Dual Nozzle Jetting Tool for Tank Sludge Removal
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Solution Overview
Problem
Traditional cleaning systems for fluid storage tanks are inefficient, leading to sludge accumulation, increased health and safety risks, and prolonged shutdown times due to manual removal and high waste volumes, while also causing operational capacity loss and corrosion.
Innovation Solution
A jetting tool system that performs sludge mapping and characterization, uses biosurfactants to separate sludge into oil and water phases, and includes automated nozzles for efficient circulation and separation, reducing the need for manual intervention and minimizing waste disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manual cleaning systems are used, then personnel can directly remove sludge, but health and safety risks increase and shutdown times are prolonged
Solution Approach 1:
The patent replaces manual mechanical cleaning with an automated jetting system that uses high-pressure fluid circulation to remove sludge. The jetting tool with movable head and interchangeable nozzles eliminates the need for personnel to manually enter and clean tanks, thereby improving health and safety while reducing shutdown time through automated operation.
Solution Approach 2:
The cleaning system is designed to operate autonomously within the tank without requiring manual intervention. The jetting tool circulates fluid through the sludge layers, automatically separating and removing contaminants, which reduces both safety risks to personnel and the time required for manual operations.
2Loss of substance
If traditional cleaning systems are used, then sludge can be removed, but waste disposal volumes are high
Solution Approach 1:
The patent employs biosurfactants that change the physical-chemical parameters of the sludge mixture, reducing surface tension and enabling phase separation. This chemical parameter change allows oil and water phases to separate from solid contaminants, reducing the overall waste volume that requires disposal while maintaining high cleaning efficiency.
Solution Approach 2:
The cleaning process utilizes phase transitions by introducing biosurfactants that cause the sludge mixture to separate into distinct oil and water phases. This phase separation allows for selective removal and reduced waste volume, as the liquid phases can be recovered and reused rather than disposed of entirely.
3Productivity
If manual sludge removal is used, then cleaning can be performed, but operational capacity is lost and corrosion accelerates
Solution Approach 1:
The automated jetting system replaces manual cleaning operations, enabling faster and more thorough sludge removal. This reduces the time tanks remain out of service, preserving operational capacity, while the gentle fluid circulation method avoids the mechanical damage and moisture exposure that accelerate corrosion.
Solution Approach 2:
The patent uses biosurfactants as intermediaries between the cleaning system and sludge. These surfactants facilitate sludge breakdown and phase separation without requiring aggressive mechanical scraping or prolonged tank opening, thereby minimizing corrosion while maintaining high productivity.
4Productivity
If single nozzle jetting tools are used, then equipment complexity is low, but cleaning efficiency and versatility are limited
Solution Approach 1:
The jetting tool is designed with a movable head that can accommodate multiple interchangeable nozzles, making it a universal cleaning device capable of handling different sludge types and tank configurations. This multi-functionality increases cleaning efficiency without significantly increasing overall system complexity, as the same basic tool structure serves multiple purposes.
Solution Approach 2:
The jetting tool features a movable head that can be positioned and oriented dynamically within the tank, and nozzles can be interchanged based on cleaning requirements. This dynamic adaptability improves cleaning efficiency by optimizing jet direction and coverage, while the modular nozzle system keeps complexity manageable through standardized interfaces.
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
The system significantly reduces cleaning time, minimizes health and safety risks, and effectively separates sludge, allowing for faster tank reuse with reduced waste and exposure to hazardous environments.
Implementation Method 1
The jetting tool is configured to receive fluid from the flowline and expel the fluid through at least one of the first nozzle and the second nozzle of the jetting tool
Implementation Method 2
uses biosurfactants to separate sludge into oil and water phases
Data Source
AI summary
System, tool and method for cleaning a tank that stores oil products. A jetting tool has a first nozzle (114) and a second nozzle (116). The jetting tool may be movably disposed within the tank, such as vertically and/or horizontally and is configured to receive fluid from a flowline (105) to expel the fluid through at least one of the first nozzle and the second nozzle of the jetting tool.