Heat exchangers find widespread use in power generation, chemical processing. Costs due to overdesign, additional fuel consumption and maintenance, loss of production, etc. A large part of the text is devoted to the use of chemical and other additives to reduce or eliminate the problem of fouling. The fouling of heat exchangers, reactors and catalysts remains one of the most urgent problems. Fouling mechanism an overview sciencedirect topics. Heat exchanger fouling in phosphoric acid evaporators evaluation of field data, r. A heat exchanger is a device that allows heat energy in one process fluid to pass to another process fluid in a controlled manner whose purpose is either to remove heat from afluid cooling or to add heat to a fluid. Fouling is one of the main problems in design and operation of heat exchangers. Online monitoring of commercial heat exchangers is done by tracking the overall heat transfer coefficient, because the overall heat transfer coefficient tends to decline over time due to fouling. Costs associated with heat exchanger fouling include production losses due to. Fouling and fouling mitigation of calcium compounds on. Fouling and fouling mitigation on heat exchanger surfaces. Fouling of heat exchangers in processing industries is a chronic operating problem. The effect of fouling and the heat exchanger surface on thermal performance the above observations have important implications for the fouling performance.
The actual fouling rate is different for each application. Overview of heat exchanger analysis with set temperature boundary conditions. Completely revised and updated to reflect current advances in heat exchanger technology, heat exchanger design handbook, second edition includes enhanced figures and thermal effectiveness charts, tables, new chapter, and additional topicsall while keeping the qualities that made the first edition a centerpiece of information for practicing engineers, research, engineers, academicians. Fouling is usually distinguished from other surfacegrowth phenomena in that it occurs on a surface of a component, system, or plant performing a defined and useful function and that. This weeks monday morning minutes post explores heat exchanger fouling factors and suggests a couple of rules of thumb to follow.
Fouling is the accumulation of unwanted material on solid surfaces to the detriment of function. A heat exchanger is a heat transfer device that exchanges heat between two or more process fluids. R d fouling factor or unit thermal resistance of deposit m 2 kw u d overall heat transfer coefficient of heat exchanger after fouling wm 2 k u overall heat transfer coefficient of clean heat exchanger wm 2. This handbook presents the most important technologies concerning the reduction of fouling in heat exchangers and the appropriate technologies of removal and cleaning. Heat exchanger, heat, fouling, energy, effectiveness.
Fouling and corrosion fundamentals of heat exchanger. Heat exchangers are devices used to transfer heat between two or more fluid streams at different temperatures. In fact, fouling has been recognised for a long time, and research on heat exchanger fouling was conducted as early as 1910 and the first practical application of this research was implemented in the 1920s. Heat exchangers are commonly used in industry, and proper design of a heat exchanger depends on many variables. The problems that restrict the efficient operation of equipment are described and the costs, some.
Costs associated with heat exchanger fouling include production losses due to efficiency deterioration and to loss of production during planned or unplanned shutdowns due to fouling, and maintenance costs resulting from the removal of fouling deposits with chemicals andor mechanical antifouling devices or the replacement of corroded or plugged. It has extensive domestic and industrial applications. This series of biannual conferences provides the latest fundamental and. The design, installation, commissioning and operation of heat exchangers to minimise fouling. Matlab, a fundamental tool for scientific computing and engineering applications, chapter. Since there are many reference works on fouling mechanisms and their effects panchal et al. Proven dramatic results show it can help companies save thousands of hours of cleaning and millions of dollars in costs every year. In the design and operation of heat exchangers cooled with water, a coefficient of biological must be considered, which affects the efficiency of the equipment. Heat exchanger fouling and cleaning conference series.
Heat exchanger design methodologies deal with fouling by simply compensating for the reduced heat transfer efficiency with the addition of larger heat transfer surfaces see section 5. Part of the nato asi series book series nsse, volume 145. Influence of fouling on heat exchanger effectiveness in a. One of the most misunderstood items in the heat exchanger schedule is the fouling factor. The findings could support in developing the improved heat exchanger material surfaces, retain efficiency of the heat. Biological fouling may be defined as the growth of living matter on heat exchanger surfaces. Over 90% of all heat exchangers suffer from fouling. Advice on the selection, design, installation and commissioning of heat exchangers to minimise fouling is given. In contrast to the parallel flow heat exchanger, the counter flow heat exchanger can have the hottest coldfluid. Antifouling he new technology can reduce heat exchanger. They are widely used in space heating, refrigeration, air conditioning, power stations, chemical plants, petrochemical plants, petroleum refineries, natural. Heat exchangers are used in both cooling and heating processes. Both fouling and scaling essentially provide an additional and often times significant resistance to heat transfer in your heat exchanger. What is heat exchanger analysis performance calculation.
