Fouling von Wärmeübertragungsflächen

Fouling of heat transfer surfaces . Fouling of heat transfer surfaces in industry causes considerable costs. Overcoming fouling is therefore essential for technical and economic reasons. Solution of the problems requires a better understanding of the physical, chemical and biological processes causing fouling. It is shown, that the prediction of the fouling behaviour of heat transfer equipment based on existing mathematical models is not jet satisfactory. This article presents a new physical model describing particulate and precipitation fouling based on the assumption of a deposition and a removal process. Experiments to prove the results of the theoretical considerations were carried out using an aqueous CaSO₄ solution. The test unit which is also suitable for in-situ measurements is described in detail. Measured and predicted asymptotic fouling factors agree with acceptable accuracy.     

FLOW BOILING HEAT TRANSFER WITH FLUIDIZED SOLID PARTICLES

In order to solve the fouling problems in boiling processes,a boiling system was designedby adding solid particles to the boiling liquid In this paper.both theoretical analyses andexperimental studies on the boiling heat transfer in such a three-phase flow boiling were carried out.Based on the analysis of heat transfer characters of this three-phase flow boiling,a mathematical mod-el for the heat transfer coefficient of flow boiling was developed.The experiments show that,in thepresence of particles the boiling heat transfer is enhanced and is about 2 times that of the vaporliquid two phase one with better flow stability.The fluidized particles rub the heat transfer wall toprevent and to clean the fouling.     

Prevention of crystallization fouling during eutectic freeze crystallization in fluidized bed heat exchangers

Eutectic freeze crystallization is a promising separation technique to produce salt and ice crystals with very high purities and requires less energy than competitive evaporative crystallization techniques. A drawback of this technique is crystallization fouling, which seriously reduces heat transfer rates. Solid–liquid fluidized bed heat exchangers may be attractive crystallizers for this purpose, since they have demonstrated to prevent severe crystallization fouling, for example of ice crystals. This paper presents crystallization experiments with a single-tube fluidized bed heat exchanger. A first experimental series showed that fluidized beds are also able to prevent salt fouling during cooling crystallization from KNO₃ or MgSO₄ solutions. A second series revealed that fouling during eutectic freeze crystallization is more severe than during separate salt or ice crystallization and is therefore difficult to prevent by the fluidized bed. The explanation for this phenomenon is that the salt crystallization process strongly reduces the solute mass transfer limitation for ice crystals growing on the wall resulting in an increased growth rate and more severe crystallization fouling. The addition of a non-crystallizing component strongly reduces fouling and enables to perform eutectic freeze crystallization in fluidized bed heat exchangers for industrial applications.     

FLOW BOILING HEAT TRANSFER IN A NEW VAPOR-LIQUID-SOLID THREE-PHASE CIRCULATING FLUIDIZED BED EVAPORATOR

In order to enhance heat transfer and solve the fouling problems in boiling processes, a boiling system was designed by adding solid particles to the boiling liquid. In this paper, both theoretical analyses and experimental studies on the flow boiling heat transfer in a vapor-liquid-solid three-phase circulating fluidized bed evaporator were carried out. Based on the analysis of the heat transfer characters of this three-phase flow boiling, a mathematical model for predicting the flow boiling heat transfer coefficients of the vapor-liquid-solid three-phase circulating fluidized bed evaporator was developed. The experiments show that, in the presence of solid particles the flow boiling heat transfer is enhanced and is about 2 times that of the vapor-liquid two-phase one. The predicted results of the flow boiling heat transfer coefficients agreed well with the experimental data.     

