Maintaining the efficient operation of heat transfer systems in industrial plants is a key part of ensuring operational fluidity. One of the biggest challenges in this regard is coke-type deposits, which can build up in systems over time, reducing efficiency and increasing operating costs.
This article looks at a modern strategy to combat the coke-type deposits problem proposed by Ecol, including diagnostics, innovative service solutions and the benefits of this approach.
Heating oils are a medium used in industrial systems to transfer heat energy. They make it possible to effectively maintain the correct operating temperature of machines and plants. These oils must meet high quality requirements, such as:
Properly selected and high quality heating oil can be used for several years, making it an important element in optimising processes.
Despite their high quality, heating oils are subject to natural ageing processes. Repeated heating and long periods of use lead to the formation of coke-type deposits. It is these deposits that are the source of many problems, such as:
Coke-type deposits are formed as a result of thermal ageing of heating oils. The high operating temperature and the chemical reactions involved promote the precipitation of deposits that settle on the walls of pipes, heat exchangers and other system components.
The accumulation of coke-type deposits significantly reduces the efficiency of heating systems:
Regular removal of deposits is therefore key to maintaining the efficiency and effectiveness of the heating system.
We have developed a state-of-the-art strategy to combat coke-type deposits that combines diagnostics, laboratory testing and advanced cleaning methods.
This approach allows the service to be tailored to the unique needs of each site.
Our activities are fully measurable and transparent, as evidenced by the final reports and qualitative surveys carried out after the service has been provided.
The first step in the successful removal of coke-type deposits is to understand the problem in detail and to understand the specific construction and operation of the heat transfer system.
At this stage, technical consultations, precise tests under laboratory conditions and analysis of the results play a key role.
At the start of implementation, Ecol’s experts analyse the needs, the specifics of the installation, the operating history and current problems with the heat transfer system. This allows a precise definition of the purpose and expectations of the service.
Under laboratory conditions, we carry out cleaning tests with different chemical formulations. On the basis of tests with oil from a given system, we study the removal efficiency and the behaviour of the agent at different concentrations and temperatures. This allows us to select the most effective active substance for the case in question.
In addition to efficacy, we also analyse the safety of the application. We determine the minimum effective dose that will allow effective cleaning of the heat transfer system installation, but at the same time will not adversely affect other components of the installation or the quality of the oil after the process. This measure translates into reduced costs and minimised operational risks.
Based on the test data, we prepare an individual system cleaning strategy. This document includes, among other things, information on flushing time, agent concentration, types of application equipment, critical points in the system and a schedule of activities. We take into account both technical aspects and economic optimisation to ensure maximum value for the customer.
Once the diagnostic phase has been completed and an individual action strategy developed, we move on to the actual implementation of the cleaning process. This is the key operational stage during which the plan is put into practice.
Thanks to precise execution and constant supervision, the implementation of the process is carried out in a way that takes into account the specific characteristics and rhythm of the plant.
On the basis of a prior analysis, we select suitable units for flushing heat transfer systems, taking into account, among other things, the length of the system, pipe diameters and the location of the access points. The units are strategically positioned to allow the effective flow of the cleaning agent through each segment of the system.
In critical or hard-to-reach areas, we create temporary flushing circuits that allow the cleaning of separated parts of the plant to be carried out autonomously, without interfering with the entire process network. This flexible solution minimises downtime and increases the efficiency of operations.
According to a predetermined plan, we apply a pre-selected chemical in the appropriate concentration. The process is carried out under technical supervision and the flushing parameters (pressure, temperature, flow) are continuously monitored to achieve maximum chemical effectiveness without risking damage to the installation.
Throughout the process, we carry out constant monitoring of the system’s technical condition – we analyse filter contamination and oil cleanliness class using a mobile laboratory on site. This allows us to react quickly if irregularities are detected and to adjust cleaning parameters in real time.
After the initial flushing is completed, we carry out an endoscopic examination of the interior of the plant. With this technology, we are able to accurately locate areas where deposits persist despite the chemical and plan additional cleaning measures in these zones.
In particularly contaminated areas that require intensive mechanical treatment, we use high-pressure hydrodynamic cleaning (above 1,000 bar). This technique allows the physical detachment of deposits without unnecessary disassembly of most of the system.
Once all the activities are completed, we carry out final tests of the oil cleanliness class and a technical evaluation of the installation. We provide the results, together with photo documentation and a description of the individual steps, to the client in the form of a summary report. This not only confirms the effectiveness of the measures, but also provides a knowledge base for further monitoring of the plant’s condition.
The method proposed by Ecol does not focus solely on the application of a cleaning agent, but on a comprehensive service combined with diagnostic measures focusing on each individual case. Each problem is dealt with on an individual basis and then undergoes a testing phase in close cooperation with our accredited laboratory. During the tests, we not only select the most effective cleaning agent, but also examine the amount of cleaning agent that does not exceed a reasonable limit.
On the basis of our investigations and tests and our individual approach to each case, we determine an effective strategy for the removal of coke sludge so that the objective achieved is satisfactory and economically viable.
Thanks to the use of a mobile laboratory, it is possible to constantly monitor the quality of the process. Endoscopic testing and hydrodynamic cleaning allow the dirtiest areas to be located and cleaned effectively, increasing the efficiency of the entire process.
The end result of successfully removing coke-type sludge from the heat transfer systems is:
The effectiveness of this strategy has been proven in practice in an industrial environment and the results have been measurable. After the work is completed, each time clients receive not only the service, but also a valuable final report, providing a knowledge base for further operation and prevention.
If your heat transfer systems is struggling with sludge, don’t wait for a drop in efficiency or costly breakdowns. Get in touch with our team and explore options for implementing a strategy that really works.
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