Abstract:
An acoustic cleaning device and method for cleaning of the surfaces within a vessel is provided. The device may consist of one acoustic transducer or a series of smaller acoustic transducers mounted inside the vessel in a specific fashion in order to direct acoustic waves throughout the cleaning liquid and onto the interior surfaces of the vessel. An acoustic cavitation is produced by the pressure variations in sound waves moving through the cleaning liquid and a cleaning action is accomplished throughout the entire vessel interior. The acoustic cleaning device may be arranged in a variety of ways to accomplish the cleaning. The acoustic cleaning device may be used with a variety of chemical cleaning solutions and is ideal for particle surface contaminant removal.

Description:
[0001]    This application claims the benefit under 35 U.S.C. Section 119(e) of U.S. Provisional Patent Application No. 61/142,686 filed on Jan. 6, 2009 in the United States Patent and Trademark Office entitled “Acoustic Cleaning Device and Method.” 
     
    
     BACKGROUND 
       [0002]    The disclosure relates generally to cleaning devices and methods and more specifically to an acoustic cleaning device and method for industrial equipment. 
         [0003]    Surface fouling is a major problem in industrial equipment. Such equipment includes ozone generators, boilers, reactors, heat exchangers, furnaces (for coal, oil, waste, etc.), and the like. Typically, the equipment involves a vessel containing internal surfaces that are subjected to fouling by accumulating particulates, minerals, and other products and byproducts of chemical reactions, combustion, sedimentation, and the like. Such particulate build-up may progressively interfere with the equipment operation by reducing efficiency and throughput, and potentially causing damage. 
         [0004]    Effective cleaning of the equipment is therefore highly desirable and is attended by a number of relevant considerations. However, often direct access to the fouled surfaces is difficult as they may be small, hard to reach, irregularly shaped, and blocked by a variety of obstacles. Additionally, often these vessels are very large and stationary and cannot be moved for the intended cleaning. Therefore, a thorough cleaning of such internal surfaces is hard to achieve. Additionally, it is desirable to minimize the length of time required for the cleaning in order to maintain operational continuity, industrial equipment downtime, safety, and related costs associated with the cleaning. 
       SUMMARY 
       [0005]    The problems presented in present cleaning devices and methods for industrial equipment are solved by the device and method of the present invention. 
         [0006]    In accordance with one embodiment of the present invention, an acoustic cleaning device is provided. The acoustic cleaning device is used for the cleaning of the surfaces within a vessel. The acoustic cleaning device may consist of one acoustic transducer or a series of smaller acoustic transducers mounted inside the vessel in a specific fashion in order to direct acoustic waves throughout the cleaning liquid and onto the interior surfaces. An acoustic cavitation is produced by the pressure variations in sound waves moving through the cleaning liquid and a cleaning action is accomplished throughout the entire vessel interior. The acoustic cleaning device may be arranged in a variety of ways to accomplish the cleaning. 
         [0007]    The acoustic cleaning device may be used with a variety of chemical cleaning solutions and is ideal for particle surface contaminant removal. It may also be used to increase the efficiency of chemical cleaning. 
         [0008]    Other objects, features, and advantages of the present invention will become apparent with reference to the drawings and detailed description that follow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a pictorial representation of a cross section view of the interior of a vessel with numerous compartments in accordance with an illustrative embodiment. 
           [0010]      FIG. 2  is a pictorial representation of a front view of a vessel with numerous compartments in accordance with an illustrative embodiment. 
           [0011]      FIG. 3A  is a pictorial representation of an example of the acoustic cleaning device within a vessel in accordance with an illustrative embodiment. 
           [0012]      FIG. 3B  is a pictorial representation of an example of the acoustic cleaning device within a vessel in accordance with an illustrative embodiment. 
           [0013]      FIG. 4A  is a pictorial representation of an example of the acoustic cleaning device within a vessel in accordance with an illustrative embodiment. 
           [0014]      FIG. 4B  is a pictorial representation of an example of the acoustic cleaning device within a vessel in accordance with an illustrative embodiment. 
           [0015]      FIG. 5  is a pictorial representation of an example of the acoustic cleaning device within a vessel in accordance with an illustrative embodiment. 
           [0016]      FIG. 6A  is a pictorial representation of an example of the acoustic cleaning device arranged for cleaning a portion of the cross-section of a vessel interior in accordance with an illustrative embodiment. 
           [0017]      FIG. 6B  is a pictorial representation of an example of the acoustic cleaning device arranged for cleaning the entire cross-section of a vessel interior in accordance with an illustrative embodiment. 
           [0018]      FIG. 7  is a pictorial representation of an example of the acoustic cleaning device arranged for cleaning the entire cross-section of a vessel interior in accordance with an illustrative embodiment. 
           [0019]      FIG. 8A  is a pictorial representation of an example of the acoustic cleaning device arranged for cleaning a portion of the cross-section of a vessel interior in accordance with an illustrative embodiment. 