Impact of deposit ageing on thermal fouling: Lumped parameter model

The thermal and hydraulic performance of heat exchangers can be seriously impaired by the formation of fouling deposits on the heat transfer surfaces. The thermal effect of fouling can be complicated when the deposit is subject to ageing, represented here as a change in deposit thermal conductivity (but not thickness) over time. In this article, we revisit the ageing concept for crude oil fouling proposed by Nelson (Refiner Nat Gas Manufacturer. 1934;13:271–276, 292–298), using a numerical model incorporating first order kinetics to generate quantitative comparisons of different ageing rates. Results are reported for lumped parameter systems (which also simulate point measurement methods commonly used in laboratory testing) that demonstrate that ageing can have a substantial influence on the rate of heat transfer and hence on the surface temperature and rate of fouling. Rapid ageing (compared with the rate of deposition) does not pose problems, but slow ageing, or the use of constant heat fluxes in experiments, can lead to modified thermal fouling behavior. It is concluded that deposit ageing dynamics should be considered alongside deposition rate dynamics when interpreting experimental fouling data and when modeling fouling behavior in support of heat exchanger design or operation. © 2009 American Institute of Chemical Engineers AIChE J, 2010     

Roughness and constriction effects on heat transfer in crystallization fouling

This contribution addresses apparent negative fouling resistances for crystallization fouling. Two effects contribute to this phenomenon; surface roughness enhances heat transfer in the roughness controlled phase. In the crystal growth phase, surface roughness as well as the constriction of flow cross section due to the fouling layer build-up is taken into consideration. Fouling experiments were carried out in a double pipe heat exchanger with a supersaturated aqueous CaSO₄ solution at a Reynolds number of 17,500 corresponding to a flow velocity of 0.65 m s⁻¹. The measured pressure drop between inlet and outlet allowed the calculation of the integral friction factor for the current surface roughness. With the given friction factor it was possible to estimate the actual heat transfer coefficient of the inner tube. Accounting for the increase in heat transfer caused by surface roughness in the roughness controlled phase, the fouling resistance was recalculated. In the subsequent growth phase flow acceleration due to constriction effects is considered in addition to the roughness effect. Overall the integral fouling resistance and consequently the deposit thickness are underestimated by a factor of up to 2.5 when simply using heat balance. With the proposed approach apparent negative fouling resistances can be eliminated quantitatively.     

多相流流化床换热器研究进展

蒸发沸腾换热是化工、轻工、能源、动力等行业生产过程中的关键技术,而蒸发沸腾换热器侧壁面结垢是一个长期困扰急待解决的难题。本文介绍了将流化床技术与换热、蒸发、沸腾过程相结合开发出的多相流化床蒸发器的研究进展,如液-固流化床、汽-液-固三相流蒸发沸腾换热技术和汽-液-固三相循环流化床蒸发器技术。该技术解决了蒸发器和再沸器的结垢问题。     

Fouling of tube bundles under pool boiling conditions

This paper aims to provide experimental heat transfer results for boiling of CaSO₄ solutions on the outside of tube bundles, and also to shed some light into the mechanisms which influence heat transfer fouling under pool boiling conditions. Heat transfer coefficients for three heater rods with an identical diameter of 10.67 mm on a 35 mm vertical pitch have been measured. The independent variables bulk concentration and heat flux have been varied from 0.8 to 1.6 g/L and 33 to 300 kW/m², respectively. The experimental results show that the mechanisms of fouling on the middle and top heater substantially differ from those at the bottom heater, due to the dominant effects of bubble impingement on the heat transfer surfaces. In particular, the competing effects on the degree of wall superheat and the supersaturation of the boiling liquid play a significant role. Spalling effects are more pronounced on the upper heaters where thin, friable deposits were found with low density and adherence, particularly at higher heat fluxes and lower concentrations. In terms of tube bundle efficiency, the best results were found for lower concentrations.     

