Tank cleaning spray balls are key components used for tank cleaning, available in various sizes, flow rates, and configurations to suit a wide range of cleaning tasks. Spray balls ensure professional and sustainable cleaning results in low-pressure applications, while offering the advantages of high cost-effectiveness and simple operation. They are ideal for low-flow applications with Level 1 soiling and are used in numerous industries.
Fixed spray balls are generally used in storage tanks containing low-viscosity, low-temperature materials, such as raw milk storage tanks. They are also used for cleaning tanks with side agitators or smaller storage containers, such as cleaning the positive/negative pressure safety valves or overflow pipes on the tank top. Compared to rotating spray balls, fixed spray balls are less expensive, but achieving the same cleaning effect requires a longer cleaning time and consumes more cleaning fluid.
Rotating spray balls are generally used in storage tanks containing higher-viscosity materials, such as yogurt fermentation tanks and filling tanks. Compared to fixed spray balls, rotating spray balls have shorter cleaning times and lower CIP cleaning energy consumption.
Rotating jet cleaning balls are generally used for cleaning tanks that are difficult to clean, such as browning tanks. This type of spray ball is expensive, but provides the best cleaning results.
During production, the nozzles should not come into contact with the product and should be above the highest liquid level.
Principle
The cleaning principle of tank spray balls primarily relies on the impact force of large droplets produced by the spray ball and the shear force generated by the liquid flowing down the tank wall due to gravity after accumulating on the wall. The spray ball cleans the tank by utilizing the impact force of the large droplets it produces and the shear force generated by the liquid flowing down the tank wall due to gravity. The connection methods for spray balls generally include fixed spray balls and ordinary rotating spray balls, which require a cleaning pressure of 1.5-2 bar, while rotating jet cleaning balls require a cleaning pressure of 4 bar. Too low a cleaning pressure will not generate a strong impact force; too high a cleaning pressure will atomize the cleaning liquid, also failing to generate a strong impact force. Types of spray balls include fixed spray balls and rotating spray balls. The former is mainly used for storage tanks containing low-viscosity, low-temperature materials, while the latter is used for cleaning large tanks or the most demanding cleaning tasks.
Spray Ball Selection Considerations
Changyuan spray balls (also known as cleaning balls or tank cleaning balls) are commonly used for cleaning the inner walls of reactors, fermenters, mixing tanks, storage tanks, batching tanks, tankers, IBCs, water tanks, and other industrial containers. Several factors should be considered during selection.
1. Cleaning Conditions
Type of equipment or container to be cleaned (e.g., tanks, pipes, reactors), shape (vertical/horizontal/cylindrical, etc.), diameter and height.
Understanding the nature of the contaminants on the surface to be cleaned (e.g., grease, dust, scale) and their viscosity.
Required cleaning level (e.g., general cleaning, disinfection, or sterile level).
2. Spray Ball Type
Fixed spray ball: Suitable for simple cleaning of small tanks, low cost, and suitable for scenarios with low fluid pressure.
Rotating spray ball: Suitable for medium-sized tanks and containers, providing a larger cleaning range and better results.
High-efficiency 3D rotating spray ball: Suitable for medium to large and complex tanks and containers, and high-contamination scenarios, relying on 360-degree multi-axis full coverage and strong impact force for cleaning.
3. Material Selection
Stainless steel: Such as 304 or 316L, suitable for most food, pharmaceutical, and chemical industries, corrosion-resistant and hygienic.
Plastic: Such as polypropylene (PP), polytetrafluoroethylene (PTFE), suitable for strong acid or strong alkali environments.
4. Cleaning Parameters
Flow rate: Ensure the spray ball operates within the appropriate flow rate range to avoid insufficient or excessive flow.
Working pressure: The pressure should be determined according to the viscosity of the cleaning material to ensure sufficient pressure for effective cleaning.
Temperature: The selected material must be able to withstand the temperature range of the cleaning fluid.
5. Installation Method
Installation position: Determine the installation point of the spray ball (top, side, or bottom) to ensure the spray liquid covers all cleaning surfaces.
Connection method: Common methods include threaded connections, quick-connect fittings, or flange connections, which must match the piping.
7. Industry Requirements
Hygienic certification: Food and pharmaceutical industries require compliance with standards such as FDA and 3A sanitary standards.
Explosion-proof requirements: The chemical industry needs to consider whether explosion-proof requirements are necessary.
Maintenance Methods
Spray balls play a very important role in coating systems. Improper operation or maintenance can easily lead to system failure, so correct maintenance and upkeep are crucial for system stability and lifespan. Below are the maintenance methods and precautions for spray balls:
1. Cleaning the tray and spray balls: Spray balls need to be kept clean during use to prevent dry deposits and particles from being forced into the spray ball mechanism, causing it to slow down or stop rotating. Clean regularly with detergent. When cleaning, remove the spray balls and manually clean each ball, preferably using a soft brush or sponge.
2. Regular inspection and replacement: Regular inspection of small spray balls is necessary, usually every 6 months, to ensure they are still performing optimally. If any abnormalities or signs of damage appear, it is recommended to replace them promptly. Large spray balls can be inspected annually, and replacement should be decided based on actual conditions.
3. Preventing impact and damage: Spray balls are prone to collision and damage during the coating process, especially when using new coatings. Ensure that the coating material does not come into contact with the spray balls to avoid jamming or damaging them. Furthermore, handle spray balls carefully, avoiding excessive bending or contact with hard or sharp tools.
4. Avoiding vibration and friction: Spray balls need to remain balanced while rotating. Loss of balance can lead to vibration and friction in the spray system, resulting in coating quality problems. Therefore, pay attention to whether the ground is level and whether the spray ball cascading mode is correct.
5. Adjusting the number of spray balls appropriately: Too many or too few spray balls will affect the coating quality. Therefore, the number of spray balls needs to be fine-tuned according to actual conditions and the equipment manufacturer's recommendations.
In short, the key to spray ball maintenance is to inspect and clean them multiple times before and after coating, and to handle and maintain them carefully to ensure their normal operation and extend their service life. Paying attention to details will make your spray system more stable and achieve better coating results.
Spray balls, as a key component in tank cleaning, require crucial knowledge regarding selection, principles, and maintenance. Proper selection of spray balls ensures efficient cleaning under various operating conditions, meeting the diverse needs of different industries. Understanding their working principles helps optimize cleaning parameters and improve cleaning effectiveness. Furthermore, correct maintenance methods extend the lifespan of the spray balls and guarantee the stable operation of the cleaning system. A thorough understanding and application of this knowledge are crucial for improving the quality of tank cleaning in industrial production, ensuring product quality and production safety, and promoting the sustainable development of related industries.
