1

Ethanol Industry

Content / Navigation

�� Lechler 5TC High Impact Machine

�� Lechler ACCUClean Series 515/519

�� Lechler Gyro Series 577/579

�� Lechler Stainless Whirly Series 569

�� Ethanol References

�� Lechler Tank CIP Nozzles Overview

�� Electronic Documents

�� Ordering via Lechler Online Shop

�� Contact

4. Edition

Lechler GmbH

Precision Nozzles · Nozzle Systems

P.O. Box 12 23

72544 Metzingen / Germany

Phone: +49 (0 ) 71 23 962-0

E-Mail: info@lechler.de

CIP Nozzles for Ethanol Production

2

Content

�� Lechler 5TC High Impact Machine 3Minimum Cycle Times Lechler 5TC 3Pressure-/Flowrate and Throwing Range of Lechler 5TC’s 45TC Configurations 55TC Drawings 5Notes for Usage 55TC Documents 65TC Movie Clips 65TC horizontal Mounting (M20 Horizontal) 6

�� Lechler ACCUClean Series 515/519 7ACCUClean Configurations 8ACCUClean Drawings 8ACCUClean Documents 8ACCUClean Movie Clips 8

�� Lechler Gyro Series 577/579 9Gyro Configurations 10Gyro Drawings 10Gyro Movie Clips 10

�� Lechler Stainless Whirly Series 569 11Whirly Configurations 12Whirly Drawings 12ACCUClean Movie Clips 12

�� Ethanol References 13

�� Lechler Tank CIP Nozzles Overview 14

�� Electronic Documents 15

�� Ordering via Lechler Online Shop 15

�� Contact 16

2CIP Nozzles for Ethanol Production

Index | Content

3

�� Lechler 5TC High Impact Machine

The Lechler 5TC is a self-rotating, gear-controlled

tank cleaning head. The internal gear and the li-

quid pressure result in a specific rotation speed of

the unit. The high impact is a result of the solid jets

but this means also that a certain time is necessary

until each part of the tank was hit by the jets. This

time is called cycle time. A cycle has completed on-

ce the cleaning head has rotated 44 times. It refers

to the cleaning of a tank with a diameter of 10 m.

Please have a look at diagram 1. Larger tanks or

strong contamination can lead to longer cleaning ti-

mes. That means several cycles are necessary for

a proper cleaning.

The Lechler 5TC is available in versions with 2 or 4

nozzles. Illustration 1 shows the version with 4 no-

zzles. 4 nozzles is the preferred version because

of faster cycle times.

Minimum Cycle Times Lechler 5TC

3CIP Nozzles for Ethanol Production

Index | Content

Illustration 1: Test of a Lechler 5TC.4xx. (4 nozzles) atthe measurement facility in Metzingen

0

5

10

15

20

25

30

35

2,0 3,0 4,0 5,0 6,0 7,0 8,0

5TC.208.5TC.210.5TC.407.5TC.408.5TC.410.

40 psi 60 psi 80 psi 100 psi

Min

imu

m C

ycle

Tim

e [M

in.]

Pressure [bar]

Diagram 1: The min. cycle time refers to a tank with a diameter of 10 m and 44 rotations of the tank cleaning unit.Each part of the tank was then hit by a water jet. 5TC.2xx refers to a version with 2 nozzles. 5TC.4xx refers to aversion with 4 nozzles. Versions with 4 nozzles have faster cycle times.

4

Pressure-/Flowrate and Throwing Range of Lechler 5TC’s

The 5TC was designed for a pressure of 100 psi (ca. 7 bar). Higher pressures up to max. 150 psi (10

bar) are also possible. However, this leads to higher wear of the gear components.

For uninterrupted rotation it is recommended to apply a pressure not below 40 psi (2,7 bar).

Diagrams 2 and 3 show pressure-/flowrate characteristics and the projected radius. The latter means

the max. range possible for still good cleaning results.

