Presentasi,,,

Solusi berteknologi untuk Pembersihan Mesin
& Peralatan Industri

September 2012

PT. INE JAYA

I. Teori Dasar
“CHAM Clean ” solusi untuk membersihkan peralatan dan
mesin, khususnya peralatan yang sulit atau tidak dapat dibersihkan
dengan metode pembersihan yang lama/sudah ada sebelumnya.

Metode Lama CHAM Clean Chemical
 Pencelupan(direndam)
 Metode Mekanik
: Mudah untuk membersihkan
: Pentetesan. bagian dalam dan luar
: Penggosokkan peralatan.
⇒ Tidak mungkin diterapkan Skala yg berada  Sirkulasi/Peredaran
dalam bentuk mesin yang
 Oxidi by Heat : Tidak Perlu Pembongkaran
rumit.
 Oxidized by water : Mudah untuk membersihkan
berbagai bentuk mesin.
 Accumulated
 Metode Kimia
organic or  Ramah Lingkungan
: Menggunakan Acid pada
permukaan mesin. inorganic scales : Produk Berbasis Kimia
(Biasanya Hydrochloric (Netral/Ringan(Mild) Acid)
Acid/Asam Klorida)
⇒ Meminimalis Kerusakan
⇒ Merusak Permukaan.
 Produktivitas
Mustahil untuk Pembersihan
yang sempurna Total Pengeluraran

II. Kompetensi Produk

Keuntungan dari Produk “CHAM Clean”

1. Tidak Menimbulkan Kerusakan pada Peralatan

▶ Hampir tidak ada kerusakan Seperti baru/kembali semula setelah dibersihkan

2. Tidak Berbau

▶ Hampir tidak berbau Tidak menimbukan bau di tempat kerja

3. Aman

▶ Tingkat keasaman (Acid) & Kandungan Alkali Rendah Aman bagi Mata dan Kulit Pekerja

4. Mudah dan Lebih Murah dinetralisasikan setelah dilakukan pembersihan

▶ Tingkat Keasaman (Acid) & Kandungan Alkali Rendah Biaya Murah untuk penetralisasian

III. Mekanisme/Cara Kerja
Mekanisme dalam Menghilangkan Scale

scale scale

Metal Metal

Metode dengan kimia Acid Metode Baru(CHAM Clean)

Gambaran dengan Mikroskop

[×500] [×500] [×500
]

Sesudah menggunakan
Sebelum Sesudah dengan CHAM Clean
Bahan Dasar Acid/Asam

Best Partner With Excellent Chemical Solutions 5

1. Shell tube tipe (Heat Exchanger) IV. Kasus

* Bagaimana Membersihkan Tabung/Heat Exchanger*

Sirkulasi didalam Tube

Penguapan
(Udara)

Sirkulasi diluar Tube(Shell)

Tangki Pompa
Kimia

Dengan Selang Sambungan


1. Shell tube tipe (Heat Exchanger) IV. Kasus
① Pembangkit Listrik(Power Plant – Pendingin Udara)

▲ Setelah Penguraian (Oksidasi) Scale dikeluarkan
dari dalam tabung Tembaga

Kimia Tipe ST-400 P atau MSR-100

Digunakan Untuk Murni Tembaga/Tembaga Campuran

Metode Sirkulasi dengan Pompa
▲ Sirkulsi Kimia dalam Tabung
Durasi 4 – 8 Jam

Kepadatan (Desitas/ +/- 25%
Density)
Temp. 10 ~ 50℃

Karatan Menguraikan Scale pd tembaga dan
Pencemaran pd Pendingin Udara


*Cara baru dengan CHAM Clean


2. Fin tube (Heat exchanger) III. Cases

⊙ Fin Side ⊙ Tube side

▲ Chemical spraying by circulation
① Steel industry – Dust collector(Zn)

▲ Before cleaning


2. Fin tube tipe(Heat exchanger) IV. Kasus
② Pabrik Petrochemical
▼ Sebelum ▼ Sesudah

▲ Pendingin direndamkan

▲ Pembersihan dengan ▪ Scale yg berat dapat dihilangkan dgn metode penyemprotan selama 3 jam
metode Penyemprotan
▪ Rekomendasi Temperatur: 50℃, Actual temp. : 24℃


