Optimization of Acoustic Wave for Process Equipment Cleaning using Design of Experiments

In the industrial process equipment's like electrostatic precipitators and boilers ash deposits and dust particles are formed which affects the overall efficiency of the plant due to the formation of scales. For smooth operation and effectiveness of such industrial equipment's, removal of these scales at regular intervals are very important. The conventional methods are costlier as it requires shut down of the plant during cleaning operations. This problem can be avoided by passing acoustic waves of low frequency and high SPL through a process equipment at the regular interval. In the present study simulation and experimental work is carried out for acquiring the preliminary data using horn with different lengths, throat diameters and no. of bends. Three levels for each of these factors were considered and Taguchi's L9 orthogonal array was selected for optimizing acoustic parameters. Using combinations of these factors and levels, simulation study and experimental study were carried out. Simulations were carried out using COMSOL MULTIPHYSICS 4.3 in which SPL and frequency spectra was obtained. The S/N ratio and grey relational analysis were employed to optimize the process parameters. Confirmation test has been conducted to validate the optimized parameter. For this optimal combination the SPL achieved was 107.62 dB and frequency obtained was 64 Hz.