4CIP Nozzles for Ethanol Production

Index | Content

27,5

25

22,5

20

17,5

15

12,5

10

7,5

50 1 2 3 4 5 6 7 8 9

5TC.410.

Flo

w R

ate

[m3 /h

]

Pressure [bar]

5TC.210.

5TC.408.

5TC.208./5TC.406.

5TC.407.

125

100

75

50

25

Flo

w R

ate

[U.S

. - G

PM]

0 20 40 60 80 100 120

Pressure [psi]

Diagram 2: Flowrate daigram Lechler 5TC

9

8

7

6

5

4

3

2

10 1 2 3 4 5 6 7 8 9

Pressure [bar]

Pro

ject

ion

rad

ius

[m]

5TC.x10. 5TC.x08. 5TC.x07. 5TC.x06.

Diagram 3: Effective Cleaning Range for the differentjet sizes. For example: 5TC.x10. has a jet size of 10mm, 5TC.x06. has a jet size of 6 mm. The bigger thejet size the higher the cleaning range.

Please keep in mind: it is always advisable to mo-unt a bigger tank cleaning device than usually ne-cessary to get additional reliability

5

5TC Configurations

The Lechler 5TC is available in different versions. The outer dimensions are the same for all versions.

The differences are number of nozzles per unit (2 or 4) and diameter of the nozzles orifice (6, 7, 8 and

10 mm).

�Weight: 8 kg

� Materials: AISI 316L, Gear components made of PTFE and carbon fibre

� Installation: Vertically facing downward

� Filtration: We recommend the use of a strainer with 0,1 to 0,2 mm mesh size

� Lechler Inc. has a different name for the 5TC. It is called M20. There are no technical differences

5TC Drawings

The following drawings are available for download in case you have a working internet connection:

� 5TC.210.17.015.PDF

� 5TC.XXX.17.AS.PDF

� 5TC.XXX.17.BS.PDF

Notes for Usage

� Use the tank cleaning head between temperatures of 2°C and 95°C. Frost can lead to substantial

damage

� The cleaning heads are not designed for the use with gases

� Once cleaning has been completed it is recommended to flush the 5TC with water. Particularly if

chemicals were used

� It is not necessary to lubricate the gear components. During the utilization these components are

lubricated by the cleaning liquid

� If vibrations are not avoidable in the supply line, the threaded connection of the tank cleaning head

should be secured with Loctite (or another water resistant metal adhesive). Thus it is prevented

that the tank cleaning head separates from the thread.

� If the cleaning liquid is particle-loaded, then a filter with a mesh size of 0,1 to 0.2 mm is

recommended

� During application liquid leaks from different places of the tank cleaning head. This represents no

malfunction, but is desired, in order to lubricate the gear components and ensure drainage

5CIP Nozzles for Ethanol Production

Index | Content

Ordering no. Numberof

nozzles

Nozzle-ø in

[mm] Δp [bar] [ Δpmax = 10 bar]

2,0

40 psi[US gal./

min] 3,0 5,0 7,0 10,0

max.tank-ø

[m]at

5 bar

V [l/min].

<)

Spra

yan

gle

120,2

151,8

145,5

167,6

189,7

246,7

37,3

47,1

45,1

52,0

58,8

76,5

147,2

185,9

178,2

205,3

232,4

302,1

190,0

240,0

230,0

265,0

300,0

390,0

224,8

284,0

272,1

313,6

355,0

461,5

268,7

339,4

325,3

374,8

424,3

551,5

12,5

14,0

10,0

11,0

12,5

14,0

2

2

4

4

4

4

8,0

10,0

6,0

7,0

8,0

10,0

5TC. 208. 17.

5TC. 210. 17.

5TC. 406. 17.

5TC. 407. 17.

5TC. 408. 17.

5TC. 410. 17.

360°

ConnectionType

1-1/2”MaleNPT

1-1/2”Female

NPT Flange

G 1-1/2”FemaleISO 228

AS

AS

AS

AS

AS

AS

BR

BR

BR

BR

BR

BR

BS

BS

BS

BS

BS

BS

015

015

015

015

015

015

5TC Documents

This page offers you several other documents about the Lechler 5TC for download.

