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Tuesday, February 16, 2016

Cost-efficient heating of cleaning agents – with the heat exchange module MAFAC HEAT.X

Cost-efficient heating of cleaning agents – with the heat exchange module MAFAC HEAT.X

Alpirsbach Black Forest Germany  in January  2016 –
For low-energy operation of their aqueous parts washers, MAFAC developed the new heat exchange module MAFAC HEAT.X. The compact unit heats cleaning agents using externally available heat instead of expensive electricity. 
In view of rising energy costs and the constantly increasing competition, the sustainable operation of production lines is becoming more and more important. This situation, as well as the endeavour to reach the climate targets, calls upon companies to identify and utilize the energy-saving potential on their shop floors.The new heat exchange module MAFAC HEAT.X gives companies the chance to improve the energy consumption aspect of their parts cleaning process, and to efficiently reduce the energy costs.
Intelligent heat exchange
The MAFAC HEAT.X module works with a highly efficient heat exchange process. The available heating agent flows through a coaxial heat exchanger, while the cleaning agent which needs to be heated is simultaneously conveyed through the pipe-in-pipe system of the heat exchanger. The waste heat of the heating agent increases the temperature of the cleaning agent, which is then returned to the cleaning process. Because the liquids flow in opposite directions, the heat exchange is almost free of loss.In this way, the electricity used for heating can be replaced by alternative sources of energy. The MAFAC HEAT.X module is suitable for supplying heat from three different energy sources/concepts:
  1. Hot water from heat treatment,
  2. from co-generation,
  3. or from regenerative water heating applications (solar heat).
Positive energy balance and process reliability in parts cleaning
In particular companies whose production processes generate much waste heat, such as foundries, benefit from the new heat exchange module by optimising their energy balance in the sense of an energy management system pursuant to DIN EN ISO 50001. By increasing the temperature of their cleaning agents using waste heat to feed a heat exchange system, they do not throw away valuable energy but supply it to a sub-process. This reduces their energy consumption by up to 60 % and lowers their CO2 emissions (617 g CO2/kWhEnd according to GEMIS-Strom-Mix Deutschland). 
The MAFAC HEAT.X modules guarantees constant heat exchange and thus the process-safe operation with a continuously excellent cleaning performance.This is achieved by a highly turbulent flow in the coaxial ducts, and the smooth surfaces in the pipes which are free of edges and deposits.The high degree of turbulence promotes the heat exchange, and also have a self-cleaning effect. As another advantage, the highly integrated power density of the MAFAC HEAT.X allows the module to provide the heat derived from heat exchange much faster than with conventional electrical operation. This reduces ramp-up times and accelerates the compensation of temporary loss of temperature, for example when inserting large components. Another benefit: The highly robust coaxial technology of the module requires little maintenance.
The heat exchange module is suitable for flexible use. It can be used in mixed with electricity and water and can be connected to different machine types Retrofit kits make the connection very easy, also for older machines.
The new heat exchange module MAFAC HEAT.X was developed for warming up cleaning fluids by means of external heat supplied to them. In this way, the energy consumption for bath heating can be reduced by more than 90%.The new heat exchange module MAFAC HEAT.X was developed for warming up cleaning fluids by means of external heat supplied to them. In this way, the energy consumption for bath heating can be reduced by more than 90%.

Overview of the technical data

Standard equipment:
  • Heat exchange system in coaxial pipe technology
  • Robust, self-cleaning, low-maintenance heat exchange process
  • Sheet steel housing painted in RAL 7035
  • High-quality insulation of all fluid-carrying components
  • Mixed process operation possible (electrical and water heating)
  • Circular pump for process water
  • One-way restrictor
  • Suction filtration 1,000 ┬Ám
  • Ventilation connection
Heat supply side:
  • Analog temperature display for hot water supply
  • Regulating stop valve
  • Manual stop ball valve
  • Drain connection / system draining
  • Energy consumption monitoring
  • Temperature-related LED display of the operating status
  • Retrofit kits for tailored connection to the respective machine
  • Chemical rinsing units for removal of contamination films in the pipe system and in the heat exchanger
  • Additional filtration unit for extension of the useful life of the agents required for the cleaning process
  • Mixed process operation possible (electrical and water heating)
Nominal output of the HEAT.X:
24 kW with a heat-side flow volume of 1.4 m3/h and a temperature difference between flow and return flow of 15 K
Flow (inlet provided by customer):
Temperature max. 100 °C
Volume 1.2-1.6 m3/h
Pressure 1.5-4 bars
Return flow:
Temperature min. 10 °C above bath temperature
Temperature difference flow/return flow (mean value):
min. 10 K
Dimensions of the MAFAC.HEAT.X (W x D x H):
700 x 535 x 1400 mm

MAFAC is one of the leading manufacturers in aqueous parts cleaning. The company offers a wide range of compact machines for a large variety of cleaning requirements tailored to customers' requirements, for example in automotive and aerospace industry, machine building, metal-cutting production, hydraulic and electrical engineering. All machines are developed and manufactured in Alpirsbach in the Black Forest with a staff of 80 employees. Founded in 1968, MAFAC has been involved in industrial parts cleaning since 1974 and focused on this field since 1990. Its patented cleaning technology of counter- or co-rotation of spray system and basket receptacle system sets new standards in terms of cleanliness and efficiency. Currently, the company is active in more than 20 countries including Asia, South America and in the USA, with a world-wide network of technical agencies and a branch establishment in France.