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RUSONICS – Descale

Scale formation and Fouling of heat Exchangers, Process tubes, Evaporators

The chemical-free cleaning process for cleaning and avoiding scale formation. Scaling in process equipment is a huge menace. Resulting in a loss in production and energy due to lower efficiency, loss of production capacity planned or unplanned shutdowns, and high maintenance costs for cleaning these equipment.

Process Operations

Scale formation occurs in the process industry where liquids flow in tubes and heat is exchanged. Fouling is due mainly to unwanted substances that accumulate and collect on the inside surfaces. 

Maintenance is mandatory in heat exchangers but cannot be done online and is performed using chemicals or mechanical equipment to remove the residue inside the heat exchanger. The clean heat exchangers with the highest heat transfer coefficient reportedly use less energy for operations, which decreases the emissions of CO2.

The RUSONICS ultrasonic technology allows continuous, online cleaning of process equipment, increases energy recovery and heat transfer rates through the prevention of formation of scaling or fouling on the heat exchange surfaces, reduces the need for both mechanical maintenance and use of harsh cleaning chemicals, protects the environment by reducing CO2 emissions since heat exchangers can be run at optimum heat transfer efficiency as well as decreases the toxicity to the environment by reducing the use of harsh chemicals.         

Since fouling reduces the heat recovered from product streams, more heat must be supplied by the heat source to more or less match the reduced feed temperature. Operating costs can go up to 6% from higher fuel consumption. RUSONICS  increases turbulent flow and sustains surface cleanliness, allowing improved heat transfer. Use Cavitation to our advantage.

Installing RUSONICS can bring performance levels similar to when the equipment was first put into service five years prior.

Fouling of tubes slows the effective diameter through which heat transfer occurs. Throughput limits include hydraulic pressure or duty constraints. Standard procedures for restoring some throughput include online spalling of the tubes or incurring a production shutdown to clean the assets.

Cleaning a heat exchanger can require more than 20+ activities, including unit bypass, depressurising, in-situ pre-clean treatments, scaffold assembly, Hx disassembly, crane, bundle extraction, transporting to a cleaning area, cleaning contractor, water, chemicals and remediation of the water, chemical and waste products. This process repeats in reverse for putting an exchanger back into service. Each step involves multiple contractors, permits, meetings, reports, and potential delays. Huge Costs.

Opening heat exchangers for cleaning is a significant safety and hazardous environmental risk. Hundreds of company colleagues fall prey to the chemicals and cleaning each year.

Approx. 2,5% of global CO2 emissions reportedly come from process equipment fouling and poor performance, leading to energy losses.

Features and Advantages

With Technology support from our UK partners, one of the most prolific suppliers of expertise and equipment for Produced Water Treatment packages worldwide, Diva Envitec installs and operates cost-effective, efficient equipment for the Oil and Gas Sector.

Technical Specifications
  • Increase Process Run-time
  • Increase Profitability
  • Enhanced Energy Recovery
  • Reduced Fuel Costs
  • Effective Heat Transfer
  • Improved Product Throughput
  • Reduced Pumping costs
  • Reduced maintenance costs
  • Reduce Downtime
  • Health, Safety, and the Environment
  • Reliable
  • Low CO2 Emissions
  • Descaling of Heat Exchangers
  • Avoid fouling of Evaporators
  • Clean Pumps and Valves
  • Tubes and Pipelines
  • Chemical
  • Pharmaceutical
  • Fertilisers
  • Oil & Gas
  • Pulp and paper (Black liquor)
  • Refineries
  • Food & Beverage