Please note: In some documents you will found the designation M20. That is the designation of

Lechler Inc. There are no technical differences.

� 5TC Installation Guide (English) Download

� Instructions for the conversion from 2 to 4 nozzles (English) Download

� Maintenance and Repair Instructions (English) Download

�Wartungs- und Reparaturanleitung (German) Download

� Ersatzteilliste (German) Download

� Anfrageblatt (German) Download

� Flyer (German) Download

� Flyer (English) Download

� TEFZEL® Gear (for less gear friction) (English) Download

5TC Movie Clips

� 5TC.4xx. Demonstration at low pressure (18Mb) Download

� 5TC.4xx. Demonstration at high pressure (6Mb) Download

� 5TC.2xx. Demonstration at high pressure (5Mb) Download

5TC horizontal Mounting (M20 Horizontal)

The Lechler 5TC can be also mounted horizontally. A special skid is used to hold the 5TC nozzle in po-

sition (Illustration 3). Horizontal mounting is especially effective for cleaning horizontally-arranged

tanks like e.g. tankers. Compared to the usual mounting (illustration 2) horizontal mounting provides a

much more better spray coverage at the bulkheads of the tank.

66CIP Nozzles for Ethanol Production

Index | Content

Illustration 3: Lechler M20 Horizontal

Illustration 2: The M20 Horizontal provides a much mo-re effective cleaning cycle due to continuous lengthwi-se sweeping action. Graphics based on observationsfilmed during testing at the University of Florida

7

�� Lechler ACCUClean Series 515/519

Tank cleaning devices called Lechler ACCUClean

are self rotating and gear-driven. The same princi-

ple as used for 5TC nozzles. In contrast to conven-

tional free spinning units, here a simple internal

turbine limits rotation velocity (illustration 5). As a

result, the sprays remain compact, even with in-

creasing pressure. Additionally, the sprays can

dwell longer on each point of the target surface,

developing their full cleaning performance.

It is recommended to operate ACCUClean no-

zzles between 2 and 5 bar. Higher pressure ge-

nerally means higher wear and smaller droplets.

This might have adverse effects on the cleaning

result. Max. pressure 10 bar. Furthermore it is not

recommended to operate the nozzle with compres-

sed air. However, compressed air can be tempor-

ary used to blow the device dry.

The Stainless Steel Whirly is used in tanks up to 6

m where an aggressive impacting spray is needed,

but less flow is required.

Examples:

� Pre-Fermenter Tank

� Molecular sieves

� Yeast propagation

� Initial/Final Liquefaction

� Nutrient tank

� Yeast Mud tank

7CIP Nozzles for Ethanol Production

Index | Content

Illustration 4: Lechler ACCUClean Series 515/519

Illustration 5: Lechler ACCUClean Series 515/519

Drivingturbine

Gearwheel for theHollowshaft of thehead

Illustration 6: Test of a Lechler ACCUClean series 519

8

ACCUClean Configurations

� Materials: Body: Stainless steel AISI 316L, Gear parts: PEEK

� Bearing: Axial ball bearing made of stainless steel AISI 316L

� Temperature: 5 - 85°C

� Operating pressure: 2 – 5 bar, max. 10 bar

� Max. tank diameter: up to 3 m (515.219.) - max. 6 m (519.469.)

� Installation: only vertically - facing upward or downward

� Filtration: We recommend the use of a 50 mesh line strainer to ensure smooth

operation of the gear train.

