216 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
The client’s instrumentation allowed monitoring of
process parameters, which indicated the occurrence of foul-
ing and the length of the wash cycle. The key parameters
monitored in this experiment were temperature differences
as well as the flow rate during production versus while
washing the crystallizer. Fouling prevention was evaluated
for a duration of approximately 6 months.
Results
Figure 5 shows the flow rate and temperature log in the
crystallizer. The starting of ultrasonic fouling prevention is
visualized by a red time marker. Rapid flow rate drop and
temperature rise correspond to production interrupt for
manual cleaning.
Already during the first production cycle, when sonica-
tion was first initiated, a slight improvement in production
cycle duration (approximately 7 days) was observed. The
first full production cycle, during which ultrasound was
continuously applied, extended from around five days to
approximately ten days .
Figure 6 visualizes by a bar chart the average produc-
tion cycle length without and with sonication. Ultrasonic
fouling prevention (sonication) indeed increased the effec-
tive production cycle length by approximately 100%.
REFERENCE CASE: PIPES
The production process of the end user needed to be
stopped for scale removal frequently and at irregular inter-
vals. Scale buildup was identified in various circulation
lines, including those with outer diameters ranging from
75 mm to 300 mm, particularly in the sulfur slurry han-
dling piping .This scaling or fouling phenomenon was
attributed to the precipitation of sulfur and other minerals
within the process, resulting in a 50% decrease in liquid
flow thus necessitating the complete shutdown of produc-
tion operations and the disassembly of piping for high-
pressure jet cleaning. The cleaning process, spanning from
4 to 48 hours, led to significant production losses, and
posed potential safety risks to operators.
The Altum solution operates through the application of
ultrasound to susceptible piping prone to fouling, employ-
ing its software-guided ZPD solution. This treatment
involves subjecting the fouling to microscopic vibrations,
inducing cavitation on the inner surface of the equipment
to dislodge fouling substances. Multiple transducers are
employed to ensure a uniform ultrasonic field and vibra-
tion distribution, facilitating the efficient removal of foul-
ing deposits.
Figure 5. Flow rate (yellow) and temperature (blue) log in the pipe. Red time marker represents
starting of the ultrasonic fouling prevention (sonication).
The client’s instrumentation allowed monitoring of
process parameters, which indicated the occurrence of foul-
ing and the length of the wash cycle. The key parameters
monitored in this experiment were temperature differences
as well as the flow rate during production versus while
washing the crystallizer. Fouling prevention was evaluated
for a duration of approximately 6 months.
Results
Figure 5 shows the flow rate and temperature log in the
crystallizer. The starting of ultrasonic fouling prevention is
visualized by a red time marker. Rapid flow rate drop and
temperature rise correspond to production interrupt for
manual cleaning.
Already during the first production cycle, when sonica-
tion was first initiated, a slight improvement in production
cycle duration (approximately 7 days) was observed. The
first full production cycle, during which ultrasound was
continuously applied, extended from around five days to
approximately ten days .
Figure 6 visualizes by a bar chart the average produc-
tion cycle length without and with sonication. Ultrasonic
fouling prevention (sonication) indeed increased the effec-
tive production cycle length by approximately 100%.
REFERENCE CASE: PIPES
The production process of the end user needed to be
stopped for scale removal frequently and at irregular inter-
vals. Scale buildup was identified in various circulation
lines, including those with outer diameters ranging from
75 mm to 300 mm, particularly in the sulfur slurry han-
dling piping .This scaling or fouling phenomenon was
attributed to the precipitation of sulfur and other minerals
within the process, resulting in a 50% decrease in liquid
flow thus necessitating the complete shutdown of produc-
tion operations and the disassembly of piping for high-
pressure jet cleaning. The cleaning process, spanning from
4 to 48 hours, led to significant production losses, and
posed potential safety risks to operators.
The Altum solution operates through the application of
ultrasound to susceptible piping prone to fouling, employ-
ing its software-guided ZPD solution. This treatment
involves subjecting the fouling to microscopic vibrations,
inducing cavitation on the inner surface of the equipment
to dislodge fouling substances. Multiple transducers are
employed to ensure a uniform ultrasonic field and vibra-
tion distribution, facilitating the efficient removal of foul-
ing deposits.
Figure 5. Flow rate (yellow) and temperature (blue) log in the pipe. Red time marker represents
starting of the ultrasonic fouling prevention (sonication).