Xuancheng Pharmaceutical Shell-and-Tube Heat Exchanger UHP Cleaning Services

Abstract: Shell-and-tube heat exchangers in Xuancheng pharmaceutical plants — used in evaporation, concentration and crystallization — accumulated dense lithium sulfate scale as lithium-bearing liquor concentrated, blocking 40% of the tubes and cutting heat transfer sharply. We applied 200-250 MPa ultra-high-pressure (UHP) water jetting with imported polished rotary nozzles and a rotary air gun: clear tubes finished in reciprocating passes, blocked tubes cleared progressively, restoring 100% tube pass rate and heat transfer efficiency above 95%. This article reviews common scale forms, the UHP process and the on-site service workflow for pharmaceutical plants in Xuancheng.

1. Why Xuancheng Pharma Plants Need Heat Exchanger Cleaning

Xuancheng, in southeast Anhui, hosts a dense pharmaceutical and fine-chemical cluster: the bio-pharma park in Xuancheng Economic Development Zone, the Guangde pharmaceutical intermediate base and the Ningguo chemical park cover APIs, intermediates and fine chemicals. Evaporation, crystallization, solvent recovery and vacuum drying all rely on shell-and-tube heat exchangers for heating and condensing — equipment that runs hot, concentrated and prone to crystallization.

Some process streams carry lithium salts; as liquor concentrates, lithium sulfate precipitates and crystallizes on the inner tube wall. Unlike ordinary carbonate scale, this salt scale is dense and extremely hard. It thickens over time, shrinking flow area until tubes plug completely. Fouled exchangers lose efficiency sharply — steam consumption rises, crystallization cycles lengthen, and in severe cases the unit is forced offline, directly hurting batch output.

We have served Xuancheng and surrounding areas for years, completing hundreds of cleaning jobs on shell-and-tube heat exchangers, reactors, condensers and pipelines across Xuanzhou, Langxi, Guangde, Ningguo, Jingxian, Jixi and Jingde, and we understand the rhythm of equipment maintenance under GMP.

2. Common Heat Exchanger Cleaning Scenarios in Xuancheng Pharma Plants

Evaporation and concentration: liquor heated in tube bundles concentrates until salts crystallize on the tube wall — the fastest scaling section. Typical symptoms are rising steam consumption, slower heating and falling evaporation efficiency; inspection usually reveals a dense crystalline layer inside the tubes.

Crystallization and separation: cooling exchangers on crystallizers stay in contact with high-concentration salt liquor and easily deposit lithium sulfate hard scale. Poor cooling leads to uneven crystal size and yield fluctuation — among the most complained-about heat exchangers in pharma plants.

Solvent recovery: vacuum concentration and solvent recovery condensers accumulate salt scale mixed with some organic matter, forming dense composite deposits. Reactor jackets, vacuum concentrators, storage tanks and process pipelines also foul and need companion treatment.

3. Core Technology: Ultra-High-Pressure Water Jetting

Because lithium sulfate scale is hard, dense and slow to dissolve chemically, we use 200-250 MPa ultra-high-pressure water jetting: pure water only, no chemicals. The jet breaks the scale by impact and cutting action, avoiding any chemical residue concern in pharmaceutical production, and the only waste is settled sludge water — simple to treat and environmentally sound.

Equipment: UHP pump unit (≥250 MPa, 15-25 L/min), imported polished rotary nozzle (316L, mirror-polished to prevent tube jamming, self-rotating 360° by water back-pressure), UHP rotary air gun (0.6-0.8 MPa compressed air drive, for impact-clearing of blocked tubes), rigid lance and quick-coupling safety hose.

Process parameters: clear tubes cleaned at 200-250 MPa, nozzle speed 500-1500 rpm, lance feed 0.5-1.5 m/min in 2-3 reciprocating passes until return water is free of debris and the wall shows bare metal; blocked tubes are cut from the lighter end with the rotary air gun, advanced section by section until through, then finished by the normal program. After cleaning, tubes are blown dry and capped. Acceptance follows GB/T 25146-2010: 100% tube pass rate, borescope spot check on ≥10% of tubes, and a leak-free hydrostatic test after head reinstallation.