ACCUClean Drawings

The following drawings are available for download in case you have a working internet connection:

� AV-515.YYY.7T.ZZ.00.0

� AV-519.YYY.7T.AS.00.0

ACCUClean Documents

� ACCUClean Field Service Instructions (English) Download

� ACCUClean Field Service Instructions (German) Download

ACCUClean Movie Clips

� Series 515 (360°) at Lechler Inc. in a glass box (14Mb) Download

� Series 515 (360°) at Lechler GmbH test side (2Mb) Download

� Series 515 (360°) at Lechler GmbH test side (closer look) (2Mb) Download

� Series 519 (360°) at Lechler GmbH at 4 bar (1Mb) Download

8CIP Nozzles for Ethanol Production

Index | Content

Eø

[mm]

Con-nectionBS PP*

1

LengthH

[mm]

Flow rate [ l/min]p [bar] ( pmax = 6 bar)

<)68

103

137

171

228

296

1,0

1,0

1,0

1,5

1,5

1,5

3/4”

3/4”

1”

1 1/2”

1 1/2”

1 1/2”

515.219.7T.AL

515.289.7T.AL

515.339.7T.AN

519.379.7T.AS

519.429.7T.AS

519.469.7T.AS

S prayangle

2

97

145

193

242

322

419

3

118

178

237

296

395

513

5

153

229

306

382

509

662

6

168

251

334

419

558

726

40 ps i[US gal./

min]

30

45

60

75

100

130

D[mm]

170

170

170

267

267

267

Orderingnumber

360°

360°

85

85

85

140

140

140

E = Narrowest free cross section · * NPT on request

9

�� Lechler Gyro Series 577/579

The Gyro series has proven to be very reliable in a

lot of different cleaning tasks. The stainless steel

and Teflon construction allows the use of most

cleaning solvents. Gyros are easy to maintain and

simple in assembly / disassembly.

It is recommended to operate ACCUClean no-

zzles between 1 and 3,5 bar. Higher pressure ge-

nerally means higher wear and smaller droplets.

This might have adverse effects on the cleaning

result. Max. pressure 5 bar. Furthermore it is not

recommended to operate the nozzle with compres-

sed air.

Gyros are used in vessels up to 6 m where an ag-

gressive repeated high impact coarse spray is

needed.

Features:

� Driven and lubricated by the cleaning fluid

� Flat fan bores for especially powerful cleaning

� Large open cross-sections

� Teflon slide bearing

� Recommended pressure: 2 bar

� Not applicable with demineralised water

Examples:

� Beer Wells (most common usage)

� Pre-Fermenters (very common)

� Yeast propagation tanks

� Initial/Final Liquefaction

� Nutrient tank

� Yeast Mud tank

Gyros can be rebuilt easily with the rebuild kits which can be ordered by the following part numbers:

NPT 1" 057.701.55

NPT 2" 057.702.55

NPT 3" 057.703.55

9CIP Nozzles for Ethanol Production

Index | Content

Illustration 7: Gyros are available in 3 different sizes

~

ø 151

102

Hex 70 2" NPT

~

ø 187

116

ø 116 3" NPT

~

ø 117

68

Hex 41 1" NPT

Weight 0,91 kg Weight 1,63 kg Weight 1,93 kg

Illustration 8: Connections Sizes 1”, 2” and 3”

1010CIP Nozzles for Ethanol Production

Index | Content

Gyro Configurations

� Materials: Body: Stainless steel AISI 316, Slide bearing: Teflon

� Temperature: 5 - 90°C

� Operating pressure: 1 – 3,5 bar, max. 5 bar

� Installation: Side bearings are lubricated by the cleaning medium and can be installed

in all positions.

Gyro Drawings

The following drawings are available for download in case you have a working internet connection:

� 1” Gyros

� 2” Gyros

� 3” Gyros

Gyro Movie Clips

� Series 577 (360°) at Lechler Inc. in a glass box (8Mb) Download

Spray Angle Effective-gninaelCisp 04epyT

NPT1" NPT2" NPT3" 1 2 3 5 [USgal/min] L W Ø [m]

577.289.17 BN 115 163 200 258 50 68,4 118 4577.369.17 BN 182 258 316 408 80 68,4 118 4577.409.17 BW 228 322 394 509 100 103 151 5577.439.17 BW 273 386 473 610 120 103 151 5577.499.17 BW 380 538 659 851 170 103 151 5577.569.17 MB 570 806 987 1274 250 116 188 6577.599.17 MB 685 969 1187 1532 300 116 188 6577.619.17 MB 798 1128 1382 1784 350 116 188 6

