Ensure Optimal Selection with this Comparison of Online Cleaning Solutions for Heat Exchangers and Condensers

Germany’s MAN Turbine Manufacturing initiated the development of on-line or continuous condenser cleaning systems for their power plants in the last century. The company asked its two senior engineers (Hermann Heeren and Josef Taprogge) independently to come up with a solution for efficiency loss due to fouling.

Hermann and Josef retreated to their design benches to wrack their brains for the best solution. Inspiration struck both individually, so today there are two on-line cleaning systems on the market. The solutions they devised are as follows.

Both condenser cleaning systems proved workable, although Hermann jokingly asked Joseph if he would also recommend using sponges as a tool to avoid scaling in dental hygiene strategy.

But seriously, let’s have a closer look at these two systems. We’ll do so by pointing out the disadvantages of one approach in comparison to the other (click “+” for details).

Failure to maintain the ball-type condenser cleaning system can result in tube fouling, reducing diameter and compromising efficiency. Subsequent replacement ball addition risks misfitting, leading to tube blockages. Once cleaned tubes become a blockage hazard. Regular maintenance is critical to prevent such issues, ensuring optimal system performance and longevity.

In practice, the recurring issue arises when operators opt to cut costs by neglecting the timely replenishment of sponge balls. This oversight leads to operational challenges and compromises system efficiency. Timely ball replenishment is essential to maintain the optimal performance of these condenser cleaning systems and prevent costly disruptions in the operation of your chiller.

We can conclude that both systems are effective in avoiding fouling that decreases the condenser’s efficiency and while doing so, minimizing electricity waste from the compressor. As a supplier of continuous tube brushing systems, however, we like to highlight the fact that brushing allows worry-free operation with minimal need for checking and the lowest operating cost.

A hotel chiller (450 RT) runs with a 270 kW compressor motor with 600 tubes. The compressor running time is 5,000 hrs. per year over a period of 10 years. Total running time 50,000 hrs.
Over the functional lifespan, an easy 1,000 MWh can be saved on electricity (based on 10% waste) which in most countries is around US$ 100,000.
For comparison, the typical Capex of this chiller is also around US$ 100,000 (US$ 200-300 per RT).

We can conclude that chillers with continuous cleaning system save as much on electricity over their functional lifespan as the investment in the next chiller will be. The system pays for your next chiller, therefore.