Heat Exchanger Cleaning in the Plastics Industry

Heat exchangers play a crucial role in the plastics manufacturing, blow moulding and recycling industries in a variety of ways including:

• Temperature Control during various processes like melt and moulding, extrusion, and cooling. Without proper temperature control, the plastic products will not have the desired properties and the process will be less efficient.
• Heating is usually applied to surrounding equipment to maintain temperatures of operation
• Cooling is just as important as heating to maintain product density and flow rates
• Drying plastic materials by removing moisture from the air
• Sterilising where plastic products may be used in the food and medical industries

Why do Heat Exchangers need Cleaning?

Over time, heat exchangers can become contaminated and clogged after being exposed to various types of materials, which can include plastic particles, dust, oil/vapours and other contaminants. These contaminants can accumulate on the surfaces of the heat exchanger, reducing its efficiency and affecting heat transfer. 

Additionally, if plastic materials are not properly cleaned before being processed, they can cause contamination and clogging. The accumulation of debris and buildup can impede the flow of materials and fluids through the heat exchanger, decrease the heat exchanger’s capacity to transfer heat, leading to lower efficiency and higher energy consumption.

The cleanliness of heat exchangers is essential to maintaining their efficiency and prolonging their lifespan. 

How do you Clean Heat Exchangers?

When it comes to cleaning heat exchangers, there are several different methods that can be used to remove dirt, debris, and other buildup that can accumulate on the surfaces of the heat exchanger over time. These include:

• Chemical flushing: Using chemicals to dissolve and remove buildup from the heat exchanger surfaces. Chemicals such as acids and alkalis are used to break down the buildup, which is then flushed away.
• Mechanical cleaning: Mechanical tools such as brushes, scrapers, and high-pressure water jets remove buildup from the heat exchanger surfaces. This type of cleaning is often used for heat exchangers that have heavy buildup or are difficult to reach.
• Ultrasonic cleaning: Ultrasonic cleaning is an unrivalled way of removing contamination from the complicated engineering of heat exchanges, it not only dissolves the contaminant into the solution but the ultrasonic energy rips it from the surface anywhere that the solution touches, giving you a very high-end finish and confidence of outcome.
• Pyrolysis burn-off: This method is not that common because usually heat exchangers are made from softer metals such as copper or aluminium but in some cases where they are made of steel then we can burn off materials like oils or polymers that have contaminated them. The good thing about pyrolysis is it’s 100% removal of material and only requires a quick jet wash to remove the ash.
• High-pressure jet washing: Using high-pressure water jets removes certain types buildup from the heat exchanger surfaces. Jet washing is effective in removing dirt and debris, but it is not recommended for use on heat exchangers that have been contaminated with chemicals.

All these methods are used to remove buildup and debris from heat exchangers, allowing them to operate at optimal efficiency and prolonging their lifespan but it’s the combination of cleaning methods that will produce the best results. 

The thorough cleaning of heat exchangers can help prevent equipment breakdown, save on energy costs and improve the final product quality.

Take a look at how we cleaned a heat exchanger and other parts from a plastic recycling drying system. The end result is pretty impressive!

The Benefits of Cleaning Heat Exchangers

Regular cleaning and maintenance of heat exchangers is crucial for efficiency and safety in plastics manufacturing, blow moulding, and recycling. 

Keeping heat exchangers clean, can improve energy efficiency, reduce emissions, and prolong the lifespan of equipment, while ensuring the highest quality of final products. Additionally, it can prevent equipment breakdown, downtime and save companies from unexpected costs!

Using multiple cleaning methods will ensure the best results. Combining these methods with our experience, knowledge, flexibility and passion delivers the best results for every one of our clients. The same results cannot be achieved from in-house cleaning or cleaning operations with a single cleaning method.