Product code V [l/min] DimensionsInlet Δ p [bar], pmax= 5 bar [mm]

11

�� Lechler Stainless Whirly Series 569

Whirly nozzles are free spinning nozzles for tank

sizes up to 3 meters (cleaning). The rotation velo-

city of the cleaning head is a result of pressure and

flow rate. Usually it is recommended to apply a

pressure between 1,5 and 2 bar. Higher pressures

lead to smaller droplets and this results in less

cleaning performance.

Whirly nozzles can be mounted in odd positions

because it uses a double ball bearing. This bearing

configuration allows mounting at any angle from

straight down to straight up.

Whirlies are made of stainless steel AISI 316L.

The bearing is made of the AISI 316L with a PEEK

cage.

Features:

� Max. tank diameter for cleaning: 3 m

� Driven and lubricated by the cleaning fluid

� Flat jet nozzles

� Fits thought small tank openings

� AISI 316L/PEEK double ball bearing

� Recommended pressure: 1,5 – 2 bar

� Can be mounted in odd positions

� Not recomended for use with compressed air

� Line-strainer with a mesh size of 0,3 mm/50

mesh recommended

�When mounted horizontally rotation starts at 2

bar.

Examples:

� Yeast propagation tanks

� Beer Stripper

11CIP Nozzles for Ethanol Production

Index | Content

Illustration 9: Lechler Whirly Series 569

Illustration 10: Whirly nozzles spraying at 1 bar atLechler’s measurement facility in Metzingen/Germany

1212CIP Nozzles for Ethanol Production

Index | Content

Whirly Configurations

� Materials: Body: Stainless steel AISI 316L, Gear parts: PEEK

� Bearing: Double ball bearing made of stainless steel AISI 316L

� Temperature: 5 - 140°C

� Operating pressure: 1 – 3 bar, max. 2 bar recommended

� Max. tank diameter: up to 3 m

� Installation: only vertically - facing upward or downward

� Filtration: We recommend the use of a 0,3 mm/50mesh line strainer to ensure smooth

operation.

� Ex: ATEX version also available

Whirly Drawings

The following drawings are available for download in case you have a working internet connection:

� AV-569.YYY.1Y.10.00.0

� AV-569.YYY.1Y.AL.00.0

� AV-569.YYY.1Y.TF.07.0

� AV-569.YYY.1Y.TF.10.0

ACCUClean Movie Clips

� Series 569 (360°) at Lechler Inc. in a glass box (7,5Mb) Download

Type

Eø

[mm]Connection

Flow rate [ l/min]p [bar] ( pmax = 6 bar)

<)

3,2

3,6

4,8

7,1

569.059.1Y

569.139.1Y

569.199.1Y

569.279.1Y

S prayangle

40 ps i[US gal./

min]

E = Narrowest free cross-section · *NPT on request

3/4”BS PP

AL

AL

AL

AL

3/4” S lip-on

1 “ S lip-on 1 2 3

TF07

TF07

TF07

TF07

TF10

TF10

TF10

TF10

36

52

69

103

51

73

97

145

62

89

119

178

15

22

30

45

Ordering number

1” Tri-

C lamp

10

10

10

10

360°

1313CIP Nozzles for Ethanol Production

Index | Content

�� Ethanol References

Poet Biorefining (formerly known as Broin Ethanol)

� 20 plants in 5 states owned and operated by Poet

� 10 plants built by Poet and locally owned & operated

� 15 plants planned in next near future

� 1 Billion Gallons per Year production by end of 2007

� Lechler Tank Cleaning Nozzles standard in most plants

Lechler nozzles are used at some locations by the following plant designers:

� Praj Industries Ltd.

