Application of fractal theory for characterisation of crystalline deposits

The objective of this investigation was to study the mechanisms of mixed salt crystallisation fouling on heat transfer surfaces and to characterise the structure of the deposits formed on the heat transfer surfaces. 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, which are the most common constituents of scales formed on heat transfer surfaces, were studied experimentally. After clarification of the effects of operating parameters on the deposition process, deposits on the heat transfer surfaces were collected for analysis. The crystalline samples were analysed using Scanning Electron Microscopy, X-Ray Diffraction and Ion Chromatography techniques. It was found that crystallisation fouling on heat transfer surfaces exhibits fractal geometry. Therefore, the concept of fractal theory was used to quantify the structure of the deposits by introducing a new quantity called the fractal dimension.     

流动过冷沸腾传热强化及阻垢

在流动沸腾传热实验中,考察了CaCO3污垢溶液的形成过程及各种工艺条件对流动过冷沸腾传热的影响. 研究条件包括流体速度、溶液温度、CaCO3溶液浓度及热通量,实验中发现了一些规律. 同时还考察了不同阻垢剂[聚天冬氨酸(PASP)、2-膦酸丁烷-1,2,4-三羧酸(PBTCA)及氨基三甲叉膦酸(ATMP)]对流动过冷沸腾传热的影响. 结果表明,所选阻垢剂均能抑制污垢的生成并降低了污垢热阻,而且存在最佳浓度范围. 但不同阻垢剂的阻垢效果不尽相同,在本实验条件下,ATMP的阻垢效果最好,PBTCA次之,PASP的阻垢效果较差.     

The effect of surface properties on CaSO4 scale formation during convective heat transfer and subcooled flow boiling

In this paper the effects of surface energy and surface roughness on the deposition of calcium sulphate during convective and subcooled flow boiling heat transfer to aqueous CaSO₄ solutions are studied. The surfaces of several test heaters have been treated by Ion Beam Implantation, Unbalanced Magnetron Sputtering, Mixed Sputtering and Plasma Arc Deposition to reduce surface energy. One heater was electropolished to reduce surface roughness and one heater was etched by an electrochemical method to increase surface roughness. Fouling runs with these heaters, and with an untreated surface as control, were carried out at different heat fluxes, flow velocities and salt concentrations. The results show that heat transfer surfaces with low surface energy experienced significantly reduced fouling, while electropolishing did not have a notable beneficial effect. The combined effect of reduced surface energy and flow velocity on fouling reduction is considerably stronger than previously reported for pool boiling.     

Performance of plate heat exchangers during calcium sulphate fouling — investigation with an in-line filter

The uncertainty about the fouling behaviour is one of the main reasons why plate and frame heat exchangers are not more widely installed in the chemical process industry and in power generating facilities. In the present investigation, the deposition of calcium sulphate in two different plate heat exchanger geometries was investigated. The deposition process was deliberately focused on crystallisation fouling through the installation of an in-line filter and the mode of preparation of the test solution. The investigated operating parameters were solution concentration, flow velocity, and bulk and surface temperatures. The heat exchangers were opened after each experiment to record the appearance and distribution of the deposits. The key result of this investigation is the strong correlation between the plate design and the tendency for deposit formation.     

稠油开采污水蒸发结垢过程传热传质计算方法

蒸发器是一种根据热法脱盐原理,利用稠油热采地面系统废热驱动,实现污水脱盐软化,进而回用锅炉实现水资源循环利用的装置。但是,由于油田污水水质的特殊性,使得其极易在蒸发器表面发生结垢行为。通过对污水水质分析,得出其结垢类型主要为碳酸钙垢。建立了碳酸钙垢在强制对流传热和过冷流动沸腾情况下于换热表面结垢的传热传质模型,计算了污水在蒸发过程中析晶污垢形成的数量,得出了与实验数据符合较好的计算模型。对稠油污水在蒸发器中的结垢情况可以进行较好的预测,并对安全生产和设备高效利用有一定参考价值。     

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.     

两相流载气蒸发研究和传热数据关联

两相流载气蒸发是在蒸发器的垂直加热管中引入一种惰性气体,使液体的蒸发在气液两相界面上进行的过程.本文研究了载气蒸发的流型区域和传热规律,对载气蒸发的特性进行了机理分析,并以叠加模型关联了实验数据,获得了准数方程式.     

