214 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
integration of conventional ultrasound cleaning technology
with advanced beam steering software. This combination
allows for targeted application of the ultrasonic cleaning
field, enhancing the precision and effectiveness of the foul-
ing prevention process. This integration is facilitated by
optimization strategies and remote monitoring through
Internet of Things (IoT) connectivity, ensuring seamless
operation and efficiency in various industrial contexts.
REFERENCE CASE: CRYSTALLIZER
Due to scaling issues in a Draft-Tube-Baffle (OTB) crystal-
lizer (OD =2600 to 3200 mm and L =7720 mm), the
process had to be stopped roughly every five days to wash
the crystallizer. The cleaning took approximately one day
per production halt, resulting in 70+ days of lost produc-
tion annually. The crystallizer formed a clear bottleneck in
the process: when it was not able to receive the incoming
process liquid, it had to be fed back to the previous process
stage. If the crystallizer was out of order due to, for exam-
ple, a washing period or reduced capacity caused by foul-
ing, some batches were even lost completely. The goal was
to lengthen the production cycle and reduce maintenance
stops by preventing scale built up.
In the OTB crystallization process, Altum’s solution
works by sonicating the location prone to fouling with
ultrasound. Altum’s solution affects scaling locally by pre-
venting its built up with microscopic vibrations on the
inner surface of the equipment to detach the foulant. This
is done with multiple channels to ensure an even ultrasonic
field and vibration. With Altum’s solution, this vibration is
precise and software-guided to ensure equipment safety and
the best possible results.
Solution Design
Delivery of the power ultrasonic field is designed by creat-
ing a digital twin of the case using finite-element model-
ling (FEM). Frequency domain simulations were employed
using structural mechanics, pressure acoustics and electro-
static modules in COMSOL Multiphysics (version 6.2).
Figure 2 shows the simulation geometry, a volumetric sub-
set of a crystallizer. Ultrasonic transducers are attached at
an optimal arrangement, in the proximity of an inlet pipe.
Figure 2. (a) Simplified geometry of a crystallizer and (b) volumetric subset extracted for simulations Four
power ultrasound transducers are attached in the proximity of the crystallizer inlet
integration of conventional ultrasound cleaning technology
with advanced beam steering software. This combination
allows for targeted application of the ultrasonic cleaning
field, enhancing the precision and effectiveness of the foul-
ing prevention process. This integration is facilitated by
optimization strategies and remote monitoring through
Internet of Things (IoT) connectivity, ensuring seamless
operation and efficiency in various industrial contexts.
REFERENCE CASE: CRYSTALLIZER
Due to scaling issues in a Draft-Tube-Baffle (OTB) crystal-
lizer (OD =2600 to 3200 mm and L =7720 mm), the
process had to be stopped roughly every five days to wash
the crystallizer. The cleaning took approximately one day
per production halt, resulting in 70+ days of lost produc-
tion annually. The crystallizer formed a clear bottleneck in
the process: when it was not able to receive the incoming
process liquid, it had to be fed back to the previous process
stage. If the crystallizer was out of order due to, for exam-
ple, a washing period or reduced capacity caused by foul-
ing, some batches were even lost completely. The goal was
to lengthen the production cycle and reduce maintenance
stops by preventing scale built up.
In the OTB crystallization process, Altum’s solution
works by sonicating the location prone to fouling with
ultrasound. Altum’s solution affects scaling locally by pre-
venting its built up with microscopic vibrations on the
inner surface of the equipment to detach the foulant. This
is done with multiple channels to ensure an even ultrasonic
field and vibration. With Altum’s solution, this vibration is
precise and software-guided to ensure equipment safety and
the best possible results.
Solution Design
Delivery of the power ultrasonic field is designed by creat-
ing a digital twin of the case using finite-element model-
ling (FEM). Frequency domain simulations were employed
using structural mechanics, pressure acoustics and electro-
static modules in COMSOL Multiphysics (version 6.2).
Figure 2 shows the simulation geometry, a volumetric sub-
set of a crystallizer. Ultrasonic transducers are attached at
an optimal arrangement, in the proximity of an inlet pipe.
Figure 2. (a) Simplified geometry of a crystallizer and (b) volumetric subset extracted for simulations Four
power ultrasound transducers are attached in the proximity of the crystallizer inlet