What are the different tank cleaning solutions available for industrial tanks?

Industrial tanks require several different cleaning solutions depending on the tank type, contents, and surface preparation goals. The main methods include high-pressure water jetting, robotic crawler systems, vacuum blasting, and manual cleaning, each suited to specific conditions and contamination levels. This article walks through the key questions maintenance engineers and operators ask when evaluating tank cleaning solutions for industrial environments.

What types of industrial tanks require regular cleaning?

A wide range of industrial tanks require regular cleaning, including oil storage tanks, chemical process vessels, cargo holds, water treatment tanks, fuel storage tanks, and offshore storage units. Any tank that holds liquids, sludge, or residues, particularly in petrochemical, energy, marine, and manufacturing sectors, will accumulate deposits that degrade performance and create safety hazards over time.

The cleaning frequency and method depend heavily on what the tank stores. Oil storage tanks, for example, develop thick sludge layers at the base that reduce usable capacity and contaminate fresh product. Chemical vessels may develop scale, corrosion, or residue buildup that compromises the integrity of future batches. Cargo holds on ships collect salt, grime, and cargo residue that must be removed between loads to meet cargo quality standards and prevent structural corrosion.

Beyond product contamination, uncleaned tanks pose serious structural risks. Residue buildup accelerates corrosion, which weakens tank walls and can lead to costly failures. Regular cleaning also creates the clean, dry surface conditions needed for inspection, coating, and repainting, extending the operational lifespan of the asset significantly.

What are the main methods used for industrial tank cleaning?

The main tank cleaning solutions used in industrial settings are high-pressure water jetting, vacuum blasting (closed-circuit sandblasting), robotic crawler systems, chemical cleaning, and manual mechanical cleaning. Most modern industrial operations combine two or more of these methods depending on the contamination type, tank geometry, and surface preparation requirements.

High-pressure water jetting

Water jetting uses pressurised water, typically in the range of 500 to 3,000 bar (“7,250 to 43,500 PSI”), to dislodge and remove deposits from tank surfaces. It is highly effective for removing sludge, scale, and old coatings, and it leaves no abrasive residue behind. It can be performed manually or with automated robotic systems.

Vacuum blasting and closed-circuit sandblasting

Vacuum blasting, also known as closed-circuit sandblasting, combines abrasive blasting with simultaneous vacuum extraction. The abrasive and debris are collected immediately at the source, which prevents harmful particles from becoming airborne. This method is particularly valuable in confined tank environments where dust and contamination control are critical, and it also recycles the abrasive material to reduce costs.

Robotic crawler systems

Robotic crawlers are electrically driven machines that travel across steel tank surfaces using magnetic adhesion. They can carry a range of modular tools, including blast cans, swing arms, and abrasive nozzles, to perform cleaning, surface preparation, and inspection tasks with minimal human entry into confined spaces.

Chemical and manual cleaning

Chemical cleaning uses solvents or detergents to dissolve specific residues and is often used as a preparatory step before mechanical cleaning. Manual mechanical cleaning involves operators working directly inside the tank with hand tools and is typically reserved for areas that automated systems cannot reach.

How does high-pressure water jetting work for tank cleaning?

High-pressure water jetting works by forcing water through a small nozzle at very high pressure, ranging from 500 to 3,000 bar (“7,250 to 43,500 PSI”), creating a focused, high-velocity jet that strips away deposits, coatings, and contaminants from the tank surface. The kinetic energy of the water does the cutting and cleaning work, requiring no abrasive material.

In tank cleaning applications, the jetting nozzle is directed at the internal surfaces of the tank, walls, floor, roof, and structural components such as wind girders. The high-velocity stream breaks up sludge and scale, and the dislodged material is flushed away with the water flow. For applications requiring a clean, dry result, closed waterblasting systems use a vacuum dome to collect both water and debris at the point of contact, leaving the surface ready for inspection or coating without further drying time.

The pressure range selected depends on the material being removed and the substrate being cleaned. Lower pressures around 500 to 1,000 bar (“7,250 to 14,500 PSI”) suit softer deposits and general washing, while pressures approaching 3,000 bar (“43,500 PSI”) are used for heavy-duty surface preparation, old coating removal, and achieving the surface roughness profile required before repainting.

What’s the difference between manual and automated tank cleaning?

Manual tank cleaning requires operators to physically enter the tank and clean surfaces using hand-operated tools, while automated tank cleaning uses robotic systems or mechanised equipment to perform the same tasks remotely, reducing or eliminating the need for confined space entry. The key difference is the level of human exposure to hazardous conditions inside the tank.

Manual cleaning gives operators direct control and flexibility, particularly in tanks with complex internal geometries or areas that machinery cannot easily reach. However, it comes with significant safety risks. Confined space entry exposes workers to toxic atmospheres, oxygen deficiency, slippery surfaces, and the physical hazards of working in enclosed, poorly ventilated environments. It also tends to be slower and more labour-intensive.

