What tank cleaning solutions work best for chemical storage tanks?

The most effective tank cleaning solutions for chemical storage tanks combine high-pressure water jetting with closed-loop containment systems, particularly when residues are hazardous or reactive. For most industrial applications, high-pressure water jetting in the range of 500 to 3,000 bar delivers the cleaning power needed to remove stubborn deposits, coatings, and chemical residues without introducing additional contaminants. The right solution depends on the tank’s geometry, the nature of the stored chemical, and the facility’s safety and environmental requirements. Below, we answer the most common questions maintenance engineers and field technicians ask when evaluating tank cleaning solutions for chemical storage.

Which tank cleaning methods are safest for chemical residues?

The safest tank cleaning methods for chemical residues are closed-loop high-pressure water jetting systems that capture and contain all wastewater and debris during the cleaning process. These systems prevent hazardous residues from escaping into the surrounding environment, protect operators from direct exposure, and comply with the strict safety standards set by organisations such as SIR (Netherlands), EWJI (Europe), WJA (UK), WJTA (USA), and DIRV (Germany).

Open cleaning methods, where water and debris are allowed to spread freely, are generally unsuitable for chemical storage tanks because residues can be toxic, flammable, or reactive. Closed waterblasting, using a vacuum dome or blast can attached directly to the cleaning head, is the preferred approach. The vacuum system draws both water and dislodged material away from the surface instantly, leaving a clean and dry result without any leakage or secondary contamination.

For tanks storing particularly aggressive chemicals, robotic cleaning systems add another layer of safety by keeping personnel out of the tank entirely during the active cleaning phase. This is especially important when residues produce harmful vapours or when confined space entry carries significant risk under local regulations.

How does high-pressure water jetting clean chemical storage tanks?

High-pressure water jetting cleans chemical storage tanks by directing a concentrated stream of water at pressures between 500 and 3,000 bar (“7,250 to 43,500 PSI”) against the internal surfaces of the tank. The kinetic energy of the water stream breaks the bond between the residue or coating and the steel substrate, lifting deposits without the need for chemical solvents or abrasive media.

The cleaning process typically follows a structured sequence. The cleaning head, whether operated manually or mounted on a robotic crawler, is positioned at a consistent standoff distance from the surface. The operator or control system moves the head across the surface in overlapping passes to ensure full coverage. At higher pressures, water jetting can remove not only chemical residues but also rust, old coatings, and mill scale, preparing the surface for inspection or recoating in a single operation.

One of the key advantages of water jetting for chemical tank cleaning is that it introduces no additional substances into the tank. Unlike chemical cleaning agents, which can react with residues or require their own disposal protocols, water jetting uses only water and relies entirely on pressure and flow rate. This simplifies waste management significantly, particularly when the collected water can be processed through an on-site treatment system.

What factors determine the right cleaning solution for a storage tank?

The right tank cleaning solution is determined by five core factors: the chemical stored, the tank’s geometry, the required surface condition after cleaning, the facility’s environmental and safety requirements, and the available operational budget. Each factor influences both the cleaning method and the specific equipment configuration needed.

• Chemical type and residue behaviour: Viscous residues, polymerised deposits, or reactive chemicals each respond differently to pressure and temperature. Some residues require higher pressures, while others benefit from heated water to aid removal.
• Tank geometry: Flat-bottomed tanks, cone-bottom tanks, and tanks with internal structures such as wind girders or agitators each require different nozzle configurations and tool attachments. Curved surfaces demand tools specifically engineered for those radii.
• Required surface condition: If the tank is being cleaned for routine maintenance, a lower pressure pass may suffice. If the goal is surface preparation before recoating, the cleaning must achieve a specific surface profile and cleanliness standard.
• Environmental and safety regulations: Facilities operating under guidelines from SIR, EWJI, WJA, WJTA, or DIRV must ensure that the chosen method contains all waste and prevents airborne contamination.
• Budget and operational constraints: Manual cleaning is lower in upfront cost but higher in labour hours and risk exposure. Robotic or semi-automated systems carry a higher initial investment but reduce long-term operational costs and safety incidents.

Can robotic systems replace manual tank cleaning in chemical facilities?

Robotic systems can replace manual tank cleaning for the majority of surface cleaning and preparation tasks in chemical facilities, particularly on accessible steel surfaces. They are not yet a universal replacement for every scenario, but for flat and moderately curved tank walls, floors, and roofs, robotic crawlers perform the cleaning task more consistently, more safely, and often faster than manual teams.

The primary benefit of robotic tank cleaning is the elimination of confined space entry during the active cleaning phase. Confined space entry is one of the highest-risk activities in industrial maintenance, and reducing or eliminating it has a direct and measurable impact on safety outcomes. Robotic systems also deliver more consistent cleaning results because they maintain a fixed standoff distance and travel speed, removing the variability that comes with manual operation.

Magnetic crawler systems, such as the DERC MagTrack, are designed specifically for steel tank surfaces and can be fitted with a range of modular tools depending on the application. The blast can attachment enables closed waterblasting, collecting all water and debris through a connected vacuum unit so the surface is left clean and dry without any leakage. For smaller tanks or tanks with curved walls, a curved blast can variant accommodates radii of up to 3 meters (“approximately 9.8 feet”), making it practical for tanks up to 6 meters (“approximately 19.7 feet”) in diameter.

