In the pursuit of industrial efficiency and sustainability, one persistent challenge often remains overlooked: fouling. This build-up of unwanted materials on heat transfer surfaces and processing equipment affects virtually every industrial sector, from power generation and food processing to pulp and paper and chemical manufacturing.

Fouling significantly impacts energy efficiency and disturbs process flows by clogging equipment. In addition to operational challenges, it significantly impacts process sustainability by affecting energy, chemical, and water usage.

What Is Fouling and Why Does It Matter?

Fouling occurs when unwanted materials accumulate on equipment surfaces. These deposits might include mineral scale, biological growth, chemical precipitates, or particulate matter. This buildup quickly becomes a significant barrier to operational efficiency.

Consequences of fouling include the following:

• Increased Energy Consumption: For example, fouled evaporators might require up to 30-50% more energy to achieve the same heat transfer. This directly increases carbon footprints.
• Excessive Water Usage: Traditional cleaning methods can demand millions of gallons of fresh water annually for a single facility.
• Chemical Waste: Conventional cleaning approaches rely on aggressive chemicals that can then enter wastewater streams.
• Equipment Downtime: Scheduled cleanings and unexpected failures due to fouling create costly production interruptions.

The Environmental Impact of Traditional Fouling Migitation Approaches

For decades, industries have accepted fouling as an inevitable operational cost, addressing it through scheduled mechanical cleanings, chemical treatments, and equipment redundancy. These traditional methods come with significant environmental impacts:

• Harsh cleaning chemicals contribute to water pollution
• Increased energy usage translates to higher greenhouse gas emissions
• Premature equipment replacement generates manufacturing waste
• Water-intensive cleaning processes contribute to water scarcity

As companies worldwide commit to sustainability targets, these hidden environmental costs can no longer be ignored. The good news? Modern technologies are transforming how we approach fouling prevention, creating opportunities to align industrial operations with environmental responsibility.

Innovative Approach to Fouling Prevention: High-Power, Controlled Ultrasound

Altum provides an efficient alternative to traditional fouling mitigation methods. By utilizing ultrasound’s properties, like the ability to create microscopic vibrations and control crystallization, Altum is able to prevent fouling from happening altogether. It is a chemical-free alternative, and doesn’t require any process downtime. The solution is externally applied onto equipment, no welding or disassembling required.

The technology works by emitting precisely controlled ultrasonic waves that prevent particles from adhering to surfaces. The solution utilizes high-power ultrasound, which is controlled via innovative software to optimize the parameters: this also helps control the energy demand of the solution. The fouling prevention capabilities of the solution are so effective, that our customers are able to get rid of mechanical and chemical cleaning altogether.

This proactive approach represents a paradigm shift from reactive cleaning to preventive maintenance, which transforms the way industries manage their environmental footprint. By addressing fouling at its source, Altum’s technology solves the sustainability issues related to traditional methods while improving operational efficiency.

Direct sustainability benefits from ultrasonic fouling prevention: 

• Energy efficiency improvements: heat transfer efficiency remains stable, pipelines and pumps can function as intended without restricted flow
• Water conservation: less or no water-intensive cleaning methods required
• Chemical reduction: fewer harsh cleaning or antiscaling chemicals required
• Extended equipment lifespan: less wear and tear, as equipment stay clean and face less strain

Aligning with Global Sustainability Goals

The impact of Altum’s fouling prevention technology extends beyond operational improvements to directly support key United Nations Sustainable Development Goals (SDGs). By addressing fouling at its source, our solution contributes to global sustainability efforts in measurable ways.

SDG 6: Clean Water and Sanitation

Altum’s technology significantly reduces water consumption associated with industrial operations by:

• Eliminating water-intensive cleaning cycles that traditionally consume thousands of gallons per application
• Reducing chemical discharge into waters by replacing chemical cleaning agents with non-invasive ultrasound
• Extending equipment lifecycles, which decreases manufacturing water footprints
• Supporting closed-loop water systems by keeping pipes and other equipment clear of obstructions

SDG 7: Affordable and Clean Energy

Energy efficiency is at the heart of our solution:

• Maintaining optimal heat transfer efficiency, reducing energy requirements by up to 30% in some applications, such as evaporators
• Decreasing pumping energy needs by preventing flow restrictions
• Minimizing energy-intensive maintenance operations
• Supporting cleaner operation of renewable energy systems, such biogas facilities where fouling is a significant challenge

SDG 12: Responsible Consumption and Production

Our approach fundamentally transforms how industries manage resources:

• Extending equipment lifespan, reducing the need for premature replacements and associated manufacturing impacts
• Optimizing production efficiency by maintaining consistent performance metrics
• Reducing waste generation from descaling and cleaning operations

SDG 13: Climate Action

Climate benefits are materialized across the entire operation:

• Reduced energy consumption directly translates to lower carbon emissions
• Less chemicals required, which also means less CO2 emissions
• Decreased maintenance operations minimize transportation-related emissions from service crews
• Extended equipment lifecycles reduce embodied carbon from manufacturing replacement parts
• Improved efficiency of industrial processes leads to lower overall carbon intensity per unit of production

By implementing Altum’s fouling prevention solution, companies aren’t simply improving their operations—they’re making a meaningful contribution to global sustainability initiatives. It’s better for both business and the planet, and helps companies future-proof their operations against strict environmental regulations.

Case Examples of Improved Process Sustainability

We’ve achieved great results in improving sustainability with our customers. For example, by preventing fouling in a black liquor evaporation process, we were able to:

• Decrease CO2 emissions by 700+ tons per year due to improved energy efficiency
• Save 200 000 liters of wastewater per year due to less cleanings
• Decrease chemical usage by 10 tons per year due to improved process and less cleaningn

In another black liquor evaporation case, fouling prevention led to:

• 3+ million tons savings in CO2 emissions per year due to improved energy efficiency
• Savings of 500 000 liters of wastewater due to less cleanings

Conclusion: Aligning Industrial Efficiency with Environmental Responsibility

Altum’s innovative ultrasonic technology represents a fundamental shift in aligning industrial efficiency with environmental responsibility. By preventing fouling before it occurs, our solution eliminates environmental hazards traditionally associated with fouling management, from excessive energy and water consumption to chemical usage and equipment waste. The results speak for themselves: cleaner operations, reduced environmental footprints, and improved bottom lines.

As we look toward a future where sustainability is no longer optional but essential, Altum’s fouling prevention solutions can support your sustainability journey while transforming industrial challenges into opportunities.