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Ultrasound Technology to Prevent Fouling in Mineral Processing
S. Ahmadzai, T. Kekkonen, T. Rauhala, P. Moilanen
Altum Technologies Oy, Helsinki, Finland
N. McAlonen
Altum Technologies Inc., Nevada, USA
ABSTRACT: Fouling in mineral processing applications, particularly in pipes and crystallizers, poses significant
operational challenges, including blockages and reduced heat transfer efficiency. Power ultrasound technology,
known for its efficacy in various industrial applications, has been demonstrated to be particularly effective in
the prevention of fouling. One of the key advantages of power ultrasound in the context of mineral processing
is its ability to prevent the accumulation of mineral deposits within pipes and crystallizers. This prevention is
crucial in maintaining the optimal flow capacity and production output. For instance, the use of ultrasound
has been observed to significantly increase the flow capacity in pipes, as evidenced by a notable rise from 1,200
gallons per minute to 2,500 gallons per minute in certain applications. Moreover, the ultrasound technology has
been instrumental in reducing the time and resources spent on cleaning and maintenance. For example, in cases
where the technology was implemented, there was a reported reduction in cleaning time by a factor of 80% and
an increase of 100% in production cycle length. This reduction not only translates to lower operational costs
but also enhances the overall efficiency of the mineral processing systems.
Keywords: power ultrasound, ultrasonic cleaning, fouling prevention
INTRODUCTION
Scaling and fouling accumulation is a widespread challenge
across multiple industries, presenting substantial technical
difficulties and economic setbacks. This issue, which affects
equipment of all types and geometries, results in the for-
mation of unwanted deposits on internal surfaces, thereby
reducing production efficiency. Such fouling can obstruct
pipes, impair heat transfer, and disrupt the standard func-
tioning of machinery such as crystallizers. Over time, per-
sistent fouling may cause corrosion and other types of wear,
consequently shortening the lifespan of the equipment. In
severe instances, fouling can compromise safety, particu-
larly when it impacts crucial machinery, creating hazardous
working conditions. (Garrett-Price et al., 1985)
In response to the inefficiencies and substantial costs
associated with scaling and fouling, a variety of chemical
and physical methods are implemented. Preventative mea-
sures include treating water used in industrial processes
to eliminate mineral content that contributes to scaling.
Additionally, selecting materials less susceptible to fouling
for equipment construction, or adjusting process param-
eters such as temperature and flow rate, can help minimize
conditions favorable to fouling. However, in cases where
fouling persists and necessitates cleaning of crystallizers or
pipes, industries traditionally turn to hydroblasting. This
method, while effective for removing fouling, does not
address performance degradation prior to the equipment
being taken offline for cleaning.
Ultrasound Technology to Prevent Fouling in Mineral Processing
S. Ahmadzai, T. Kekkonen, T. Rauhala, P. Moilanen
Altum Technologies Oy, Helsinki, Finland
N. McAlonen
Altum Technologies Inc., Nevada, USA
ABSTRACT: Fouling in mineral processing applications, particularly in pipes and crystallizers, poses significant
operational challenges, including blockages and reduced heat transfer efficiency. Power ultrasound technology,
known for its efficacy in various industrial applications, has been demonstrated to be particularly effective in
the prevention of fouling. One of the key advantages of power ultrasound in the context of mineral processing
is its ability to prevent the accumulation of mineral deposits within pipes and crystallizers. This prevention is
crucial in maintaining the optimal flow capacity and production output. For instance, the use of ultrasound
has been observed to significantly increase the flow capacity in pipes, as evidenced by a notable rise from 1,200
gallons per minute to 2,500 gallons per minute in certain applications. Moreover, the ultrasound technology has
been instrumental in reducing the time and resources spent on cleaning and maintenance. For example, in cases
where the technology was implemented, there was a reported reduction in cleaning time by a factor of 80% and
an increase of 100% in production cycle length. This reduction not only translates to lower operational costs
but also enhances the overall efficiency of the mineral processing systems.
Keywords: power ultrasound, ultrasonic cleaning, fouling prevention
INTRODUCTION
Scaling and fouling accumulation is a widespread challenge
across multiple industries, presenting substantial technical
difficulties and economic setbacks. This issue, which affects
equipment of all types and geometries, results in the for-
mation of unwanted deposits on internal surfaces, thereby
reducing production efficiency. Such fouling can obstruct
pipes, impair heat transfer, and disrupt the standard func-
tioning of machinery such as crystallizers. Over time, per-
sistent fouling may cause corrosion and other types of wear,
consequently shortening the lifespan of the equipment. In
severe instances, fouling can compromise safety, particu-
larly when it impacts crucial machinery, creating hazardous
working conditions. (Garrett-Price et al., 1985)
In response to the inefficiencies and substantial costs
associated with scaling and fouling, a variety of chemical
and physical methods are implemented. Preventative mea-
sures include treating water used in industrial processes
to eliminate mineral content that contributes to scaling.
Additionally, selecting materials less susceptible to fouling
for equipment construction, or adjusting process param-
eters such as temperature and flow rate, can help minimize
conditions favorable to fouling. However, in cases where
fouling persists and necessitates cleaning of crystallizers or
pipes, industries traditionally turn to hydroblasting. This
method, while effective for removing fouling, does not
address performance degradation prior to the equipment
being taken offline for cleaning.
