Alternating Dual-Solution Clean-In-Place Method for Thermally Degraded Soil Removal
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Solution Overview
Problem
Current clean-in-place (CIP) methods for industrial equipment, such as spray dryers, require long durations (up to 12-18 hours) due to the difficulty in removing thermally degraded soils containing proteins, carbohydrates, and fats, leading to significant downtime and resource consumption.
Innovation Solution
A method involving alternating cycles of two cleaning solutions applied through separate sets of nozzles, where the first solution provides a soil disruption effect and the second solution, often at higher pressure, effectively removes the loosened soil, potentially with gas generating agents to enhance cleaning action.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional single-solution CIP methods are used, then the equipment can be cleaned, but the cleaning time is excessively long (up to 12-18 hours)
Solution Approach 1:
The cleaning process is divided into multiple sequential stages using different cleaning solutions with specific functions: a first cleaning solution for initial soil disruption and a second cleaning solution for final soil removal. This segmentation allows each solution to be optimized for its specific task, dramatically reducing total cleaning time from 12-18 hours to under 10 hours while maintaining thorough cleaning effectiveness.
Solution Approach 2:
The patent employs periodic alternation between different cleaning solutions in a cyclical manner, switching between the first and second cleaning solutions multiple times during the cleaning process. This periodic action enhances the removal of tenacious soils by repeatedly changing the chemical environment, achieving complete cleaning in significantly reduced time compared to continuous single-solution methods.
2Reliability
If longer cleaning durations are used to remove thermally degraded soils, then cleaning effectiveness is maintained, but downtime and resource consumption increase significantly
Solution Approach 1:
The patent changes multiple parameters simultaneously: using different chemical compositions, concentrations, temperatures, and application methods for different cleaning solutions. The first cleaning solution uses specific parameters for soil disruption, while the second solution uses optimized parameters for soil removal. This multi-parameter optimization achieves complete cleaning of thermally degraded soils while reducing resource consumption and time.
Solution Approach 2:
The first cleaning solution performs preliminary action by disrupting and loosening the tenacious thermally degraded soils before the second cleaning solution is applied. This preliminary breakdown of soil structure makes the subsequent removal phase much more efficient, reducing both time and resource requirements while ensuring complete cleaning effectiveness.
3Reliability
If high concentrations of cleaning chemicals are used, then soil removal effectiveness improves, but environmental impact and safety concerns increase
Solution Approach 1:
The patent applies different cleaning solutions with locally optimized properties to different cleaning needs. The first cleaning solution has specific chemical characteristics optimized for soil disruption, while the second solution has different properties optimized for soil removal. This local quality differentiation allows each solution to work at optimal effectiveness with lower overall chemical concentrations, reducing environmental impact while maintaining cleaning performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces cleaning time, potentially to under 10 hours, while maintaining effectiveness in removing challenging soils, thus minimizing downtime and resource usage.
Implementation Method 1
the first and/or second cleaning solutions include a gas generating agent
Data Source
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Figure 1B
Figure 2
AI summary
A method for cleaning a piece of equipment in place includes a plurality of cleaning cycles and optionally a rinse, where each cleaning cycle includes applying a first cleaning solution from a first supply tank through a first set of nozzles; and applying a second cleaning solution from a second supply tank through a second set of nozzles. The first cleaning solution may be applied for about (20) s to about (10) min, and the second cleaning solution for about 1 min to about (60) min. The cleaning cycle can be repeated from (5) to (150) times, and the first and second cleaning solutions can be recirculated during the process.