CaCO3 fouling on microscale–nanoscale hydrophobic titania–fluoroalkylsilane films in pool boiling

Micrometer–nanometer hydrophobic titania–fluoroalkylsilane composite coatings were prepared on substrates based on liquid‐phase deposition. Coatings and crystallization forms were characterized with instruments of surface analyses. Experimental facilities of pool boiling were established to evaluate heat and mass transfer on coated surfaces in deionized water and saturated calcium carbonate solution. Obvious pool boiling enhancement was observed on thinner microscale–nanoscale hydrophobic titania–fluoroalkylsilane composite films at higher heat fluxes compared to that on thicker titania–fluoroalkylsilane coatings or on titania coatings and stainless steel surfaces. Lower fouling resistance was obtained on titania–fluoroalkylsilane coatings in pool boiling of saturated calcium carbonate solution and crystal form was aragonite, which was different from calcite on titania coatings. Results of inhibition of fouling and enhancement of heat transfer on titania–fluoroalkylsilane coatings were contributed to special surface microscale–nanoscale structure and material wettability. Asymptotic model was used to fit experimental data of fouling resistance, and reasonable agreement was obtained. © 2013 American Institute of Chemical Engineers AIChE J, 59: 2662–2678, 2013     

碳酸钙在流动过冷沸腾条件下的结垢机理研究

Fouling of heat transfer surfaces during subcooled flow boiling is a frequent engineering problem in process industries. It has been generally observed that the deposits in such industrial systems consist mainly of calcium carbonate （CaCO3）, which has inverse solubility characteristics. This investigation focused on the mechanism to control deposition and the morphology of crystalline deposits. A series of experiments were carried out at different surface and bulk temperatures, fluid velocities and salt ion concentrations. It is shown that the deposition rate is controlled by different mechanism in the range of experimental parameters, depending on salt ion concentration. At higher ion concentration, the fouling rate increases linearly with surface temperature and the effect of flow velocity on deposition rate is quite strong, suggesting that mass diffusion controls the fouling process. On the contrary, at lower ion concentration, the fouling rate increases exponentially with surface temperature and is independent of the velocity, illustrating that surface reaction controls the fouling process. By analysis of the morphology of scale, two types of crystal （calcite and aragonite） are formed. The lower the temperature and ion concentration, the longer the induction period and the higher the percentage of calcite nreciDitated.     

三相流沸腾传热

对三相流沸腾传热进行了理论分析和实验研究，研究了三相流沸腾传热特性，提出了三相流沸腾传热系数的计算方法，实验结果表明，由于固体粒子的存在，强化了沸腾传热，三相流沸腾传热系数是相同条件下汽－液两相流沸腾传热系数的两倍。固体粒子的存在，能有效地防止和清除传热壁面上的污垢。     

微小通道内流动沸腾换热的预测新模型

为了得到适用于微小通道内流动沸腾换热的预测方法,本文以近些年发表的9篇文献中的2924个实验数据点组成数据库,考虑到随着通道直径减小,表面张力对微小通道内两相流动和换热的影响起到主要作用,将Chen形式的换热模型中的核态沸腾和对流换热两部分的修正系数进行了优化。沸腾抑制系数和对流增强系数由气相韦伯数、两相雷诺数、沸腾数、气泡抑制数等量纲为1数组成,反映出了表面张力、水力直径、流动条件、热力条件对于换热的综合影响。结果表明,拟合出的微小通道中沸腾换热的新模型,适于预测水力直径3 mm以下的细管道中CHF（临界热流密度）点以前的换热系数。与实验数据比较,新模型预测的平均绝对误差为19.0%。     

磁场调控磁性纳米流体流动和传热研究进展

磁性纳米流体在实现能量高效和可控传递领域极具发展潜力。本文综述了磁场作用下磁性纳米流体对流换热及沸腾换热的最新进展,主要包括强制对流换热、混合对流换热、自然对流换热、池沸腾换热及管内沸腾换热等方面的实验研究,分析了磁场类型、强度、梯度、频率、方向及磁铁位置等对磁性纳米流体流动和热传输特性的影响,指出可通过改变外加磁场来实现对磁性纳米流体流动和传热的控制,并探讨了磁性纳米流体流-磁耦合作用下的传热机理以及目前所面临的挑战。在此基础上,提出了未来磁场调控磁性纳米流体对流换热和沸腾换热的主要发展方向：制备稳定的磁性纳米流体,建立系统有效的流动和传热理论模型,并从微介观尺度诠释热-流-磁耦合协同换热机理。     

Study of reverse osmosis membranes fouling by inorganic salts and colloidal particles during seawater desalination

Fouling phenomenon is considered among the major reasons that cause significant increase of operating cost of desalination plants equipped with reverse osmosis (RO) membranes. This phenomenon is studied in the present work in the case of RO polyamide aromatic membranes using model seawater containing inorganic salts and colloidal compounds. Different solubility conditions of CaCO₃ and CaSO₄ were applied to study RO performances with and without colloid presence. During experiments, the membrane permeate fluxes were continuously monitored. Moreover, studies of chemical composition, structure, and morphology of the materials deposited on the membrane surface were conducted using energy dispersive microanalysis (EDS) X-ray diffraction and scanning electronic microscopy (SEM). Results show that in conditions of calcium carbonate oversaturation there is a reduction in the permeate flow of 11.2% due to fouling of the membrane by the precipitation of this compound. While in the same conditions of calcium sulphate oversaturation the reduction of the flow is 5%, so we can conclude that in conditions of oversaturation of both salts, calcium carbonate produces a greater fouling of the membrane that in its view causes greater decrease in the flow of permeate. All this based on the results of the test with both salts in oversaturated conditions. Resulting in the formation of calcite and gypsum crystals onto the membranes as XRD analyses stated. Additional presence of colloidal silica in those conditions intensifies strongly the fouling, leading until to 24.1% of permeate flux decrease.     