           [0020]      FIG. 8B  is a pictorial representation of an example of the acoustic cleaning device arranged for cleaning a portion of the cross-section of a vessel interior in accordance with an illustrative embodiment. 
           [0021]      FIG. 9  is a pictorial representation of an example of the acoustic cleaning device in accordance with an illustrative embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    In the following detailed description of illustrative embodiments of the present invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific illustrative embodiments in which the present invention may be practiced. These illustrative embodiments are described in sufficient detail to enable those skilled in the art to practice the present invention, and it is understood that other embodiments may be utilized and that logical mechanical and electrical changes may be made without departing from the scope and spirit of the present invention. To avoid detail not necessary to enable those skilled in the art to practice the present invention, the detailed description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims. It should be noted that the definition of “vessel” as used herein is a large container containing at least one cavity through which a liquid can move. 
         [0023]    With reference now to the figures, and in particular, with reference to  FIGS. 1-2 , the interior of a vessel  102  with numerous hollow compartments  104  is provided as an example of the environment in which illustrative embodiments of the present invention may be implemented. It should be appreciated that  FIGS. 1-2  are only exemplary and are not intended to assert or imply any limitation with regard to the environments in which different embodiments may be implemented. 
         [0024]      FIG. 1  is a pictorial representation of a cross section view of the interior of a vessel  102  with numerous compartments  104  in accordance with an illustrative embodiment.  FIG. 2  is a pictorial representation of a front view of a vessel  102  with numerous compartments  104  in accordance with an illustrative embodiment. A vessel  102  with numerous hollow compartments  104  is used in the present illustrative embodiment as the numerous hollow compartments  104  are particularly difficult to clean in an industrial setting. 
         [0025]    With reference now to  FIGS. 3A-4B , pictorial representations of examples of the arrangement of the acoustic cleaning device  106  within a vessel  102  are depicted in accordance with illustrative embodiments. As illustrated in  FIGS. 3A  and  3 B, the acoustic cleaning device can be located in a number of possible locations within each vessel and the location is determined based on the specifics of each particular cleaning project, the chemistries of the cleaning liquids being used, as well as the specific conditions of the vessel being cleaned. For example, in  FIG. 3A , the acoustic cleaning device  106  is located in a vertical position at the proximal end of the vessel  102 . In  FIG. 3B , the acoustic cleaning device  106  is located at the distal end of the vessel  102 . 
         [0026]    As a further example of the various arrangements of the acoustic cleaning device  106  within a vessel  102 ,  FIGS. 4A and 4B  illustrate how the acoustic cleaning device  106  can be located in a horizontal position within a vessel  102 . It should be noted that these various arrangements are for illustrative purposes only and one skilled in the art would recognize that the acoustic cleaning device may be located in a variety of positions within the vessel. 
         [0027]      FIG. 5  illustrates the acoustic cleaning device  106  in further detail.  FIG. 5  is a pictorial representation of an example of the acoustic cleaning device  106  within a vessel  102  in accordance with an illustrative embodiment. The acoustic cleaning device includes a frame  110  and an acoustic transducer  108 . The frame  110  is removably fixed to the interior of the vessel  102 . The acoustic transducer  108  can be attached to the frame  110  before the frame  110  is installed in the vessel  102  or the acoustic transducer  108  can be attached to the frame  110  once the frame  110  is in place inside the vessel  102 . 
         [0028]    With reference now to  FIGS. 6A-6B , pictorial representations of an example of the acoustic cleaning device  106  within a vessel  102  are depicted in accordance with illustrative embodiments.  FIG. 6A  is a pictorial representation of an example of the acoustic cleaning device  106  arranged for cleaning a portion of the cross-section of a vessel  102  interior in accordance with an illustrative embodiment. Multiple acoustic transducers  108  are attached to the frame  110  in an arrangement for the purpose of being used for cleaning a portion of the cross-section of the vessel  102  interior.  FIG. 6B  is a pictorial representation of an example of the acoustic cleaning device  106  arranged for cleaning the entire cross-section of a vessel  102  interior in accordance with an illustrative embodiment. Multiple acoustic transducers  108  are attached to the frame  110  in an arrangement for the purpose of being used for cleaning the entire cross-section of the vessel  102  interior. As is illustrated in  FIGS. 6A and 6B , with the use of the frame  110  the acoustic transducers  108  can be arranged such that a specific portion of the vessel  102  is cleaned, such as for concentrated cleaning of a portion of the vessel  102 , or the acoustic transducers  108  can be arranged such that the entire interior of the vessel  102  is cleaned. 