2. Fin tube (Heat exchanger) III. Cases
③ Radiator
Before After

▲ Radiator


3. Plate(Pelat) tipe (Heat exchanger) IV. Kasus

[Metode Baru] Total biaya Hemat dengan metode Sirkulasi [Metode Lama]

Menyambungkan
Pembongkaran
Ke Pompa Menjaga efisiensi secara maksimal dari mesin
- Penghematan biaya energi

Memasukkan Maksimalkan Umur dari Heat Exchanger Direndamkan
- Minimalkan kerusakan logam selama 30 Menit
bahan Kimia didalam tub
Penghematan biaya & waktu untuk
membongkar & pemasangan kembali
Sirkulasi Penyikatan

Pengeringan dan
Pemasangan
Pembilasan kembali

Perakitan
Heat –Exchanger Bak kimia
Pompa
Uji Coba
Masalah dalam metode Lama

• Memperpendek umur Heat Exchanger dengan menggunakan pembersih Asam(Acid)
• Penyikatan membuat kerusakan secara mekanis dan membutuhkan tambahan biaya dan tenaga kerja

• Kerusakan pada gasket / karet untuk pembongkaran & pemasangan– menambah biaya dan waktu kerja


3. Plate tipe (Heat exchanger) IV.Kasus
② Plate tipe Heat Exchanger
Tipe Kimia MSR-100
1. Lumpur, Scale keras pd bahan Stainless steel Digunakan untuk Stainless steel
Slimes, SiO2 scales on Stainless steel plate
Metode Direndam atau Sirkulasi
Durasi 1 ~ 4 jam
Desitas/Density +/- 25%
Suhu 10 ~ 60℃
Karatan Lumpur, Skala yg mempunyai Silika(SiO2)

Tipe Kimia ST-400P
2. Lumpur, Batu garam di bahan Titanium
Digunakan untuk Titanium
Durasi 1 ~ 4 jam
Suhu 10 ~ 60℃
Karatan Lumpur, Skala oleh air laut

Tipe Kimia ST-200P
3. Skala fosfat di bahan Stainless steel
Digunakan untuk Stainless steel
Durasi 2 ~ 4 jam
Suhu 10 ~ 60℃
Karatan Skala fosfat

4. Minyak pelumas dan karbon di bahan Titanium Tipe Kimia ST-100L
Digunakan untuk Steel, Steel Alloy, Copper Alloy
Metode Sirkulasi
Durasi 2 ~ 4 jam
Suhu 70 ~ 80℃
Karatan Karbon dan miyak pelumas keras


4. Turbine Rotor III. Cases
▲ Preparation for cleaning

▲ Screen tent installation ▲ Worktable installation ▲ Checking before cleaning

▲ Chemical ready and Observation ▲ Connecting Hose & ready for cleaning ▲ Finished check-up for cleaning

III. Cases

▲ Showering with chemical (Mclean-100) (1) ▲ Showering with Chemical (2)

III. Cases

▲ Rinse by water after chemical treatment (1) ▲ Rinse by water after chemical treatment (2)

Precision cleaning of Radiator(Air-Con) for Fuel Cost Saving

▲ Vehicles Radiator ▲ Spraying & Washing by water

▲ Before cleaning (Oxidized scales) ▲ After cleaning (Removed perfectly)

Precision cleaning of Radiator(Air-Con) for Fuel Cost Saving

* Applied case
① Engine Oil Cooler (Before/After)

② (Difference of Before & After)

③ KORAIL compressor Air Cooler (Before/After)

5. Air conditioning unit III. Cases
② Evaporator & Condenser
▼ Chemical input

Steam line
for heating

Returned Heater
chemical

▲ Before use ▲ After cleaning


5. Air conditioning unit III. Cases

▼ Rust removed Evaporator’s inside (Before & After) ▼ Rust removed Condenser’s inside (Before & After)

▼ Freezer inside Endoscope (Before & After)

◀Uneven or thick rust were
removed▶

◀Rust & scales were
removed▶

Lower part wall of the Lower part wall of the Tube support – lower Tube support – lower
Condenser 1 Condenser 3 part of Condenser 1 part of Condenser 3


6. Cooler III. Cases

Compressor After Cooler Scales & Carbonized oil before cleaning Dipping (RR-101B)

Washing by high pressure After cleaned perfectly by RR-101B(In & Out side)

Spread cylinder

Coolant in/out

▲ Coolant circulation path is almost ▲ After cleaning, Coolant
blocked by contaminated scales. path is recovered as it was.


