The hidden costs of ineffective chemical cleaning in shipping

Ineffective chemical cleaning in marine operations can result in significant hidden costs. These costs extend far beyond the price of the cleaning products themselves and affect various aspects of marine operations, from equipment maintenance to environmental compliance.

Financial Impact of Ineffective Cleaning

Ineffective cleaning can create substantial hidden costs for shipping companies, impacting maintenance budgets, operational efficiency and can also affect safety.
Keeping equipment clean can be of vital importance to operational process efficiency. Process surfaces restored to optimal condition, lowers the maintenance costs and extends equipment's lifetime. And by saving energy, operating costs are lowered as well.

1. Asset Degradation and Replacement Costs

Here are some examples of the impact of scale, contaminated engine parts and rust on equipment:

• In cooling water system, limescale deposits with a thickness of more than 0.5 mm obstruct the transfer of heat and cause thermal overloading of the components being cooled. Scale acts as an insulating layer on heat transfer surfaces in coolers, heaters, and heat exchangers. This reduces the efficiency of heat transfer, leading to increased energy consumption and higher operational costs. In pipes, valves, and narrow passages, scale buildup can restrict fluid flow, causing blockages and reducing system performance.
• Ineffective cleaning and maintenance of diesel engine components can lead to contaminated air coolers that result in inefficient cooling. This reduces combustion quality and engine power output, negatively impacting overall performance. The excess heat generated by poor cleaning practices can lead to premature wear of critical engine parts such as pistons, rings and valves, requiring costly replacement, often leading to more frequent maintenance, with some operators resorting to complete disassembly of aftercoolers for thorough cleaning and inspection every 2-3 years, a time-consuming and expensive process.
• Persistent rust buildup resulting from ineffective chemical cleaning for rust removal demands more frequent and intensive cleaning efforts which drive up labor expenses and potentially requiring professional services. Ineffective rust cleaning accelerates corrosion, compromising ship integrity and requiring expensive repairs. Critical ship systems degrade faster, leading to early replacement of piping, machinery, and other components.

These examples highlight the significant financial strain caused by poor cleaning practices, emphasizing the need for effective solutions in maritime operations.

2. Operational Costs

Using multiple cleaning products from different suppliers increases procurement and logistics costs and complicates on-board inventory management. This can lead to overstocking, product expiration, and improper storage and handling.
Additionally, frequent crew changes necessitate repeated product familiarization, increasing training costs and the risk of product misuse. This leads to time and productivity losses. Scale buildup and fouling from inadequate cleaning reduce performance and prolong cleaning times, causing costly delays that disrupt vessel's schedules and impact customer satisfaction and contract commitments.

3. Safety and Efficiency Concerns

Handling multiple cleaning chemicals presents significant safety and efficiency challenges. Each product requires specific safety data sheets, usage instructions, and storage conditions, which increases the risk of misuse and endangers crew safety.

Additionally, managing numerous products complicates cleaning processes in several ways:

• Training requirements: crew members must be trained to understand and correctly use each individual product, which consumes time and creates confusion, especially for new or rotating crew members.
• Product selection confusion: with a wide range of products available, determining the correct chemical for a specific cleaning task becomes more challenging. This can lead to improper product use, ineffective cleaning, or damage to surfaces and equipment.
• Storage and organization: multiple products require additional storage space and careful organization to ensure safety and accessibility. Poor organization can lead to mix-ups, accidental spills, or hazardous chemical interactions.
• Inventory management: monitoring and restocking numerous products adds administrative complexity. Keeping track of varying quantities, expiration dates, and usage rates increases the risk of shortages, overstocking, or wastage.
• Resource waste: misuse of products such as using excessive amounts or the wrong chemical leads to unnecessary consumption of cleaning chemicals, increasing costs and waste.

