XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 213
Hydroblasting, while widely used in the industry, leads
to several challenges. Production is often halted, reduc-
ing the lifespan of the equipment and causing significant
operational disruptions and costs. The technique’s reliance
on high-pressure water jets not only risks damaging sensi-
tive production components but also poses health hazards
to operators. Furthermore, hydroblasting typically results
in excessive water consumption. As alternatives, there are
online scale prevention and fouling mitigation strategies,
including the use of chemical additives. These, however,
may be inefficient and could alter the solution chemistry,
thus raising concerns about their environmental impact
and potential health risks.
In light of the drawbacks associated with traditional
cleaning methods like hydroblasting, the industry is increas-
ingly turning towards more sustainable and less disruptive
solutions for addressing scaling and fouling. The ideal
approach is one that upholds equipment efficiency without
necessitating frequent shutdowns or introducing additional
risks. In this context, ultrasonic cleaning has emerged as
a promising alternative over the past few decades. This
method involves immersing equipment in baths equipped
with ultrasonic transducers, where ultrasonic vibrations
create cavitation in the liquid Figure 1, which results in
the formation of microjets that effectively dislodge residues
from metal surfaces. It enables thorough cleaning of hard-
to-reach areas, significantly reduces cleaning time, and
enhances operational performance. Moreover, ultrasonic
cleaning minimizes the risk of damage to delicate parts,
reduces excessive water usage, and eliminates the health
hazards commonly associated with hydroblasting. (Shank
et al., 2022) and (Mason, T.J., 2016)
However, the primary limitations of ultrasonic baths
include their size and the need for offline cleaning, which
requires the removal of equipment from production lines.
Additionally, the chemistry of the cleaning liquid used in
these baths may be incompatible with certain equipment
materials. To overcome these challenges, service providers
have been developing innovative solutions such as Altum
Technologies’ Zero Process-Downtime (ZPD) ultrasound
technology (Moilanen et al., 2023). The ZPD solution
employs a clamp-on power ultrasound approach, which
is engineered to obviate the need for production interrup-
tions, process alterations, or manual offline cleaning. The
solution, operational during ongoing production, provides
a dual-functionality for both prevention and removal of
scaling and fouling in crystallizers, pipes, and a range of
industrial equipment. It is designed to optimize process
uptime and maintain operational efficiency of these equip-
ment through real-time cleaning interventions.
In terms of safety and environmental impact, the ZPD
solution contributes to the reduction of health and safety
hazards associated with industrial equipment maintenance.
By keeping the equipment clean, the clamp-on solution
reduces chemical treatments and manual disassembly for
cleaning purposes. This approach aligns with energy con-
servation efforts and aids in lowering CO2 emissions. A
distinctive aspect of the ZPD ultrasound solution is the
Figure 1. Ultrasonic waves create micro bubbles which implode and release energy to detach fouling
Hydroblasting, while widely used in the industry, leads
to several challenges. Production is often halted, reduc-
ing the lifespan of the equipment and causing significant
operational disruptions and costs. The technique’s reliance
on high-pressure water jets not only risks damaging sensi-
tive production components but also poses health hazards
to operators. Furthermore, hydroblasting typically results
in excessive water consumption. As alternatives, there are
online scale prevention and fouling mitigation strategies,
including the use of chemical additives. These, however,
may be inefficient and could alter the solution chemistry,
thus raising concerns about their environmental impact
and potential health risks.
In light of the drawbacks associated with traditional
cleaning methods like hydroblasting, the industry is increas-
ingly turning towards more sustainable and less disruptive
solutions for addressing scaling and fouling. The ideal
approach is one that upholds equipment efficiency without
necessitating frequent shutdowns or introducing additional
risks. In this context, ultrasonic cleaning has emerged as
a promising alternative over the past few decades. This
method involves immersing equipment in baths equipped
with ultrasonic transducers, where ultrasonic vibrations
create cavitation in the liquid Figure 1, which results in
the formation of microjets that effectively dislodge residues
from metal surfaces. It enables thorough cleaning of hard-
to-reach areas, significantly reduces cleaning time, and
enhances operational performance. Moreover, ultrasonic
cleaning minimizes the risk of damage to delicate parts,
reduces excessive water usage, and eliminates the health
hazards commonly associated with hydroblasting. (Shank
et al., 2022) and (Mason, T.J., 2016)
However, the primary limitations of ultrasonic baths
include their size and the need for offline cleaning, which
requires the removal of equipment from production lines.
Additionally, the chemistry of the cleaning liquid used in
these baths may be incompatible with certain equipment
materials. To overcome these challenges, service providers
have been developing innovative solutions such as Altum
Technologies’ Zero Process-Downtime (ZPD) ultrasound
technology (Moilanen et al., 2023). The ZPD solution
employs a clamp-on power ultrasound approach, which
is engineered to obviate the need for production interrup-
tions, process alterations, or manual offline cleaning. The
solution, operational during ongoing production, provides
a dual-functionality for both prevention and removal of
scaling and fouling in crystallizers, pipes, and a range of
industrial equipment. It is designed to optimize process
uptime and maintain operational efficiency of these equip-
ment through real-time cleaning interventions.
In terms of safety and environmental impact, the ZPD
solution contributes to the reduction of health and safety
hazards associated with industrial equipment maintenance.
By keeping the equipment clean, the clamp-on solution
reduces chemical treatments and manual disassembly for
cleaning purposes. This approach aligns with energy con-
servation efforts and aids in lowering CO2 emissions. A
distinctive aspect of the ZPD ultrasound solution is the
Figure 1. Ultrasonic waves create micro bubbles which implode and release energy to detach fouling