8. Engine Body III. Cases
Engine Body Cleaning : PCR-100D spray High Pressure Water Spray

▲ Before cleaning ▲ Spraying with PCR-100D

▲ Water jet washing after 10 mnt ▲ After cleaning

8. Engine Body III. Cases
Cylinder Head Section Cleaning :PCR-100D Immersion  High Pressure Water Spray

▲ Cylinder Head Section ▲ Cylinder Head Dipping
▲ After Cleaning
PCR-100D, 60~70℃, 2~4HR

▲ After Cleaning

▲ Before Cleaning ▲ After Cleaning ▲ Before Cleaning ▲ After Cleaning

Piston Cleaning : Mclean-100 Immersion  Ultra-Sonic or High Pressure Spray Rinse

▲ Piston, Before cleaning ▲ Dipping into Mclean-100 ▲ Ultra Sonic Cleaning
60~90℃, 2~ 4Hr

▲ Before Cleaning ▲ After Cleaning

9. Parts III. Cases
① Steel
▼ Before ▼ After


② Rust Removing test

▲ Before : Deeply rusted. ▲ Prepare the plastic bath ▲ Put RR-101B into the bath
and heater to increase the and stir to let the chemical
temperature. circulate.

▲ Removing remained rust & ▲ After cleaning. (Apply steel
▲ Rust % grease are removed. grease by the high pressured stabilizer, if necessary)
water spray.

■ RR-101B Working temperature is 20~80℃.
The test took 24 hours at 25℃ and 6 hours at 50℃. (Deeply rusted bolts were tested)

Cleaning of Exhaust Gas Purifying Device

** Problem
: Because of adhered carbon on the exhaust gas purifying device will reducing its purification efficiency.

1) General repairing way : Burn the remained carbon by high temperature gas (waste it if not able to clean any more)
* Problem : Not able to burn the whole carbon perfectly

2) Jiwontech’s way : Circulating by RR-101B without disassemble the device (Now in using at C company)

3) Applied case : Euro 4 engine DPF loaded on commercial vehicles

Filter Case
(Remove the decayed scales on DPF exterior)

[Filter] [Enlarged picture of Filter]

9. The others IV. Cases
⑥ Guest room pipe scale(Hotel Shangri-La, Jakarta)

Pipe & Scales Scale melting test

PCR-100D, Density :10% PCR-100D, Density :10%
Temp. 25-30℃, Dipping for 72hrs Temp. :60℃, Dipping for 30min

**Shape of Washstand · Closet · Urinal ** Cleaning scheme ** Benefits in using PCR-100D, ST-407
① Open valves and drain inside. ① Without disassemble its pipe, Just using
② Close valves and fill with chemical worm water and chemical only.
ex) 25℃, 72hr or 60℃, +/- 1hr ② No smelling of PCR-100D, ST-407 is safety
③ Open valves and washing. from human eyes and skin.
** Applied chemical
- Washstand/Closet : PCR-100D
- Urinal : ST-407


Atrium Mulia Bldg – Cooler scale testing report (ST-205, 100%)
Weight Loss & Corrosion

· Chemical : ST-205 (100%) · 1㎎ = 1/1000g

· Sample Size : 100×50㎜ · 1㎛ = 1/1000㎜

· Dipping Temp. : 30℃, 60℃

ST-205 ST-205
30℃, 24hr 60℃, 4hr

Before testing(㎎)
36,373 35,897
ST-205(100%)
After testing(㎎)
Testing on 25°C Iron(SS41) 35,341 34,917
[Dens. 7.852]
Weight loss(㎎) 1,032 980

Corrosion(㎛) 13.2 12.6

Before testing(㎎)
36,923 36,913

SUS304 After testing(㎎)
36,904 36,726
[Dens. 7.93]
Weight loss(㎎) 19 187

Start dipping After 24hrs Corrosion(㎛) 0 2

ST-205(100%) Before testing(㎎)
10,587 10,310
Testing on 60°C After testing(㎎)
Copper 10,587 10,310
[Dens. 8.9]

Corrosion(㎛) 0 0

Before testing(㎎)
10,538 10,992

Brass(6:4) After testing(㎎)
10,538 10,992
[Dens. 8.4]

