Improving and enhancing industrial processes is Altum Technologies’ core mission. Our Zero Process Downtime (ZPD) technology employs high-power ultrasound to tackle one of the most persistent challenges in industrial processes: fouling.
Crystallization is a crucial process for multiple industries, and crystallizers are one application whose operation Altum’s solution can improve. But what are crystallizers, and why are they so essential for industrial processes? And how does Altum contribute to optimizing the efficiency of crystallizers?
What is crystallization, and what are crystallizers?
Put very simply, crystallization is a technique for purifying substances and separating solids from a solution. It is an essential separatory technique because it allows us to separate compounds of the highest purity.
A crystallizer is an equipment or a vessel specifically designed to facilitate and manage the formation of solid crystals from a liquid solution or melt. A crystallizer ensures the optimal formation and growth of crystals in a controlled environment by controlling factors like temperature, supersaturation level, and flow conditions.
What are crystallizers used for and why?
Crystallizers separate solutes from solvents, resulting in the formation of solid crystals. Multiple industries rely on crystallizers to achieve desired product characteristics, such as purity and appropriate particle size distribution. Crystallizers are a crucial part of producing a wide array of products, ranging from table salt to the minerals needed for battery production.
Crystallization is used in industries such as
- chemicals
- metals and minerals
- fertilizers
- pharmaceuticals
- petrochemicals
- food
- water treatment
The key advantages of crystallization and crystallizers are listed below.
- Crystallization enables efficient separation and the purity of different substances.
- Crystallizers allow selective separation and controlled growth of crystals, leading to enhanced yield of the desired end product.
- Crystallization is an energy-efficient process, contributing to cost-effectiveness and reduced environmental impact.
Fouling – A common challenge faced by crystallizers
To get the most out of crystallizers, ensuring their operational efficiency is crucial. However, companies across various sectors utilizing crystallizers face the challenge of maintaining high-quality output while minimizing energy consumption and downtime – a challenge Altum Technologies helps companies overcome.
Like any other industrial process, crystallizers can face challenges like scaling and fouling, where unwanted materials adhere to equipment surfaces, reducing efficiency and necessitating shutdowns for cleaning. To combat these issues, Altum Technologies offers a solution using Zero Process Downtime (ZPD) technology. This approach employs software-guided power ultrasound to prevent or remove fouling without stopping production, ensuring smoother operations and enhanced efficiency. Altum’s solution mitigates the need for manual cleaning and contributes to significant cost savings, improved sustainability, and streamlined operations across industries reliant on crystallization processes.
Case: Enhancing nickel sulfate crystallization with ultrasound
Our case example demonstrates Altum’s technology on a nickel sulfate crystallizer, where scaling issues required frequent shutdowns for cleaning, causing substantial production losses. By installing Altum’s multichannel ultrasound solution, the production cycle was doubled from 5 to 10 days, reducing maintenance stops and increasing annual production by more than 35 days. The benefits extended beyond financial gains, encompassing reduced maintenance costs, lower energy consumption, and improved product quality, showcasing the profound impact of Altum’s technology in optimizing the efficiency of crystallizers.
The case study underscores the importance of a clean and thus fully operational crystallizer in achieving the best possible production through put. It highlights the drawbacks of traditional cleaning methods, such as energy-intensive procedures and harsh chemicals. Altum’s ZPD technology emerges as a practical solution, offering a way to prevent scaling, reduce energy consumption, and minimize maintenance needs. Doing so not only enhances productivity but also contributes to environmental sustainability by reducing the reliance on chemical cleaning agents. By addressing the critical issue of fouling through an innovative, non-invasive approach, Altum has demonstrated the potential to substantially improve operational efficiency, sustainability, and product quality across various industries.
Let’s find out how we can help your processes be as effective, economical, and ecological as possible – don’t hesitate to contact us!