         [0029]      FIG. 7  is a pictorial representation of an example of the acoustic cleaning device arranged for cleaning the entire cross-section of a vessel interior in accordance with an illustrative embodiment. There is single acoustic transducer  108  supported by a frame  110 , the frame  110  being removably fixed to the interior of the vessel  102 , and arranged in such a manner to clean the entire cross-section of a vessel  102  interior. As is illustrated in the various Figures, the acoustic cleaning device  106  may be comprised of a single acoustic transducer  108  or multiple acoustic transducers  108 . When comprised of a single acoustic transducer  108 , the acoustic cleaning device  106  may be arranged such that a portion of the cross-section of a vessel  102  interior is cleaned or that the entire cross-section of a vessel  102  interior is cleaned. 
         [0030]    Referring now to  FIGS. 8A-8B , pictorial representations of an example of the acoustic cleaning device  106  arranged for cleaning a portion of the cross-section of a vessel  102  interior are depicted in accordance with an illustrative embodiment. The acoustic cleaning device  106  includes a frame  110  and multiple acoustic transducers  108  removably fixed to the frame  110 . The frame  100  is removably fixed to a vessel  102  interior.  FIG. 8A  shows a first position for the acoustic cleaning device  106 . After the acoustic cleaning device  106  has been used to clean a portion of the cross-section of a vessel  102  interior, the acoustic cleaning device can be rotated within the vessel  102  interior to clean another portion of the cross-section of a vessel  102  interior. The frame  110  can be rotated manually within the vessel, taken out and rearranged, or moved by means of automation. 
         [0031]    One skilled in the art will understand that the size and shape of the frame  110  can vary according to the size and the shape of the vessel  102  to be cleaned as well as the size and the shape of the acoustic transducers  108  to be attached to the frame  110 . The frame  110  may be made of any material that is non-corrosive and sturdy enough to hold the acoustic transducers  108  during the cleaning process. 
         [0032]    The acoustic transducer  108  is housed in stainless steel and includes flanges for mounting to the frame  110 . The acoustic transducer  108  includes a piezoelectric driving element that is attached to a radiating diaphragm and includes electrical wiring that connects to an ultrasonic generator  116 . When multiple acoustic transducers  108  are used, the electrical wiring is synchronized for enhanced performance. Electrical charge buildup in the acoustic transducer  108  is prevented by a bleed resistor wired in parallel with the driving element. 
         [0033]      FIG. 9  is a pictorial representation of an example of the acoustic cleaning device  106  in accordance with an illustrative embodiment. The acoustic cleaning device  106  is removably fixed to the vessel  102  interior and the doors  112  of the vessel  102  are sealed such that the cleaning solution  114  will not leak from the vessel  102 . One skilled in the art will understand that the vessel  102  may be sealed using the existing doors of the vessel or any closure that ensures the cleaning solution will not leak from the vessel. The vessel  102  is then filled with a cleaning solution  114 . The acoustic transducer  108  within the acoustic cleaning device  106  is electrically connected to an ultrasonic generator  116  that is controlled by control system  118 . The acoustic transducer  108  within the acoustic cleaning device  106  produces ultrasonic waves  120  in the cleaning solution  114  by changing size in concert with electrical signals oscillating at ultrasonic frequencies. This creates compression waves  120  in the cleaning solution  114  and this ultrasonic agitation results in a cleaning action. The ultrasonic generator  116  controls the acoustic transducer  108  within the acoustic cleaning device  106 , such as power, frequencies, wavelengths, and the like. The settings of the ultrasonic generator  116  are controlled by the control system  118  so that single or multiple frequencies are used to clean the vessel  102 . 
         [0034]    The acoustic waves  120  travel throughout the vessel and create compression and expansion in the cleaning solution  114 . In the compression wave  120 , the molecules of the cleaning solution  114  are compressed together tightly. Conversely, in the expansion wave  120 , the molecules are pulled apart rapidly. These pressure swings and the chemical action of the cleaning solution  114  provide a cleaning action throughout the vessel&#39;s  102  interior. 
         [0035]    Any rotation or movement of the acoustic cleaning device  106  can be accomplished manually or the frame  110  may be mobile, cleaning the vessel  102  interior while automatically moving from one location to the next in predetermined or random fashion by means of pre-assembled guides for the frame  110  and operated from outside of the vessel by the control system  118 . 
         [0036]    The acoustic cleaning device  106  inside the vessel direct acoustic waves  120  throughout the cleaning solution  114  and onto the interior surfaces of the vessel  102 . In this manner, acoustic cavitations and vibrations are produced by the pressure variations in sound waves  120  moving through the cleaning solution  114  and a cleaning action is accomplished throughout the vessel  102  interior. One skilled in the art will understand that the wavelengths and frequencies are set based on the cleaning needs, for example the size of the vessel, type of substances being cleaned, vessel surface materials, cleaning time requirements or limitations, cleaning solution being used, and the like. 
         [0037]    Even though many of the examples discussed herein are applications of the present invention in cleaning a vessel, the present invention also can be applied to other types of removable industrial equipment in which the equipment is placed in a vessel to be cleaned using the acoustic cleaning device and method. 
         [0038]    The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. 
         [0039]    It should be apparent from the foregoing that an invention having significant advantages has been provided.