Investigation of Scale Formation in Heat Exchangers of Phosphoric Acid Evaporator Plants

The primary problem in concentrating phosphoric acid is due to fouling on the tube‐side of the heat exchangers of the evaporator units. Scaling on the heat transfer surfaces occurs because of high supersaturation of phosphoric acid liquor with respect to calcium sulphate. A review of the existing literature reveals that no information is available on heat transfer and on crystallization fouling of industrial phosphoric acid solutions. In this investigation, the solubility of different calcium sulphate types in phosphoric acid solution was studied and its dependency on acid concentration and temperature was investigated. A large number of fouling experiments were carried out in a side‐stream of a phosphoric acid plant at different flow velocities, surface temperatures and concentrations to determine the mechanisms, which control the deposition process. After identifying the effects of operational parameters on the deposition process, a model was developed for prediction of fouling resistances. The reaction of calcium sulphate crystallization followed a second order rate with respect to the supersaturation. The activation energy evaluated for the surface reaction of the deposit formation was found to be 57 kJ/mol. The predicted fouling resistances were compared with the experimental data. Quantitative and qualitative agreement between measured and predicted fouling rates is good.     

Mathematical modelling of mixed salt precipitation during convective heat transfer and sub-cooled flow boiling

The main purpose of this investigation was to study the mechanisms of mixed salt crystallisation fouling on heat transfer surfaces during convective heat transfer and sub-cooled flow boiling conditions. In the present investigation, the effects of various operating parameters such as solution composition and hydrodynamics of the system, on crystallisation fouling of mixtures of calcium sulphate and calcium carbonate have been studied experimentally. After clarification of the effects of operating parameters on the deposition process, the results of the experiments were used to develop a mechanistic model for prediction of fouling resistances, caused by crystallisation of mixed salts, under convective heat transfer and sub-cooled flow boiling conditions. Model predictions were compared with the measured experimental data when calcium sulphate and calcium carbonate form deposits on the heat transfer surface simultaneously. Deviations ranging from 6% to 25% were observed which confirm the suitability of the model.     

Untersuchungen zum Kristallisationsfouling in Mikrowärmeübertragern

The advantages of microstructure devices concerning heat and mass transfer are well known. However, the usage of microstructure devices in chemical industry is still limited today. A limitation for industrial application is the liability of microstructures to blocking due to impurity of the fluid or by unintended deposition (fouling) in the microchannels. Fouling can lead to a degradation of the heat transfer performance, to an increase of the pressure drop, to a change of the fluid distribution in the microstructures and to a shorter residence time of the fluid. In the framework of this research project a micro heat exchanger for fundamental experimental investigations on crystallization fouling of CaCO₃ in microchannels was developed and manufactured.     

水质参数对交叉缩放椭圆管污垢的影响

采用对比的实验方法对交叉缩放椭圆管与光管的污垢热阻进行了分析,并重点研究了冷却水（松花江水）水质参数对污垢产生的影响。实验结果表明：在低流速时,交叉缩放椭圆管的污垢热阻渐近值比光管低,且没有明显的诱导期;实验中冷却水水质参数的变化对污垢影响明显。并深度分析了水质参数随时间的变化及水质参数变化对强化换热表面污垢特性的影响,为换热器提高换热效率提供了参考。     

Fiber-modified scaling in heat transfer fouling mitigation

The study of heat exchanger fouling using supersaturated calcium sulphate solutions has been widely reported. In this study fouling was investigated in a larger-scale heat exchange apparatus using stainless-steel pipe, and data were obtained at different flow rates, concentrations and temperature differences. The deposits were examined using a scanning electron microscope, X-ray diffraction and conventional photography. In a novel approach, wood pulp fibers were added to the fouling solution at various concentrations to mitigate fouling. Heat transfer enhancement above the solution-alone was observed initially and the onset of fouling delayed. When fouling eventually developed the final asymptotic level was lower than the fiber-free case for the experimental conditions specified. At a fiber concentration of 0.15% heat transfer augmentation occurred for 11 days. However, at 0.25% fiber concentration, heat transfer augmentation (no fouling) was sustained over the experimental duration of 45 days. It can be concluded that the service-life cycle of a heat exchanger can be prolonged with the addition of asymmetric, flexible, natural fibers. In this work it is argued that fibers modify the onset of deposition by boundary layer scavenging, and interact with turbulent eddies to reduce the rate of mass transfer of the foulant to the heated surface. When scale forms, the crystalline structure of the scale is interrupted by the fibers, which appear to roughen the heat transfer surface initially and increase the heat transfer coefficient. However, the scale deposit continues to build up very slowly, causing the thermal resistance to eventually override the turbulence augmented heat transfer effect of the fibers.     

