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Difference between revisions of "Acoustic Cleaners"
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[[Category:Cleaning]]{{Knoppen}} | [[Category:Cleaning]]{{Knoppen}} | ||
[[File:Acoustic_Cleaner.jpg|thumb|right|Acoustic cleaner]] | |||
'''Acoustic Cleaners''' are used wherever there is a build-up of dry materials and particulates which need to be cleaned regularly to ensure maximum efficiency, and minimize maintenance and down time. An acoustic cleaner works by generating powerful sound waves which will vibrate the dry materials differently to each other and the surrounding structures. | '''Acoustic Cleaners''' are used wherever there is a build-up of dry materials and particulates which need to be cleaned regularly to ensure maximum efficiency, and minimize maintenance and down time. An acoustic cleaner works by generating powerful sound waves which will vibrate the dry materials differently to each other and the surrounding structures. | ||
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===Bridging=== | ===Bridging=== | ||
This is when the silo blocks | This is when the silo blocks at the outlet. Previously the problem was addressed by manual cleaning from underneath the silo which in its turn introduced significant risk from falling material when the blockage was cleared. An acoustic cleaner is able to operate from the top of a silo through in situ material to clear the blockage at the base. | ||
===Rat holing=== | |||
Compaction on the side of a silo. This not only reduces the operating volume in a silo but it also compromises quality control by disrupting the first in first out cycle. Older material compacted on the side of a silo can also start to degrade and produce dangerous gases. An acoustic cleaner will produce sound waves which will make the compacted material resonate at a different rate to the surrounding environment resulting in debonding and clearance. | |||
==Advantages of acoustic cleaners== | |||
*Repetitive use during operations means that there are fewer unscheduled shut downs. | |||
*Improved material flow by the elimination of hang-ups, blocking and bridging. | |||
*Minimisation of cross contamination by ensuring complete emptying of the environment. | |||
*Improved cleaning and reduction of health and safety risks. | |||
*Increased energy efficiency. Reducing the build up on heat exchange surfaces results in lower energy usage. | |||
*Extended plant life. Aggressive cleaning regimes are avoided. | |||
*Ease of operation. It is easy to automate the horns either at regular intervals or to tie the sounding in to changes in their environment such as pressure or flow rates. | |||
*Importantly they prevent the material build up problem from occurring in the first place. These advantages mean that the financial payback is often very quick. It is also possible to compare acoustic cleaners directly to alternative solutions. | |||
*Air cannons. These are well established but are expensive with limited coverage thus requiring multi unit purchase. They are also noise intrusive and have a high compressed air consumption. | |||
*Vibrators. These are easy to fit to an empty silo but can cause structural damage as well as contributing to powder compaction. | |||
*Low friction linings. These are very quiet but are expensive to install. Also they are prone to erosion and can then contaminate the environment or product. | |||
*Inflatable pads and liners. Again these are easy to install in an empty silo. They help side wall build up but have no impact on bridging. They are also hard to maintain and can cause compaction. | |||
*Fluidisation through a 1 way membrane. This can help already compacted material. However they are expensive and difficult to install and maintain. They can also contribute to mechanical interlocking and bridging. | |||
==Specific applications for acoustic cleaners== | |||
*Boilers. Cleaning of the heat transfer surfaces. | |||
*Electrostatic precipitators. Acoustic cleaners are being used for cleaning hoppers, turning vanes, distribution plates, collecting plates and electrode wires. | |||
*Super heaters, economisers and air heaters. | |||
*Duct work. | |||
*[[Filters]]. Acoustic cleaners are used on reverse air, pulse jet and shaker units. They are effective in reducing pressure drop across the collection surface which will increase bag life and prevent hopper pluggage. Generally they can totally replace the both reverse air fans and shaker units and significantly reduce the compressed air requirement on pulse jet filters. | |||
*ID fans. Acoustic cleaning helps to provide a uniform cleaning pattern even for inaccessible parts of the fan. This maintains the balance of the fan. | |||
*[[Kilns]] inlet. Acoustic cleaners help to prevent particulate build up at the kiln inlet and this will minimise nose ring formation. | |||
*Mechanical pre Collectors. Acoustic cleaners help prevent build up around the impellers and between the tubes. | |||
*[[Mills]]. Acoustic cleaners help maintain material flow and also prevent blockages in the pre grind silos. They also help prevent material build up in the downstream separators and fans. | |||
*Planetary Coolers. Acoustic cleaners help prevent bridging and ensure complete evacuation. | |||
*Precipitator. Acoustic cleaners help clean the turning vanes, distribution plates, collecting plates and electrode wires. They can either assist or replace the mechanical rapping systems. They also prevent particulate build up in the under hoppers which would otherwise result in opacity spiking. | |||
*Pre heaters. Used in towers, gas risers, [[cyclones]] and fans. | |||
*Ship cargo holds. Used both to clean and de aerate current loads. | |||
*[[Silos]] and [[Hoppers]]. To prevent bridging and rat holing. | |||
*Static [[cyclones]]. Acoustic cleaners will work both within the cyclone and with the associated duct work. | |||