MADE IN GERMANY

CIP Systems for Biomass Heat Exchangers

cleanXchanger develops custom-engineered Clean-in-Place systems for the chemical cleaning of your heat exchangers.

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Industry Partner:

The Problem

Deposits are costing you efficiency

In all biogas plant heat exchangers, solid deposits gradually form — most commonly struvite (NH₄MgPO₄·6H₂O). These crystals build up on heat transfer surfaces, forming hard layers that restrict heat exchange.

The result: higher energy consumption, costly downtime, and labor-intensive manual cleaning.

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Inside of a heat exchanger pipe

The Problem

without cleaning

Our Solution

with cleaning

View Fouling Details

Typical challenges for plant operators

Deposits inside heat exchangers lower performance and increase operating costs — usually only detected when it’s already too late.

High Cleaning Effort

Frequent mechanical cleaning with hammers or high-pressure tools. Loss of time, tied-up personnel, reduced productivity.

Hidden Efficiency Loss

The plant appears to run normally but delivers up to 30% less performance. A higher energy demand for the same heat output = heat exchanger fouling.

Fluctuating Biomass Quality

Different substrates create varying fouling compositions. No standardized cleaning solution — more frequent and intensive cleaning required.

Increased Wear > Higher Operating Costs

Deposits increase flow resistance inside pipelines. Pumps work harder > higher energy consumption, faster wear, rising maintenance costs.

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UNSERE LÖSUNG

OUR SOLUTION FOR ALL BIOGAS PLANT OPERATORS

Automated CIP Technology

How the cleanXchanger process works

cleanXchanger replaces manual cleaning with intelligent automation. Our CIP systems chemically clean heat exchangers and piping precisely and completely during operation — without imposing additional stress on system components from the cleaning chemicals used.

Using sensors and control systems, the cleaning solution is precisely regulated, optimally heated, and circulated through the system in multiple cycles until all deposits are safely dissolved.

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01 – Water Flushing

Initial flush removes loose particles and prepares the system for chemical cleaning.

02 – Dosing & Heating

A heated, sensor-controlled cleaning solution circulates through the system and dissolves even stubborn struvite and biomass deposits.

03 – Neutralization

The solution is neutralised and the system flushed until all residues are removed.

04 – Monitoring

All parameters (pH, temperature, flow) are continuously monitored and documented to verify performance.

Benefits

Why plant operators choose us

Heat Transfer Performance

Downtime

Lower Cleaning &
Maintenance Costs

* Based on internal average calculations. Results may vary.

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View of a heat exchanger line

without cleaning

with cleaning

How cleanXchanger makes the difference

Deposits such as struvite restrict pipe cross-sections, reducing energy efficiency, uptime, and profitability. Our CIP systems chemically dissolve these deposits without dismantling or production downtime.

The result: free flow, stable thermal performance, and long-term operational efficiency.

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*You receive a brief assessment of the optimal cleaning strategy — based on real chemical laboratory analyses.

Applications

Wherever heat is recovered from biomass, cleanXchanger keeps heat exchangers clean and processes efficient.

Biogas
Plant

Chemical
Processing

Waste
Treatment

Wastewater
Treatment

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Bedarfsgerecht konfiguriert

Every system is custom-engineered

Every cleanXchanger system is individually designed based on the fouling analysis, the process medium, and the specific conditions of your site. From the heating section to chemical dosing — the modular architecture allows full flexibility in configuration and expansion.

Main Sections of the CIP System:

Standard Configuration

(Basis)

Automation & Control

Intelligent process control with continuous monitoring of process parameters and flow sensors.

Pump & Valve Unit

Robust, low-maintenance design, optimally matched to chemical cleaning requirements.

Cleaning Solution & Neutralization Tanks

Individually sized tanks made from corrosion-resistant materials.

Data & Process Monitoring

Including remote monitoring and digital reporting.

Extended Configuration

(optional)

Centrifugal Separator

Advanced process control with pH, temperature, and flow sensors.

Efficient Solids Separation

For the removal of dissolved and undissolved particles.

Water Treatment

To meet specific local regulations and environmental requirements.

Individuelle Anlagenlösung

Ihr Weg zur individuellen Anlagenlösung

Analyse-Gespräch

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Säure-/ Laugenermittlung

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Anlagenauslegung

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Kostenlose Potenzialanalyse anfragen

Anlagen im einsatz

Fallstudien

Erfolgreiche Projekte im Einsatz. Sehen Sie, wie cleanXchanger Ablagerungen beseitigt, Prozesse stabilisiert und Energieeffizienz messbar verbessert.

Jetzt individuelle Anlage anfragen

CXC20

140m³ Reinigungsvolumen

Mönsterås | Schweden

Jetzt ansehen

CXC25

140m³ Reinigungsvolumen

Mönsterås | Schweden

Discover our compact system design and flexible configuration options.

Every system is custom-built, request your free, no-obligation consultation to find out how we can improve the efficiency of your facility.

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Worldwide transport and installation included.

Our philosophy

cleanXchanger represents engineering-driven innovation in heat exchanger cleaning. Our solutions combine years of experience with analytical research and practical development. Designed on the basis of data and laboratory analysis, they deliver measurable performance, efficiency, and operational reliability.

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