Two Methods for Cleaning Heat Exchanger Tubes: Chemical Cleaning vs. Hydroblasting

Shell and tube heat exchangers are crucial in many industries, from oil and gas to food and beverage. Despite the differences in these fields, they share the need for well-maintained shell and tube heat exchangers to prepare products for consumers.

When using a shell and tube heat exchanger, the fluid that is more likely to corrode or foul is typically placed on the tube side. This is because the tubes are easier to clean or replace than the shell. This makes it vital for operators to know how to properly clean and maintain the tubes.

Shell and tube heat exchangers come in various sizes and configurations. Some are easier to clean than others, mainly because some have tube bundles and bonnets that can be easily removed from the shell, while others are connected to the body of the exchanger. Knowing the type of bonnet your exchanger has and the appropriate cleaning method is crucial when purchasing the exchanger.

There are several ways to clean the tubes of a heat exchanger, each with pros and cons. It’s important to choose the right method for your specific machine and operation.

Chemical Cleaning

Chemical cleaning is effective for fixed-channel box designs, which can be particularly challenging to clean because the tubes are not detachable from the shell. The chemicals can be circulated through the tubes or cascaded. This approach is advantageous for exchangers with substantial build-up, as the chemicals can remove more deposits than many alternative cleaning techniques.

However, chemical cleaning is one of the more expensive options. It often necessitates mechanical cleaning afterward to eliminate any residual substances that could contaminate future batches. Additionally, this method can be time-consuming and pose potential environmental risks, depending on the type of chemicals used and waste management practices.

Hydroblasting

Hydroblasting uses high-pressure water to blast away debris or deposits in the tubes. Hydroblasting does not involve the use of hazardous chemicals, making it a more environmentally-friendly cleaning option.

This method can be done manually or with an automated system. The manual approach involves an operator using a high-pressure hose to clean each tube individually, which is effective and relatively inexpensive but can result in uneven cleaning and safety concerns due to the high water pressure.

Automated systems, such as flexible lance and rigid lance systems, allow multiple tubes to be cleaned at once, saving time. Flexible lance systems are suitable for U-tube heat exchangers and those with curved tubes, while rigid lance systems are better for exchangers with straight tubes due to the higher water pressure they can provide.

While hydroblasting is effective, if the water pressure is not carefully controlled, could weaken the tubes and create leaks. The water and debris generated during the hydroblasting process must be properly collected and disposed of, which can add to the overall cost of the cleaning operation.

Choosing the Right Cleaning Method

When it comes to selecting the best cleaning method for your heat exchanger tubes, there are several factors to consider, including the type and severity of the deposits, the materials of the heat exchanger, the available budget, and the overall impact on your operations.

In general, chemical cleaning may be the preferred option for larger heat exchanger systems or for removing stubborn deposits that are difficult to access. However, if environmental concerns or the potential for residual chemical deposits are a priority, hydroblasting may be the better choice.

It’s important to carefully evaluate the pros and cons of each method and consult with experienced professionals to determine the most suitable approach for your specific heat exchanger cleaning needs. Regular maintenance and cleaning are essential for ensuring the optimal performance and longevity of your heat exchanger equipment.

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