FIBER-MODIFIED SCALING IN HEAT TRANSFER FOULING MITIGATION

The study of heat exchanger fouling using supersaturated calcium sulphate solutions has been widely reported. In this study fouling was investigated in a larger-scale heat exchange apparatus using stainless-steel pipe, and data were obtained at different flow rates, concentrations and temperature differences. The deposits were examined using a scanning electron microscope, X-ray diffraction and conventional photography. In a novel approach, wood pulp fibers were added to the fouling solution at various concentrations to mitigate fouling. Heat transfer enhancement above the solution-alone was observed initially and the onset of fouling delayed. When fouling eventually developed the final asymptotic level was lower than the fiber-free case for the experimental conditions specified. At a fiber concentration of 0.15% heat transfer augmentation occurred for 11 days. However, at 0.25% fiber concentration, heat transfer augmentation (no fouling) was sustained over the experimental duration of 45 days. It can be concluded that the service-life cycle of a heat exchanger can be prolonged with the addition of asymmetric, flexible, natural fibers. In this work it is argued that fibers modify the onset of deposition by boundary layer scavenging, and interact with turbulent eddies to reduce the rate of mass transfer of the foulant to the heated surface. When scale forms, the crystalline structure of the scale is interrupted by the fibers, which appear to roughen the heat transfer surface initially and increase the heat transfer coefficient. However, the scale deposit continues to build up very slowly, causing the thermal resistance to eventually override the turbulence augmented heat transfer effect of the fibers.     

Numerical and experimental analyses of anti‐fouling and heat transfer in the heat exchanger with circulating fluidized bed

Fluidized bed type heat exchangers are known to increase the heat transfer and prevent the fouling. For proper design of circulating fluidized bed heat exchanger it is important to know the effect of design and operating parameters on the bed to the wall heat transfer coefficient. The numerical analysis by using CFX 11.0 commercial code was done for proper design of the heat exchanger. The present experimental studies were also conducted to investigate the effects of circulating solid particles on the characteristics of fluid flow, heat transfer, and cleaning effect in the fluidized bed vertical shell and tube type heat exchanger with counterflow, at which a variety of solid particles such as glass (3 mmØ), aluminum (2–3 mmØ), steel (2–2.5 mmØ), copper (2.5 mmØ), and sand (2–4 mmØ) were used in the fluidized bed with a smooth tube. Seven different solid particles have the same volume, and the effects of various parameters such as water flow rates, particle diameter, materials, and geometry were investigated. The present experimental and numerical results showed that the flow velocity range for collision of particles to the tube wall was higher with heavier density solid particles, and the increase in heat transfer was in the order of sand, copper, steel, aluminum, and glass. This behaviour might be attributed to the parameters such as surface roughness or particle heat capacity. Fouling examination using 25,500 ppm of ferric oxide (Fe₂O₃) revealed that the tube inside wall is cleaned by a mild and continuous scouring action of fluidized solid particles. The fluidized solid particles not only keep the surface clean, but they also breakup the boundary layer improving the heat transfer coefficient even at low‐fluid velocities.     

污水换热器流态化在线防、除垢实验

采用污水源热泵供暖空调是节能减排的有效途径,但换热器结垢问题尚未得到有效解决。本文将固液流态化除垢技术应用到污水源热泵换热器的防、除垢中,并设计了一套污水换热器流态化除垢系统。该系统以沙粒作为除垢颗粒,通过理论分析和实验验证相结合的方法,研究了固液流态化除垢的最佳流速、除垢能力、强化换热效果及减少磨损的最佳工作参数。实验结果表明;当换热管内污水流速达到0.87m/s时,直径2～3mm沙粒可流化,沙粒循环回收率达到95%,实现了污水换热器在线清洗;沙粒对壁面的碰撞力可有效去除换热管壁的软垢及铁锈,除垢效果明显;该除垢系统持续运行24h后,污水换热器传热系数提高了25.6%;沙粒体积分数为4%,流速为扬动流速,是减少磨损和保证除垢效率的最佳工作参数。     

