Sugar-Based Cleaning Composition for Evaporator Scale Removal
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Solution Overview
Problem
Conventional cleaning compositions and methods for evaporators, such as sugar evaporators, are insufficient for effectively removing scale and fouling deposits, leading to inefficiencies and increased energy costs due to the need for prolonged cleaning times and high concentrations of calcium chelants like EDTA.
Innovation Solution
A sugar or sugar-moiety containing cleaning composition is applied to dissolve the sugar component in the scale, reducing the time required for scale removal by breaking down the binder holding the scale together, allowing for easier washing away of the remaining soils, with concentrations ranging from 0.5 wt-% to 5 wt-% sugar and/or sugar moiety and optional calcium chelants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional calcium chelant solutions (EDTA) are used to remove scale, then scale removal is achieved, but cleaning time is prolonged and high concentrations are required
Solution Approach 1:
The invention changes the chemical composition parameter by replacing conventional calcium chelants (EDTA) with sugar-based cleaning compositions. This parameter change enables effective scale removal at lower concentrations and shorter contact times, directly resolving the contradiction between cleaning effectiveness and time consumption
Solution Approach 2:
The invention substitutes the chemical mechanism of calcium chelation with a sugar-based dissolution mechanism. Instead of using EDTA to chelate calcium ions, the patent employs sugar compositions that dissolve the sugar component in scale, thereby breaking down the binder holding scale together and enabling easier removal
2Reliability
If high concentrations of calcium chelants are applied to improve scale removal, then cleaning effectiveness increases, but cost and chemical usage increase
Solution Approach 1:
The invention changes the concentration parameter by demonstrating that sugar-based compositions achieve effective scale removal at concentrations of 0.5 wt-% to 5 wt-%, significantly lower than the high concentrations of conventional chelants required. This reduces both chemical usage and cost while maintaining cleaning effectiveness
Solution Approach 2:
The invention employs sugar-based compositions that are less expensive and more environmentally benign than conventional calcium chelants like EDTA. The sugar compositions can be used at lower concentrations and are easier to rinse away, reducing overall chemical consumption and disposal costs
3Reliability
If prolonged contact time is used to remove scale effectively, then complete cleaning is achieved, but productivity decreases
Solution Approach 1:
The invention changes the time parameter by reducing the required contact time from prolonged periods to shorter durations. The sugar-based compositions work more rapidly to dissolve scale binders, enabling complete cleaning in less time and thereby increasing evaporator uptime and productivity
Solution Approach 2:
The sugar-based composition performs preliminary dissolution of the sugar component in scale before mechanical removal is needed. This preliminary chemical action weakens the scale structure by dissolving the binder, making subsequent mechanical removal faster and more complete, thus improving both cleaning effectiveness and productivity
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 sugar-based cleaning compositions significantly reduce the time and difficulty of scale removal from evaporators, outperforming conventional EDTA solutions by dissolving the scale into fine, easily removable particulates, thereby enhancing cleaning efficiency and reducing energy costs.
Implementation Method 1
applying a sugar and/or sugar moiety-containing compound cleaning composition to a surface in need of scale removal, wherein the scale contains sugar and at least one soil selected from the group consisting of calcium oxalate, calcium dihydrogen phosphate, silica and combinations thereof; and contacting the scale with the cleaning composition for an amount of time sufficient to dissolve the sugar in the scale
Data Source
AI summary
Methods of cleaning sugar evaporators with a cleaning composition comprising a sugar or sugar-moiety containing compound are disclosed. The methods are capable of improved scale and fouling removal from treated surfaces, including scale containing calcium oxalate, calcium dihydrogen phosphate, silica and/or other components from sugar evaporators. The methods reduce time required for scale removal without the need for highly alkaline cleaning compositions, elevated temperatures and/or mechanical force applied to the scale.