m

20 www.alfalaval.com

Important RJH Tank Cleaning Machine Performance Terms

Wetting intensity Directly applied cleaning media, measured in l/m2. Cycle The double movement of the nozzle and the hub makes the nozzles move in 8 figures. 22 8 figures makes one cycle; subsequent cycles are each displaced from the previous.

www.alfalaval.com

Important Tank Cleaning Machine Performance Terms

- in relation to cleaning parameters

Impact The force generated by the cleaning media as applied to the surface.

Coverage Directly and indirectly applied cleaning media to the tank wall and internals.

www.alfalaval.com

Important RJH Tank Cleaning Machine Performance Terms

Complete Pattern (Full 360 coverage) 8 cycles, representing 43 revolutions of the body and 45 revolutions of the nozzle hub. Complete pattern represents 8 to 24 minutes depending on machine type and tank size.

Part pattern A fraction of a full pattern.

www.alfalaval.com

Characteristics affecting the cleaning

Viscosity Tenacity Solids content Non dissolved particles Characteristics determining which cleaning machine to be applied.

Relatively easy to clean = e.g. yoghurt dried for an hour. RSH is sufficient to clean the tank. Difficult to clean = e.g. brewery fermenter dried 3 weeks. Will require a RJH.
www.alfalaval.com

Cleaning Technology
The point of interest is the areas where water jets are NOT hitting Discussion:

Cleaning action
How are residues attacked ? Static Spray Ball
High volume/low pressure, poor heat transfer Low volume/high pressure

Water and Heat Distribution Method

Rotary jet Head

Coverage vs. Cleaning

How did the Riboflavin Test ever get associated with cleaning ? Shear stress Self Cleaning Self Draining
www.alfalaval.com

GMP Requirements

Impact - Coverage
- effect of
Static Spray Ball Rotary Spray Head Rotary Jet Head

Impact: Coverage:

10 % Cascading Partial

70 % Swirling fan Partial / full ~70 %

100 % Index Pattern Full ~50 %

www.alfalaval.com

Flow + Time:

100 %

Rotary Spray Head in action

SaniMidget

www.alfalaval.com

Rotary Jet Head in action

TJ 20G & TZ-74

www.alfalaval.com

SSB Cleaning Technology

Attack of residues Main part of tank area is dependant on high-flow and low-pressure cleaning gravity driven cascading flow, relying on chemistry and time (clean until clean) Validation: Cleaning time.

www.alfalaval.com

Static Spray Ball

Cascading Flow Low flow areas

The di-polar property of water

Wall Shear Stress in Cascading Flow 4 Pa Or Renoylds no. 1000 Wall Shear Stress in low flow areas is much lower 1 Pa.

www.alfalaval.com

Reynolds Number

Laminar Re<2000

Turbulent Re>4000

www.alfalaval.com

Static Spray Ball

Well defined Jet quality ? Externally Self Cleaning ?

Self Cleaning ?

www.alfalaval.com

Static Spray Balls and rouge

Source: Force Technology 2007 PW tank www.alfalaval.com

Installation in Process Tank

Clip-on, Weld-on and Thread version are available

www.alfalaval.com

RSH Spray Pattern Build-up

1 cycle

2 cycle

8 cycle Full Pattern

TRAX Video

www.alfalaval.com

SaniJet 25 - Operated @ 5 bar

www.alfalaval.com

Cleaning Technology
1. Pressure is the driving force - Pressure is converted to water jet velocity 2. The flow turns the tank cleaning machine 3. High Wall Shear Stress Zone 4. Machine gearing makes the indexed pattern 5. With pressure & flow control time is well defined
Water Jet

PV

t{

High Speed Turbulent Flow Conditions Wall Shear Stress, Min. 40 Pa

www.alfalaval.com

RJH Cleaning Technology

Attack of residues Flush and Cleaning time is defined by machine pattern time

Same simultaneously treatment of all residues

www.alfalaval.com

Fermentor Cleaning
After approx. 1 cycles After approx. 4 cycles

After a full pattern (8 Cycles)

www.alfalaval.com

Cleaning case

www.alfalaval.com

Rotary Jet Head

www.alfalaval.com

SaniJet 25 - EHEDG Certificate the first and only TCM certified

www.alfalaval.com

Cleaning Behind Agitator Shaft

www.alfalaval.com

Cleaning of Shadow Areas

Direct - and Indirect coverage by impact splash-back

www.alfalaval.com

Deflective Jet Cleaning

100 m Bulk Fermentor
What do Deflection you see ? Cleaning

www.alfalaval.com

Deflective Jet Cleaning

Di-polar Properties of Water
+ + + + + + + + + + -

www.alfalaval.com

Typical CIP program steps

Cold Pre-rinse
Effective removal of the residual product with minimum quantity of liquid to minimise contamination of detergent.

Detergent clean
Alkaline: Effective removal of oil and fats

Rinse
Effective Removal of detergents

Detergent clean
Acidic: Effective removal of calcium-deposits

Rinse
Effective Removal of detergents

Sterilising
Removal of microbial contamination

Final Rinse

www.alfalaval.com

Typical CIP Process

Pre-Rinse Detergent Post-Rinse Final-Rinse* Disinfection

Half pattern 3 min.

Full pattern 5 min.

Half pattern 3 min.

Half pattern 3 min.

Individual

Cleaning Time 14 min.**

* Re-use for Pre-Rinse **Well defined pressure/flow

www.alfalaval.com

Process Analytical Technology

Is there anybody who has taken a Static Spray Ball assembly apart ? What did you find ?

Is there any way of verifying whether none or one or maybe more holes are plugged during CIP ? Access the Static Spray Ball assembly, take it apart and perform visual inspection Before and/or after CIP ?
www.alfalaval.com

Rotary Jet Heads - Rotation Monitoring (PAT)

Alfa Laval Rotacheck Sensor is a P sensor mounted in the Rotary Jet Head clamp connection to track the Alfa Laval Rotary Jet Head operation no additional tank top connection is needed P is measured and the pattern recorded If the signal generated by the sensor is different from the recorded pattern it can be converted to an audible alarm and/or visual signal by the process control system

www.alfalaval.com

Examples of savings
Examples of savings using Alfa Laval Toftejorg Tank Cleaning Technology Before improvements Time Flow min m3 162 120 34 95 124 72 23 40 After Improvements Time Flow min m3 84 20 24 50 27 6,33 10 5 Savings Time % Flow % m3 48% 83% 29% 47% 97 66 13 35 CIP Savings Brewery Fermenter Yeast Manufacturer Dairy Milk Storage Dairy Starter Culture Time min 78 100 10 45 Flow % % 78% 91% 56% 87%

One brewery 17 tanks yearly savings Euro 29000 Questions ???? For further information please contact: rene.elgaard@alfalaval.com

Thank you and enjoy the rest of the seminar

www.alfalaval.com