Automated cleaning systems address these risks directly. Robotic crawlers, for example, can be deployed inside a tank and operated remotely, keeping personnel outside the confined space entirely. They deliver consistent cleaning performance across large surface areas without fatigue, and they can be equipped with cameras for simultaneous inspection. For large oil storage tanks, cargo holds, and offshore vessels, automated systems dramatically reduce both risk and turnaround time compared to manual methods.

In practice, most tank cleaning operations use a combination of both: robotic systems handle the large, accessible surface areas efficiently, while manual cleaning addresses corners, welds, and structural details where machines cannot reach.

When should you use robotic tank cleaning systems?

Robotic tank cleaning systems are the right choice when confined space entry poses significant safety risks, when large surface areas need to be cleaned efficiently, or when a consistently clean and dry surface is required for coating or inspection. They are particularly well-suited to oil storage tanks, cargo holds, and offshore structures where minimising human exposure to hazardous environments is a priority.

Specific scenarios where robotic systems add the most value include:

• Tanks with toxic or flammable residues – where confined space entry requires extensive gas-freeing procedures and continuous atmospheric monitoring
• Large flat steel surfaces – where a robotic crawler can cover significant area quickly and consistently, far outpacing manual operators
• Surface preparation before coating – where a precise, dry surface profile is needed and closed waterblasting collects all debris at source
• Offshore and remote locations – where transporting large crews into confined spaces is logistically complex and costly
• Tanks requiring simultaneous inspection – where robotic systems can carry camera equipment alongside cleaning tools

Compact robotic crawlers are also available for narrower spaces and smaller tanks. The MagTrack Mini, for instance, is a lightweight 2-wheel-drive crawler designed for both straight and curved surfaces, including offshore oil rigs, and is available as a certified ATEX Zone 2 unit for use in potentially explosive atmospheres.

What safety standards apply to industrial tank cleaning operations?

Industrial tank cleaning operations are governed by a range of national and international safety standards that cover confined space entry, high-pressure water jetting procedures, and operator training requirements. The specific standards that apply depend on the country and sector, but several organisations set the benchmark guidelines that responsible operators follow.

The key organisations that define safety standards for industrial tank cleaning and high-pressure water jetting include:

• SIR (Netherlands) – the Dutch foundation that sets certification and safety requirements for water jetting operations in the Netherlands
• EWJI (Europe) – the European Water Jetting Institute, which establishes pan-European guidelines for safe water jetting practice
• WJA (UK) – the Water Jetting Association, which publishes the UK’s code of practice for high-pressure water jetting safety
• WJTA (USA) – the WaterJet Technology Association, which provides safety guidelines and recommended practices for North American operations
• DIRV (Germany) – the German association that governs water jetting safety standards and operator certification requirements in Germany

Beyond water jetting standards, tank cleaning operations must also comply with confined space entry regulations, which typically require atmospheric testing before entry, continuous monitoring during work, rescue plans, and permit-to-work systems. In potentially explosive environments, such as oil storage tanks that may contain flammable vapours, equipment must meet ATEX certification requirements in Europe or equivalent standards in other regions.

Operator training is a critical component of compliance. Working with high-pressure systems in confined spaces requires specialised knowledge of both the equipment and the hazards involved. Certified training programmes ensure that personnel understand the risks, know how to use equipment correctly, and can respond to emergencies effectively.

How DERC Salotech’s MagTrack Supports Your Tank Cleaning Operations

We at DERC Salotech have developed the MagTrack robotic system specifically to address the most demanding challenges in industrial tank cleaning. Built on over 40 years of Dutch engineering expertise, MagTrack is a modular magnetic crawler platform that brings together high-pressure water jetting, vacuum blasting, and remote-controlled operation in a single, adaptable system.

Here is what MagTrack delivers for tank cleaning operations:

• Reduced confined space entry – operators control the crawler remotely, keeping personnel out of hazardous tank environments
• High-pressure cleaning up to 3,000 bar (“43,500 PSI”) – effective removal of sludge, scale, and old coatings across large surface areas
• Closed waterblasting with vacuum collection – the Blast Can and Curved Blast Can collect water and debris at source, leaving a clean, dry surface ready for coating or inspection
• Modular tooling – swap between blast cans, swing arms, and sandblasting tools to match the specific requirements of each tank
• Flat and curved surface capability – the Curved Blast Can handles surfaces with a radius of up to 3 metres (“approximately 10 feet”), making it suitable for smaller tanks and ship hulls
• ATEX Zone 2 certification available – for safe operation in potentially explosive atmospheres such as oil storage tanks
• Compact options for tight spaces – the MagTrack Mini reaches narrow areas and offshore locations where larger equipment cannot go

Whether you are managing a scheduled tank maintenance programme or facing an urgent cleaning requirement, we can help you find the right configuration for your application. Contact our team to discuss your tank cleaning challenges and discover how MagTrack can improve safety, reduce turnaround time, and deliver the surface quality your operations demand.