The problems that restrict the efficient operation of equipment are described and the costs. This unique and comprehensive text considers all aspects of heat exchanger fouling from the basic science of how surfaces become fouled to very practical ways of mitigating the problem and from mathematical modelling of different fouling mechanisms to practical methods of heat exchanger cleaning. Fouling is a function of the system and the equipment used. Counter flow heat exchangers are the most efficient of the three types. The fouling materials can consist of either living organisms or a nonliving. Reverse solubility salts become less solute as the temperature increases and thus deposit on the heat exchanger surface. The ufactor is defined by an expression analogous to newtons law of cooling. Extensive technical literature is available on heat exchanger design, operation and maintenance, but it is widely scattered throughout the industrial bulletins, industrial design codes and standard, technical journals, etc. However, not only is this practice far from being optimal it also increases the total capital expenditure. Fouling of heat exchangers chemical engineering monographs book 26 ebook. Jamialahmadi article pdf bayer process heat exchangers cleaning efficiency.
The phenomenon usually associated with water systems, e. With the development of fouling the heat exchanger may deteriorate to the extent. Heat exchanger analysis heat exchanger calculation. Heat exchanger design an overview sciencedirect topics. If uncontrolled, levels of fouling can negate any benefits produced by careful heat exchanger design. Whether youve loved the book or not, if you give your honest and detailed thoughts then people will find new books that are right for them. In the analysis of heat exchangers, it is often convenient to work with an overall heat transfer coefficient, known as a ufactor. Scaling is the most common type of fouling and is commonly associated with inverse solubility salts such as calcium carbonate caco 3 found in water. N2 heating of liquids is a common unit operation in food industry such as pasteurization and sterilization of dairy products. Pdf fouling and fouling mitigation on heat exchanger surfaces.
Fouling of heat exchangers chemical engineering monographs. Some novel methods which do not fall under well reported. Another large section is designed to give information on both online and offline cleaning of heat exchangers. Written by experts from germany, uk and the usa, this book is a reliable adviser for engineers, managers, technicians and students who want to. Completely revised and updated to reflect current advances in heat exchanger technology, heat exchanger design handbook, second edition includes enhanced figures and thermal effectiveness charts, tables, new chapter, and additional topicsall while keeping the qualities that made the first edition a centerpiece of information for practicing engine. Also provides quick access to heat transfer and pressure loss data, plus manual thermal design methods and examples, for heat exchangers involving single phase flow duties. Completely revised and updated to reflect current advances in heat exchanger technology, heat exchanger design handbook, second edition includes enhanced figures and thermal effectiveness charts, tables, new chapter, and additional topicsall while keeping the qualities that made the first edition a centerpiece of information for practicing engineers, research, engineers. Furthermore, the general and scientific fundamentals of heat transfer are explained. Heat exchanger is equipment used to transfer heat from one fluid to another. This unique and comprehensive text considers all aspects of heat exchanger fouling from the basic science of how surfaces become fouled to very practical ways of mitigating the problem and from mathematical modelling of different fouling mechanisms to practical methods of. The fouling factor represents the theoretical resistance to heat flow due to a buildup of a layer of dirt or other fouling substance on the tube surfaces of the heat exchanger, but they are often overstated by the end user in an attempt to. For this reason, it is necessary to apply appropriate antifouling treatments to the design of each heat. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact.
Fouling and reduced heat transfer in heat exchangers. Heat exchangers have widespread industrial and domestic applications. Parameters which influence the fouling rate in a system include. Heat exchanger design handbook mechanical engineering. The purpose of these publications is to provide improved understanding of the science and to give. Fouling and its effect on exchanger heat transfer and pressure drop. The fouling materials can consist of either living organisms or a nonliving substance inorganic andor organic.
This unique and comprehensive text considers all aspects of heat exchanger fouling from the basic science of how surfaces become fouled to very practical ways of mitigating the problem and from mathematical modelling of different fouling mechanisms to. A heat exchanger is a system used to transfer heat between two or more fluids. The purpose of this book chapter is to consolidate into basic background and. A major problem in industries that use heat exchanger equipment cooled with water in their industrial processes is biofouling. In plate heat exchangers, the degradation of performance is usually magnified because plate exchanger depend on a thin plate wall to maintain their high efficiencies. Engineers are often faced with interoffice scheduling traditions.
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