Manual intervention is still required for areas that robotic systems cannot reach, such as tight corners, nozzle connections, or areas obstructed by internal pipework. In practice, the most effective approach in chemical facilities combines robotic cleaning for large accessible surfaces with targeted manual work for confined or complex areas.

What are the biggest risks of improper chemical tank cleaning?

Improper chemical tank cleaning carries serious risks that span operator safety, environmental compliance, structural integrity, and operational continuity. The consequences of inadequate cleaning extend well beyond a dirty tank and can result in regulatory penalties, equipment damage, or life-threatening incidents.

• Operator exposure to hazardous residues: If containment is insufficient, technicians can be exposed to toxic, corrosive, or flammable chemical residues during cleaning. This is particularly dangerous in confined spaces where vapour concentrations build quickly.
• Residue cross-contamination: Incomplete cleaning leaves chemical residues that can contaminate the next product stored in the tank, causing product quality failures or dangerous chemical reactions.
• Environmental non-compliance: Uncontained wastewater carrying chemical residues can enter drainage systems or soil, triggering regulatory action under local and European environmental legislation.
• Accelerated corrosion: Chemical residues left on tank walls can continue to attack the steel substrate between cleaning cycles, shortening the tank’s service life and increasing the frequency and cost of structural repairs.
• Failed inspections: Tanks that are not properly cleaned cannot be accurately inspected. Residue on the surface masks corrosion, pitting, and weld defects that inspectors need to assess.

Organisations including SIR, EWJI, WJA, WJTA, and DIRV publish safety standards and best practice guidelines specifically to address these risks. Following their recommendations when selecting and executing tank cleaning solutions is not optional for facilities operating in regulated industries.

How often should chemical storage tanks be cleaned and inspected?

Chemical storage tanks should generally be cleaned and inspected at least once every one to five years, depending on the chemical stored, the tank’s condition, applicable regulatory requirements, and the facility’s risk management framework. High-risk chemicals, tanks showing signs of corrosion, or tanks subject to strict regulatory oversight may require annual or even more frequent cleaning and inspection cycles.

Several factors influence the appropriate cleaning frequency:

• Regulatory requirements: Many jurisdictions and industry standards mandate minimum inspection intervals for tanks storing hazardous chemicals. These requirements take precedence over internal scheduling preferences.
• Chemical aggressiveness: Tanks storing acids, solvents, or oxidising agents typically require more frequent cleaning because these substances accelerate corrosion and leave reactive residues.
• Product changeovers: Any time a tank switches from one chemical to another, a full cleaning is required regardless of the scheduled interval to prevent cross-contamination.
• Condition monitoring results: Ultrasonic thickness measurements, visual inspections, and corrosion monitoring data can all trigger an unscheduled cleaning and inspection if anomalies are detected.
• Operational history: Tanks that have experienced leaks, overfills, or process upsets may require immediate cleaning and inspection outside the regular schedule.

A proactive cleaning and inspection programme reduces the likelihood of unplanned downtime and extends the operational life of the tank. Facilities that integrate robotic cleaning systems into their maintenance schedules often find it easier to increase cleaning frequency because the time and labour cost per cleaning cycle is significantly lower than with manual methods.

How MagTrack helps with chemical storage tank cleaning

When it comes to chemical storage tank cleaning, we at DERC Salotech developed the MagTrack robotic crawler system to address exactly the challenges that maintenance engineers and field technicians face every day: safety risks in confined spaces, inconsistent manual cleaning results, environmental containment requirements, and the pressure to reduce downtime.

Here is what MagTrack brings to chemical storage tank cleaning specifically:

• Closed waterblasting with full containment: The blast can (vacuum dome) captures all water and debris during cleaning, leaving a clean and dry surface with no leakage, critical for tanks holding hazardous chemical residues.
• High-pressure performance: MagTrack tools operate at up to 3,000 bar (“43,500 PSI”), delivering the cleaning power needed for stubborn deposits, polymerised residues, and surface preparation before recoating.
• Modular tooling for different tank geometries: The curved blast can handles surfaces with radii up to 3 meters (“approximately 9.8 feet”), making it practical for smaller tanks and curved internal structures. The swing arm attachment reaches wind girders and similar constructions.
• Reduced confined space entry: By operating remotely, MagTrack keeps operators out of the tank during active cleaning, directly addressing one of the highest-risk activities in chemical facility maintenance.
• ATEX Zone 2 certified option: For facilities where explosive atmospheres are a concern, the MagTrack Mini is available as a certified ATEX Zone 2 unit, ensuring safe operation in demanding environments.
• Compact design for transport and deployment: The MagTrack Mini is lightweight and easy to transport, making it practical for facilities with multiple tanks or offshore locations.

If you are evaluating tank cleaning solutions for your chemical storage facility, we would be glad to discuss which MagTrack configuration fits your specific tank geometry, chemical type, and operational requirements. Contact our team to speak with one of our engineers directly.