Heat Exchangers Performance: Manual Cleaning vs Ultrasonic Cleaning

The performance of heat exchangers is critical to the proper functioning of various industrial processes. These pieces of equipment are essential for transferring thermal energy between fluids in applications such as power generation, refrigeration, chemical processing, and many more. However, over time, heat exchangers accumulate deposits of dirt, scale, oxides, grease, and other contaminants that affect their efficiency. Keeping them clean is crucial to ensure their optimal performance.

 

Importance of Heat Exchanger Cleaning

Over time, heat exchangers accumulate scale on their internal and external surfaces, especially in areas such as tubes, fins, and plates. These deposits, composed of minerals, sediment, rust, and chemicals, act as thermal insulators, significantly reducing heat transfer. The buildup of scale leads to multiple problems, including:

• Reduced thermal efficiency: Increases the time required to heat or cool fluids.
• Increased energy consumption: More resources are required to compensate for efficiency losses.
• Increased equipment wear: Overheating and additional pressures affect the life of the exchanger.
• High maintenance costs: Premature failures and frequent repairs generate additional expenses.

For these reasons, proper cleaning of heat exchangers is essential to maintain their performance and prolong their service life.


 

Ultrasonic cleaning - heat exchangers

Ultrasonic cleaning is an advanced method that uses high-frequency sound waves (usually between 20 and 40 kHz) to generate millions of microscopic bubbles in a cleaning liquid. This phenomenon, known as cavitation, produces controlled implosions that effectively remove dirt and contaminants, even in the most difficult-to-reach areas.

Advantages of ultrasonic cleaning for heat exchangers:

• Deep and uniform cleaning: Ultrasound reaches all surfaces, including the inside of pipes, corners and areas inaccessible to manual methods.
• Speed ​​and efficiency: Significantly reduces cleaning time, minimizing equipment downtime.
• No damage: It is a non-abrasive method that preserves the integrity of the critical surfaces of the exchanger.
• Reduced chemical use: In most cases, only a mild detergent is required, reducing environmental impact and risks to workers.
• Consistent results: The technology ensures uniform cleaning in each cycle, without depending on the manual skill of the operator.
• Extends equipment life: By removing scale and contaminants without damaging surfaces, it prolongs the functionality of the exchanger.

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Heat exchangers - manual cleaning vs ultrasonic cleaning

Manual cleaning and ultrasonic cleaning have significant differences in effectiveness, accessibility, cleaning time, potential damage and long-term costs.

1. Accessibility:

• Manual cleaning has considerable limitations, especially on complex geometries such as inner tubes, fins and hard-to-reach corners.
• On the other hand, ultrasonic cleaning reaches all surfaces, including the most inaccessible internal areas, thanks to the sound waves that evenly penetrate the cleaning liquid.

2. Efficiency:

• The quality of manual cleaning depends largely on the skill of the operator, which leads to inconsistent results and may leave residue in certain areas.
• Ultrasonic cleaning ensures uniform and consistent results, removing even the most difficult contaminants with precision.

3. Cleaning time:

• Manual cleaning is a slow and laborious process, which can significantly increase equipment downtime.
• Ultrasonic cleaning reduces the time required to complete the process, optimizing resources and minimizing interruptions.

4. Damage to surfaces:

• Manual cleaning with abrasive tools can scratch or damage critical surfaces of the heat exchanger, affecting its long-term performance..
• Ultrasonic cleaning is completely non-abrasive, preserving the integrity of materials even after multiple cleaning cycles.

5. Use of chemicals:

• Manual cleaning typically requires the use of harsh chemicals to dissolve tough scale, which can be dangerous to workers and the environment.
• In ultrasonic cleaning, the use of chemicals is minimal, as the process takes advantage of cavitation to remove contaminants.

6. Long-term costs:

• Manual cleaning can incur high costs due to the need for intensive labor, chemicals, extended downtime, and equipment wear.
• Although ultrasonic cleaning requires an initial investment in equipment, operating costs are significantly lower in the long term due to efficiency, speed and reduced wear on equipment.

Ultrasonic cleaning has proven to be a superior solution for maintaining and restoring heat exchangers. Its advantages in terms of efficiency, precision and sustainability make it a must-have technology for industries looking to maximize the performance of their equipment.

If you are looking for more efficient, faster and more reliable cleaning for your heat exchangers, DCM Ultrasonic is your best ally. Contact us today and find out how we can help you optimize your processes.