Estimation of thermo- and diffusiophoretic particle deposition

Theories are developed for estimating thermo- and diffusiophoretic deposition of particles in liquid as well as gas phase heat and mass transfer equipment, operating under turbulent conditions. Simple expressions are obtained which give satisfactory agreement with experimental data. It is shown that the phoretic effects can lead to appreciable particle deposition, and the practical implications of this, such as heat exchanger fouling, are discussed. The simultaneous occurrence of these and other deposition mechanisms is also considered.     

循环流化床的沸腾传热

A model is proposed to predict boiling heat transfer coefficient in a three-phase circulating fluidized bed (CFB), which is a new type of evaporation boiling means for enhancing heat transfer and preventing fouling. To verify the model, experiments are conducted in a stainless steel column with 39 mm ID and 2.0 m height, in which the heat transfer coefficient is measured for different superficial velocities, steam pressures, particle concentrations and materials of particle. As the steam pressure and particle concentrations increase, the heat transfer coefficient in the bed increases. The heat transfer coefficient increases with the liquid velocity but it exhibits a local minimum.The heat transfer coefficient is correlated with cluster renewed model and two-mechanism method. The prediction of the model is in good agreement with experimental data.     

强制对流传热的换热表面结垢特性实验研究

An experimental study was conducted to investigate the fouling process of calcium carbonate on the heat transfer surface, during forced convective heat transfer. The dynamic monitoring apparatus of fouling resistance was set up for the present experiments. The fouling behavio（s were examined under different factors including fluid velocity, hardness,alkalinity, solution temperature, and wall temperature. Asymptotic fouling curves varying with time were obtained. The fouling rate and asymptotic fouling resistance increased and the induction periods were shortened with the fluid velocity decreasing, hardness andalkalinity increasing, and solution temperature and heat transfer surface temperature increasing. Thecomponents of fouling that formed on the heat transfer surface included crystallization fouling and particulate fouling. The thermal performance parameter of fouling,ρfhf, varied from 380 to 2600 kg·W·（m^4·K）^-1, increasing with growing velocity and decreasing solution temperature, hardness or alkalinity. Furthermore, the thermal conductivity of fouling, λf, varied from 1.7 to 2.2 W·（m·K）^-1 .     

Investigation of induction period and morphology of CaCO3 fouling on heated surface

The accumulation of unwanted crystalline deposits (fouling) reduces the efficiency of heat exchanger considerably. In order to mitigate fouling, many measures have been taken including the use of low-energy surface and antifoulant. In this investigation, the CaCO₃ fouling experiments in both cooling water and pool-boiling systems were performed, the induction period as well as the removal of fouling was studied, and the fouling morphology was also investigated by scanning electron microscopy and atomic force microscopy (AFM). Compared with the copper surface, the self-assembled monolayers low-energy surface can prolong the induction period of fouling in the cooling water system. The induction period increases with decreasing initial surface temperature and fluid velocity. When the heat flux is fixed in different experiments, an increase in the fluid velocity will result in a decrease in the initial surface temperature. Under this condition, owing to the interactional effects between surface temperature and fluid velocity, the induction period increases with increasing fluid velocity. The removal experiments were carried out both in the induction period and in the post-induction period. The results show that only in the induction period can the fouling resistance be reduced owing to the weaker adhesion strength of fouling. In the presence of antifoulant polyacrylic acid (PAA), the crystal forms are changed and the fractal dimensions of CaCO₃ morphologies increase for both the cooling water and the pool-boiling systems. AFM images show that the steps are bunched for CaCO₃ formed in the pool-boiling system, and in the presence of PAA, the step spacing is widened compared to the case in the absence of PAA.