Pneumatic Atomization Nozzle for Tank Sanitization
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Solution Overview
Problem
Conventional tank cleaning and sanitization methods are labor-intensive, hazardous, and wasteful, requiring large amounts of water and chemicals, especially in water-scarce regions like wine production areas, and lack efficient control over cleaning processes.
Innovation Solution
A system and method that uses pressurized gas (nitrogen) and sanitizing agents, such as chlorine dioxide or peracetic acid, mixed at a nozzle to reduce water and chemical consumption, with a CIP device and spray nozzle configuration for efficient cleaning, rinsing, and sanitizing of tanks, utilizing far less fresh water and sanitizing agents while maintaining effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cleaning methods using spray balls and high-volume water circulation are used, then thorough cleaning is achieved, but water consumption increases to 150-500 gallons per tank
Solution Approach 1:
The patent applies pneumatic principles by using pressurized gas (nitrogen or air) to atomize sanitizing agents into fine droplets that are distributed throughout the tank. This pneumatic atomization technique replaces the hydraulic spray ball system, achieving thorough coverage with minimal fluid consumption (0.5-2 gallons versus 150-500 gallons traditionally).
Solution Approach 2:
The invention changes the physical state and distribution parameters of the sanitizing agent by atomizing it into fine droplets through pressurized gas. This transformation from liquid stream to aerosol mist dramatically increases surface area coverage and penetration efficiency, allowing effective sanitization with far less chemical and water volume.
2Reliability
If conventional cleaning methods using large volumes of sanitizing agents are used, then complete sanitization is achieved, but chemical consumption increases by 85-95%
Solution Approach 1:
Pressurized gas atomization delivers sanitizing agents as fine droplets that disperse uniformly throughout the tank interior. This pneumatic delivery system maximizes chemical distribution efficiency and contact surface area, achieving complete sanitization coverage with 85-95% reduction in chemical volume compared to conventional liquid spraying methods.
Solution Approach 2:
The sanitizing agent is transformed from a liquid solution into an aerosol mist through pressurized gas atomization. This phase change and size reduction dramatically increases the surface area to volume ratio, enabling thorough penetration and contact with all tank surfaces using minimal chemical quantity.
3Adaptability or versatility
If manual cleaning operations are performed, then flexibility and adaptability are maintained, but labor intensity and hazard exposure increase significantly
Solution Approach 1:
The system enables self-service automated cleaning where the tank cleans itself through internal atomization nozzles that distribute sanitizing agents throughout the interior. This eliminates the need for manual intervention, reducing labor intensity and hazard exposure while maintaining adaptability to different tank configurations through programmable operation sequences.
Solution Approach 2:
Manual mechanical cleaning operations are replaced with an automated pneumatic-chemical system. Pressurized gas atomization and automated circulation replace manual scrubbing and spraying, eliminating direct worker exposure to hazardous chemicals and confined space risks while maintaining cleaning flexibility through programmable control.
4Reliability
If multiple cleaning cycles with different solutions are used, then comprehensive cleaning is achieved, but process time and operational complexity increase
Solution Approach 1:
The system merges multiple cleaning functions into a single integrated atomization process. By combining pre-rinse, washing, and sanitization steps into one automated sequence using the same pneumatic atomization mechanism with different chemical solutions, the patent reduces total process time while maintaining comprehensive cleaning effectiveness.
Solution Approach 2:
The automated system maintains continuous useful action by immediately transitioning between cleaning stages without manual intervention or equipment reconfiguration. The atomization nozzles and circulation system remain active throughout the entire multi-stage process, eliminating idle time and maintaining productive action from pre-rinse through sanitization.
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 water usage from 150 gallons to 0.5 gallons and sanitizing agent usage by 85-95%, providing effective sanitization with reduced labor and environmental impact, while ensuring compliance with regulations.
Implementation Method 1
The spray nozzle comprises a housing inside which the sanitizing agent is mixed at pressure with the gas to disperse the sanitizing agent and gas mixture into the container
Implementation Method 2
The spray nozzle comprises a housing inside which the sanitizing agent is mixed at pressure with the gas
Data Source
AI summary
A system and method for cleaning, rinsing, and sanitizing a container is disclosed. The system has a sanitizing agent chamber for storing a sanitizing agent, the one or more solution chambers in fluid communication with the container, a pump in fluid commination with the sanitizing agent, wherein the pump is in communication with a gas, and at least one spray nozzle fluidly connected to the at least one solution chamber via a conduit positioned within the container, wherein the spray nozzle comprises a housing inside which the sanitizing agent is mixed at pressure with the gas to disperse the sanitizing agent and gas mixture into the container for sanitizing the container.