4. Xuancheng Service Track Record & Cases

A Xuancheng pharmaceutical plant shell-and-tube heat exchanger: liquor in the evaporation section carried lithium salts; after one year of operation heat transfer dropped markedly. Inspection showed dense, extremely hard lithium sulfate crystals on the tube walls, with 40% of tubes partially blocked or completely plugged. UHP water jetting was applied: heads removed and tube sheets cleaned, air test marking every tube, clear tubes finished with polished rotary nozzles, blocked tubes cleared with the rotary air gun, then blown dry and heads reinstalled with a hydrostatic test. The full bundle was cleaned in two shifts: 100% tube pass rate, heat transfer restored above 95%, steam consumption back to normal and batch output recovered.

A Guangde pharmaceutical intermediate plant condenser: solvent recovery condenser tubes carried composite salt-organic scale with under 50% effective flow area. One day of 200 MPa water jetting with rotary nozzles restored full tube flow; solvent recovery rate rose about 12%.

A Ningguo chemical park reactor jacket and piping: mixed water scale and sediment were treated with high-pressure water jetting combined with chemical cleaning, restoring jacket heat transfer and cutting pipeline resistance. Client information is anonymized; more Xuancheng and Anhui cases are available on request.

5. Service Process for Xuancheng Customers

Step 1 — free on-site survey: our engineers visit to review equipment type, tube count, scale form, blockage and shutdown windows, and give an initial assessment. Step 2 — plan and quotation: scale samples are analyzed when needed, then a cleaning plan and quotation are issued with schedule, acceptance criteria and safety/environmental measures. Step 3 — execution: the UHP pump, nozzles, air gun and auxiliary equipment are mobilized; the work zone is guarded with dedicated supervision, and disassembly, cleaning and reinstallation are documented with photos. Step 4 — acceptance and follow-up: acceptance per GB/T 25146-2010, then regular follow-up visits to track equipment condition for the next service cycle. Response time for Xuancheng and nearby customers is within 24 hours; emergency shutdowns can be expedited.

6. Xuancheng Cleaning FAQ

Q1: Why is lithium sulfate scale so hard? Can ordinary cleaning remove it?

Lithium sulfate crystallizes from concentrated evaporating liquor; the crystals are dense and very hard — far harder than normal water scale or carbonate scale. Chemical cleaning dissolves such hard crystalline deposits very slowly, and pharmaceutical plants are sensitive to chemical residue. Ultra-high-pressure water jetting breaks the scale physically without adding chemicals, making it the right choice for hard scale in pharma equipment.

Q2: Can a heat exchanger with 40% blocked tubes be restored?

Yes. First an air test marks every tube as clear or blocked; clear tubes are finished with a polished rotary nozzle, blocked tubes are cleared progressively with an ultra-high-pressure rotary air gun, then all tubes are blown and inspected. In the case above, a heat exchanger with 40% blocked tubes reached 100% tube pass rate and heat transfer efficiency above 95% after cleaning.

Q3: Will ultra-high-pressure water jetting damage the tubes?

No. The jet removes scale, not the tube wall. Imported polished rotary nozzles are used, pressure is set per scale hardness, and feed speed is kept at 0.5-1.5 m/min. Acceptance follows GB/T 25146-2010, including wall thickness spot checks and a hydrostatic test — no perforation or visible scoring.

Q4: How long will our pharmaceutical plant be offline for cleaning?

Shell-and-tube heat exchanger cleaning with head removal is normally scheduled in maintenance or shutdown windows; a single unit usually takes 1-2 days depending on tube count and blockage. After the on-site survey we provide a schedule that minimizes downtime.

Q5: Do you have a local crew in Xuancheng? How is pricing done?

We keep crews stationed in Anhui; a survey team can reach Xuancheng within 24 hours. Pricing is based on equipment type, tube count, scale form and method — survey first, then a quotation covering equipment, labor, consumables and waste disposal, with no surprise add-ons. Call or message us for a preliminary chat.

Service coverage: Anhui (Xuancheng, Wuhu, Ma'anshan, Hefei, Chuzhou, Anqing, Tongling, Bengbu) · Jiangsu (Nanjing, Zhenjiang, Changzhou, Wuxi, Suzhou) · Zhejiang (Hangzhou, Ningbo, Jiaxing) · Shanghai

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