Start dipping After 4hrs Corrosion(㎛) 0 0


Atrium Mulia Bldg – Cooler scale testing report (ST-205, 50%)

ST-205(50%)
Testing on 25°C

Start dipping After 24hrs After 48hrs

ST-205(50%)
Testing on 60℃

Start dipping After 6hrs


10. The others III. Cases
⑦ Fence Cleaning
* To ensure the safety of pedestrians, install some protective fence between car road and walk road.
And mainly stainless steel is used in consideration of urban aesthetics.
Stainless steel have many advantage likely nice appearance and durable structures but weak in Acid rain specially
and easily formed red rust and dark gray oxidized scale by vehicles exhaust gas.
•The appearance of fence is bad with oxidized scales and getting worse if it is left then finally replaced by new
with high cost.
* PT. Ine Jaya introduce SUS Clean & Mclean Z for removing such scale easily even nonprofessional user.

** Keep clean condition by cleaning every 1~2 yrs
** For SUS Clean, must use SUS 300 series only. Some SUS 200 series(China made) will cause discoloration.

Stainless 300 series fence : SUS Clean used Stainless 200 Series fence : Mclean Z used

Cleaning 前

Cleaning 後


The product list of CHAM Clean
Model Removable scales Usage(Application) Reference
Repairing various machineries
Rust, Carbonized scale on various metal, Aluminum Remove rust scale inside pipe 20 ~ 60℃
RR-101A
oxide Repair Aluminum pin tube of Heat Exchanger 20 ~ 30%
Repair Metal & Resin filter
Remove rust scale inside pipe
Simultaneously remove scales of Rust, Carbonized & 20 ~ 60℃
RR-101B Repair Aluminum pin tube of Heat
Grease/Oil on the metal 20 ~ 30%
Exchanger
Remove scale of water pipe
20 ~ 60℃
ST-205 Scales contain Calcium, Silica, Alumina Scales from Condenser & Boiler
20 ~ 100%
Repairing various Resin filter

Scales contain Calcium, Alumina Scales from Condenser & Boiler 20 ~ 60℃
ST-407
Talc & other difficult soluble scales Repairing various Resin filter 10 ~ 20%
Repairing various H.E using sea water

20 ~ 60℃
MSR-100 Complex scales contain Silica(SiO2/SiO4) Scale from Condenser & Boiler
20 ~ 50%
Repairing Plate type H.E.

Scales from sea water on Copper, Copper alloy. Repairing various H.E. using sea water 20 ~ 60℃
ST-400P
Slime, Mud. Remove Barnacles & Oyster Repairing H.E. of Copper, Copper alloy 20 ~ 50%

Rust, Carbonized scale on various metal, Aluminum Remove rust scale inside pipe 60 ~ 80℃
ST-100L
oxide Repair Aluminum pin tube of Heat Exchanger 10 ~ 30%

Heat Exchanger using Lubricating & 60 ~ 80℃
PCR-100D Hardened Oil scales
Fuel Oil 10 ~ 30%

Remove Oil on various spare parts
Carbonized scale, scale from Synthetic Heat Transfer 20 ~ 60℃
Mclean-100 Remove scale of SHTF
Fluid(SHTF) 10 ~ 30%
Remove scale in pipe of Hotel room

•Cleaning method(Dipping, Circulation, Spraying) applies after diluted the chemical with water(10~50%).
*Keeping operation temperature (20~60℃) considering working site conditions.

Safe to use on materials (metals)

◎ Good ○ Fair × Not apply

Carbon Stainless
Copper Brass Aluminum Titanium
steel steel

RR-101A ○ ◎ ◎ ◎ ○ ◎

RR-101B ○ ◎ ◎ ◎ ○ ◎

ST-205 ○ ◎ ◎ ◎ × ×

ST-407 ○ ◎ ◎ ◎ ○ ◎

MSR-100 ○ ◎ ◎ ◎ × ×

ST-400P ○ ◎ ◎ ◎ × ◎

ST-100L ◎ ◎ ◎ ◎ ◎ ◎

PCR-100D ◎ ◎ ◎ ◎ ○ ◎

Mclean-100 ○ ◎ ◎ ◎ ◎ ◎

Penghargaan Produk Ramah Lingkungan dari Pemerintah Korea Selatan

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