Asset Type
NGL Heat Exchanger Bank
Location
El Merk Site, Algeria
Client
Groupement Berkine (GB)
Project Phase
2025 Major Shutdown
Units Treated
7 Exchangers (Tube Side)
Primary Contaminant
Multi-phase paraffin wax and organic matter
Constraints
Height access at 20 m, limited tube entry, exchangers paired and inseparable
During the October 2025 shutdown at the El Merk facility, Groupement Berkine (GB)required a reliable solution to clean seven NGL exchangers that had been contaminated for many years. The fouling was severe, comprising distinct phases of paraffin wax and organic residues that had accumulated to the point of clogging tubes and preventing essential inspections. Mechanical cleaning was impossible due to exchanger design and restricted access. The units were installed 20 m above ground, paired together without separation points, and held large internal volumes—factors that significantly increased operational complexity and safety risk. Repeated attempts to solve the issue had been unsuccessful, making efficient, safe cleaning of the exchangers the most critical path of the entire shutdown.
Hydratight carried out detailed engineering studies alongside our laboratory partner to define a method capable of dissolving the hydrocarbon-based contamination while maintaining strict safety and environmental standards. An initial hydrocarbon-solvent approach (Diesel/Xylene) showed technical promise but presented unacceptable execution and HSE risks. Working collaboratively with GB, Hydratight engineered an alternative procedure that delivered the required cleaning performance without the hazards associated with aromatic solvents.
Final Cleaning Method
A four-stage process was developed using a surfactant and soft co-solvent system, supported by controlled heating and chemical conditioning:
1. Hot Water + Surfactant + Co-Solvent Circulation
Dissolved and mobilised waxy and organic deposits at 50–70°C.
2. Caustic Wash (NaOH)
Neutralised acidic residues and saponified remaining fatty materials to enhance removal.
3. Final Cleaning Cycle
A fresh solution of surfactant and co-solvent flushed out all caustic traces and remaining contaminants.
4. Citric Acid Cleaning & Passivation
Removed mineral deposits and restored metal surface condition using a nitrite-based passivation step.
Specialist Equipment Provided
- FS4000 flushing skid
- Steam generator
- External heat exchanger
- Chemical mixing tank
Despite this being the first project of its type for Hydratight, the onsite team executed the procedure with precision, discipline and strong alignment with the site engineering plan.
The cleaning process exceeded GB’s expectations. All seven exchangers were restored to a condition that allowed full tube inspection—a milestone the client had been unable to achieve for years. The work was completed safely, efficiently, and without disruption to the broader shutdown schedule. The result: renewed exchanger integrity, restored inspectability, and improved confidence in future plant reliability.
If your heat exchangers or process equipment require specialist chemical cleaning, Hydratight’s engineering-led approach delivers safe, proven and inspection-ready results.
Speak with our team to discuss your operational challenge.