� Delta-T

� ICM/Fagen

� ADM

� FUEL 21 GmbH & Co. KG

� DANISCO SUGAR GmbH

� BENP Lillebone

� CropEnergies AG

Lechler delivers nozzles for ethanol production also to OEM’s in France, Sweden and Finland.

�� Lechler Tank CIP Nozzles Overview

Lechler’s tank cleaning nozzles can be inserted into the vessel for periodic cleanings, or mounted

permanently for CIP applications. Illustration 11 will help you find the correct unit for your application

based on size and flow rate. There are two specifications, washing and rinsing.

�Washing indicates how far the flow travels with sufficient impact for thorough cleaning. This is a

relative measure, and gives a rule of thumb for comparing various models.

� Rinsing indicates how far the flow travels and still rinses the walls of the vessel. This will be a

much softer spray but still retain the desired coverage characteristics. Increasing pressure does

not always help increase the washing impact. These nozzles usually work best at 30 to 40 psi.

Larger units like the Gyros can go to 50 psi, but beyond these pressures the sprays tend to

atomize more which reduces cleaning efficiency. The 5TC high impact cleaning nozzle can be

operated up to 100 psi and beyond.

1414CIP Nozzles for Ethanol Production

Index | Content

1

2

3

4

56789

10

20

30

40

5060708090

100

200

300

400

500600700800900

1000

Flo

w R

ate

[U.S

. GPM

]

Washing Rinsing

5TC

3“ GYRO

2“ GYRO

1“ GYRO

ACCUClean

Whirly

Tank Diameter [ft]

1“

3/4“

1 1/2“

Flo

w R

ate

[lite

r/m

in.]

0 5 10 15 20 25 30 35 40 45 50

Tank Diameter [m]

1,5 3,0 4,6 6,1 7,6 9,1 10,7 12,2 13,7 15,2

7,6

15,1

22,7

30,3

37,9

75,7

151,4

227,1

302,8

378,5

757,1

1514,2

2271,3

3028,3

3785,4

Illustration 11: Flowrate and tank diameter of several Lechler tank cleaning nozzles. Please keep in mind: it is al-ways advisable to mount a bigger tank cleaning device than usually necessary to get additional reliability

1515CIP Nozzles for Ethanol Production

Index | Content

�� Electronic Documents

In case you have an active internet connection you can download related documents directly out of this

PDF. When you have no internet connection you can request a paper version of the documents.

Lechler Strainers >> Download <<

Conversion tablen and working aids >> Download <<

Lechler Tank Cleaning Brochure >> Download <<

Lechler Catalogue 108 >> Download <<

�� Ordering via Lechler Online Shop

Browse to https://shop.lechler.de and find even more documents about nozzles and atomization tech-

nology. Get yourself registered and buy nozzles online. In adition registered users have access to dedi-

cated papers.

To get registered for the Lechler Online Shop please write an eMail to: e-shop@lechler.de

We would be pleased to welcome you at our Shop.

Yours sincerely

Lechler Competence Center for Atomization Technologies

1616CIP Nozzles for Ethanol Production

Index | Content

Lechler GmbH

Precision Nozzles · Nozzle Systems

P.O. Box 12 23

72544 Metzingen / Germany

Phone: +49 (0 ) 71 23 962-0

E-Mail: info@lechler.de

©Lechler GmbH 2008

�� Contact

In case you need further assistance when selecting nozzles for your application, contact us directly.

You can reach us by phone or via eMail.

Lechler GmbH

Ulmer Str. 128

72555 Metzingen, Germany

Phone: +49-7123-962-0

Fax: +49-7123-962-444

eMail: info@lechler.de

Lechler Inc.

445 Kautz Rd.,

St. Charles, IL 60174 USA

Phone: +1-(800)-777-2926

Fax: +1-(800)-444-7069

eMail: GeneralMgr@LechlerUSA.com

Lechler India Pvt. Ltd.

Plot No B 2, Main Road, Wagle Industrial Area,

THANE 400 604, India

Phone: +91-22-2582-1196

Fax: +91-22-2582-1262