Mobile CIP Dual-Loop Mixing and Heating for Stable Chemical Cleaning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current HIMCIP systems face challenges with inconsistent fluid flow, excessive chemical degradation, greenhouse gas emissions, and safety hazards due to open flame heating and manual chemical addition, leading to inefficient cleaning and potential equipment damage.
Innovation Solution
A system utilizing two independent electric pumps and loops for controlled fluid circulation and heating, along with a mobile hopper for chemical addition, ensuring consistent mixing and temperature control, reducing emissions and improving safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a PTO mechanical or hydraulic power source is used to power a pump, then the system can be mobilized to site, but the fluid flow becomes inconsistent due to varying RPMs
Solution Approach 1:
The system divides the power source into separate electric motors for the pump and burner, each independently controlled, replacing the single PTO power source. This segmentation allows each component to operate at consistent speeds independently, resolving the fluid flow inconsistency caused by varying PTO RPMs while maintaining mobility through the mobile platform design.
2Speed
If a coil burner with open flame is used for heating, then the liquid heats faster than with electric heaters, but the cleaning chemical is neutralized by excessive heating and vaporization
Solution Approach 1:
The patent replaces the mechanical coil burner system with an electric heater system. This substitution eliminates the open flame that causes excessive heating and chemical vaporization, while the electric heater design provides controlled heating that achieves the required temperature without neutralizing the cleaning chemicals.
Solution Approach 2:
The system changes the heating parameter control from uncontrolled open flame to electrically controlled heating elements. This allows precise temperature management, maintaining the heating rate necessary for effective cleaning while preventing the temperature from reaching levels that cause chemical vaporization and degradation.
3Productivity
If chemicals are added via a hopper connected to the coil burner, then the system can be operated, but chemical reactions cause hose burst failures and spills
Solution Approach 1:
The patent extracts the chemical addition process from the heated fluid path by using a separate mixing tank for chemical preparation. This separation removes the hazardous chemical reaction zone from the high-temperature hose system, eliminating the cause of hose burst failures and chemical spills while maintaining cleaning operation capability.
4Device complexity
If a single closed loop system is used, then the system design is simple, but 100% of contaminants are recirculated and flow fluctuates
Solution Approach 1:
The system segments the single closed loop into two separate loops: a first loop for clean fluid circulation and chemical mixing, and a second loop for contaminated fluid return and filtration. This segmentation prevents contaminant recirculation while maintaining flow consistency through independent pump control, and the added complexity is offset by the reliability improvements.
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
Achieves consistent chemical mixing and heating, reduces greenhouse gas emissions, and enhances safety by eliminating open flame heating and manual chemical addition, resulting in efficient and environmentally friendly cleaning processes.
Implementation Method 1
a first electric pump circulates fluid through the first loop
Implementation Method 2
a second electric pump circulates fluid through the second loop
Implementation Method 3
a coil burner with an open flame for heating... this traditional method provides very inconsistent heating of the cleaning fluid and neutralizes a significant portion of the cleaning chemical by boiling it
Implementation Method 4
the method of mixing the chemicals... a first electric pump circulates fluid through the first loop where a starting material is mixed with the circulating fluids
Data Source
AI summary
A heavy industrial mobile CIP system, which comprises two closed loops and facilitate uniformity in chemical mixing and in heating of cleaning fluid and chemical concentration. The first loop comprises an electric pump for pumping fluid from a mixing tank and through the first loop. The cleaning chemicals are added to the fluid circulating in the first loop prior to the fluid returning to the mixing tank. The cleaning fluid is heated in the mixing tank by at least one heater. The second loop comprises a second pump to pump fluid from the mixing tank through the second loop, which is connected to the equipment to be cleaned. The fluid and debris from cleaning the equipment circulates through the second loop to the mixing tank. In some cases, a weir can be used to facilitate separation of solids in the fluid returning from the equipment into the mixing tank.