ECOMax-HE™Automatic Tube Cleaning System
Problems affecting performance in Shell and Tube Heat Exchanger:
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• Tube vibration
• Dead zone
• Leakage
• FOULING
� Design / Fabrication
� Fabrication / Maintenance
���� Operation Cost
Types of Fouling:
1. Scaling/Chemical fouling
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The cooling water contains salts of calcium & magnesium. At elevated temperature salts of
calcium & magnesium tend to precipitate & deposit on the heat exchanger surfaces. The
chemical changes within the fluid cause a fouling layer to be deposited onto the tube
surface.
Types of Fouling:
2. Biological fouling
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Organic debris that adheres to inside diameter of tube surface or blocks the intake flow at
the tube sheet. This is caused by the growth of organisms within the fluid which deposit
out onto the surfaces of the heat exchanger
Types of Fouling:
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3. Deposition fouling
This is when particles contained within the fluid settle out onto the surface when the fluid
velocity falls below a critical level, i.e., small particle dust. Although the water quality is
maintained because of the dusty surrounding in the area.
Types of Fouling:
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4. Corrosion fouling
This is when a layer of corrosion products build up on the surfaces of the tube forming an
extra layer of, usually, high thermal resistance material.
Effects of Fouling:
• Reduces the Heat Transfer Coefficient of tubes
• Reduces cooling or heating capacity of heat exchanger
• Result into increasing of specific power consumption in
order to get the required heat transfer output
• Result in heavier working duty of relate equipment and
their working life
• Result in additional operation cost for power consumption
and maintenance
Effect of Fouling :
• Fouling decrease Heat Exchanger’s overall
heat transfer coefficient, thus reduce heat
transfer ability of the Heat Exchanger
Effect of Fouling :
Heat energy transfer from hot fluid to cold fluid is reduced
Effect of Fouling :
Cooling Capacity (TR) COP =
Power Consumption (kW)
Effect in Chiller Coeffiency
of Performance (COP)
• Fouling reduces cooling/heat
rejection capacity
• Fouling increase compressor
power consumption
Fouling Scale Thickness Vs Power Consumption
1 mm of fouling accumulation in the heat exchanger tubes
increases energy consumption ~ 30%
Offline Cleaning Method: Drawbacks
• Chemical cleaning by acids or similar chemicals
• Chemical cleaning may damages tubes in long run &
reduces tube life
• Standby other equipment in the system very critical during
manual cleaning
• Acid cleaning causes environmental problem due to
disposal issues
• Frequent mechanical cleaning deforms tubes
• Frequent manual / offline cleaning requires
• Heat exchanger disassembly, needs additional manpower &
time
How to eliminate these issues?
Offline/Shutdown Cleaning & Loss of Energy:
The Solution ECOMax-HE™: Automatic Tube Cleaning System
The Solution ECOMax-HE™: Automatic Tube Cleaning System
1. Injection Pump
2. Collection Pump
3. Ball Collector
4. Ball Trap
5. Control valves
6. PLC based Control Panel
7. Multi Color HMI
8. Skid
Components:
Balls pass through each tube, How is it ensured?
• Works on the probability• No. of balls equals 40% of the no. of tubes in the
first pass of heat exchanger• Probability of balls not passing into the specific tube is 0.6• No. of cycles in one hour = 3 nos.• Probability of balls not passing in one hour = (0.6)*3• Probability of balls not passing in 24 hours = (0.6)*72 = 10.6 x
10-16
• Probability of balls passing through each tube =
[1 - (10.6 x 10-16 )]*100 = 99.999999999999999%
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Condenser Tubes after ECOMax-HE™ : After 1 Year
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Condenser Tubes after ECOMax-HE™ : After 20 Months
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The Solution ECOMax-HE™: Automatic Tube Cleaning System
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• All kinds of shell and tube heat exchanger
• Oil refinery
• Petro chemical process
• Food industry
• Industrial manufacturing
• Chiller (Condenser and Evaporator)
• Custom design to suit required configuration
Applications:
Key Features of ECOMax-HE™ :
• Fully automatic, no manual intervention
• Cleaning is done on continuous basis online
• Zero ball loss system, no balls can escape to cooling
tower
• Ensures 100% clean tubes
• Single System for Multiple Heat Exchangers
• Smart System, gives an alarm for Sponge Ball
Replacement
• Automatically operates a cleaning cycle on the
running heat exchanger
Key Features of ECOMax-HE™ :
• User Friendly Graphical User Interface (GUI)
• Touch screen Multi Color HMI
• Indicates number of cleaning cycles on individual
chiller
• Completes the cleaning cycle even if the chiller is
stopped during the cycle
• No water wastage from the system
• No mixing of CW inlet and CW Outlet Water during
operation
• Minimal pressure drop in the Ball Trap
• Negligible power consumption by the booster pumps
• Highly reliable as the system has less no. of
control valves
• Cleaning Sponge Balls would never be in contact
with pump impeller
• Compact, smaller foot print
• While venting air from Ball Collector, sponge balls
cannot escape from Ball Collector
• Sight glass on the ball collector facilitates easy
counting & monitoring of sponge balls
• No plant shut down for system installation
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Key Features of ECOMax-HE™ :
• Simultaneous injection cycle in one heat exchanger
and collection cycle in another heat exchanger is
possible
• Results in up to 20% energy saving in HVAC chillers
• Increase cooling capacity of heat exchanger
• Improves heat exchanger tube life
• Improves relate equipment working life
• Avoids costly shutdown and downtime
• Eliminates offline cleaning completely
• Very cost effective, usually offers a payback of less
than a year
• Green Technology
Key Features of ECOMax-HE™ :
ECOMax-HE™ Installed Units
Single Unit Condenser/Heat Exchanger
ECOMax-HE™ Installed Units
2 Units of Condenser / Single Control Center
ECOMax-HE™ Installed Units
5 Units of Condenser / Single Control Center
ECOMax-HE™ Installed Units
Reference Clients :
Testimonial :
Testimonial :