4. Environmental and Regulatory Costs

Improper cleaning practices may lead to environmental violations and associated fines. The increasing focus on environmental regulations may require additional investments in compliant cleaning technologies. Chemical pollutants introduced into marine environments can accumulate in the food chain, becoming more concentrated in higher trophic levels and potentially affecting human health.

The consequences of ineffective cleaning extend beyond increased maintenance and operational inefficiencies. How chemicals are managed and disposed of also plays a critical role in protecting equipment, reducing costs, and ensuring regulatory compliance. Improper disposal of cleaning chemicals can lead to equipment damage in several ways:
Corrosion
Harsh chemicals, if not properly neutralized or disposed of, can corrode metal surfaces and peel away protective coatings on equipment. This corrosion can compromise the structural integrity of machinery and lead to premature failure.

Residue buildup
Some cleaning products may leave residues if not properly rinsed or disposed of, which can accumulate on equipment surfaces. This buildup can interfere with the proper functioning of machinery, potentially causing operational inefficiencies or breakdowns.

Chemical reactions
Mixing incompatible cleaning chemicals during disposal can create dangerous reactions. These reactions might produce corrosive or toxic substances that can damage equipment if they come into contact with it.

Contamination
Improper disposal, such as pouring chemicals down drains, can lead to contamination of water systems5. This contaminated water may then be used in industrial processes, potentially damaging equipment or reducing its efficiency.

Long-term environmental effects
Chemicals that are not disposed of correctly can seep into soil and water sources. Over time, this contamination can lead to accelerated corrosion or degradation of equipment exposed to these polluted environments.

Chemical Safety Protocols for Maritime Operations
Effective chemical management is critical for maritime safety and operational integrity. To mitigate risks of contamination and ensure optimal vessel performance.

Key Chemical Handling Guidelines
1. Chemical Selection

• Use only manufacturer-approved and recommended cleaning chemicals ensures optimal performance, safety, and compliance
• Verify compatibility with ship equipment and environmental regulations, to prevent damage such as corrosion, material degradation, or system inefficiencies
• Select cleaning chemicals, containing substances that are specifically designed for use in marine environment, ensuring optimal performance and minimizing risks

2. Crew Training and Safety in Maritime Chemical Handling

• Understand chemical properties and potential hazards
• Learn proper classification and labeling of chemicals
• Recognize risks associated with different substances
• Usage of personal protective equipment (PPE)
• Develop skills in leak detection and containment

3. Careful Monitoring

• Ensure careful oversight when using organic compounds to minimize risks
• Track chemical application processes carefully
• Maintain detailed logs of chemical handling, application and inventory

4. Manufacturer Compliance

• Strictly follow manufacturer guidelines for chemical use
• Review product instructions thoroughly before application
• Train personnel on proper handling and application techniques

5. Responsible Disposal

• Develop systematic procedures for chemical waste management
• Ensure environmentally responsible disposal methods
• Comply with international maritime waste regulations

Benefits of Rigorous Chemical Management
By adhering to these comprehensive protocols, maritime operations can:

• Protect sensitive equipment from potential damage
• Maintain optimal operational efficiency
• Ensure crew and environmental safety
• Minimize the risk of contamination

Proper chemical management, from selection and application to disposal, ensures a safer work environment, protects valuable equipment and meets stringent environmental regulations. Shipping companies can save valuable resources by addressing inefficiencies through comprehensive crew training, adherence to safety protocols and implementation of best practices in chemical handling.

This proactive approach improves safety standards and enhances overall operational efficiency, while also contributing to a more sustainable environmental footprint. This holistic strategy towards chemical cleaning efficiency paves the way for a more sustainable and profitable future in the maritime industry, aligning economic interests with safety and environmental responsibility.

Unitor™ range of cleaning solutions has been developed specifically for the marine industry to ensure compliance with strict regulations. These products require less volume for effective cleaning, reducing plastic waste and man-hours spent transferring chemicals. By continuously refining our solutions, we enable marine operators to stay ahead of evolving industry demands, optimizing processes that directly impact profitability and environmental stewardship.

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