在过冷流动沸腾期间硫酸钙污垢形成过程研究

在过冷流动沸腾条件下 ,对硫酸钙的沉积过程进行了研究 ,考查了不同流速和不同加热器表面条件下硫酸钙的结垢状况。研究表明 ,表面能对污垢沉积有显著影响 ,采用现代表面处理技术 ,对金属表面进行磁控溅射 ,可以降低金属表面能 ,抑制污垢在加热器表面上的沉积。同时 ,操作的工艺条件对硫酸钙结晶垢的形成也有一定影响 ,在一定流速范围内 ,提高流速 ,可减少污垢的形成 ,提高传热系数     

直流蒸汽发生器蒸干及蒸干后传热数值分析

准确预测直流蒸汽发生器流动沸腾及蒸干对其设计、安全可靠运行极其重要。通过对B&W公司直流蒸汽发生器进行合理简化,引入两流体三流场数学模型及壁面热通量分区模型,分别进行基于常热通量和耦合传热的蒸汽发生器流动沸腾数值模拟。结果表明：蒸干发生时传热性能急剧下降,常热通量边界下壁温升高的幅度相当大（约300 K·m^-1）,而耦合传热边界下壁温飞升幅度约为25 K·m^-1,与实际情形相一致;两种热边界中预热区会发生过冷沸腾,壁面处传热由液相对流换热、淬火换热和蒸发换热3部分构成,核态沸腾区蒸发换热为主要换热方式,同时伴随着液相对流换热和淬火换热,蒸干发生时淬火换热和蒸发换热全部降到0,在蒸干后传热区域换热方式为气相对流换热。     

微/小通道内非牛顿流体多相流动与传热研究展望

概述了微/小尺度非牛顿流体多相流动与传热现象。在评述国内外已有文献的基础上,从实验研究与数值模拟二方面介绍了非牛顿流体管内多相流动与传热研究的现状、存在的问题。总结了微小通道内非牛顿流体多相流动与传热研究领域中若干值得探索的研究切入点,提出了若干值得探索的研究内容。讨论了非圆截面微通道试验器件的设计与加工、流动可视化与流型采集、流动参数测量、数值模拟等关键技术解决思路,给出了微/小通道内非牛顿流体的绝热气液二相流动可视化实验、流动沸腾传热及可视化实验设计方案,可为深入探索微/小尺度非牛顿流体管内多相流动与传热特性提供参考和借鉴。     

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.     

Investigation of flow boiling in circulating three-phase fluidised bed: Part I: Experiments and results

In flow boiling apparatus, fouling is frequently a problem. Mechanical methods to mitigate fouling include the impact of solids on the deposit to remove it. Solid particles fluidised by the two-phase boiling mixture may accomplish sufficient deposit removal to keep boiling surfaces clean. This results in a self-cleaning fluidised bed boiling heat exchanger. The particles additionally enhance the heat transfer. In this paper, a comprehensive investigation of three-phase fluidised flow boiling in a circulating system is presented. A test apparatus which is a three-phase circulating fluidised bed was built with glass construction to visualise boiling phenomena in a water system. It could also be operated as a two-phase system and this was investigated to provide the basis for comparison and also to verify reproducibility and confirm well-established flow boiling results. For the three-phase system (where steel particles were added), a range of liquid flowrates and heat fluxes was used and three different particle sizes were investigated. Three-phase results were compared with two-phase results. This work is primarily a study of boiling heat transfer enhancement as a result of addition of particles, but the effect of the particles creating a self-cleaning heat exchanger is a significant operational advantage for industrial application.As expected, heat transfer coefficients were higher overall for the three-phase system than for the two-phase system. The onset of nucleate boiling was independent of heat flux and the heat transfer coefficient initially increased with increasing Reynolds number whereafter there was some deterioration of heat transfer. Visualisation of boiling heat transfer phenomena for the three-phase system is also provided which allows mechanistic explanations of the measured phenomena.In Part II of this paper, a correlation is developed, based on boiling heat transfer modelling, to describe heat transfer during boiling in a three-phase circulating fluidised bed. A flow-dependent function is added as is a boiling heat transfer enhancement factor. This correlation is validated against this experimental data and found to show agreement within about 20% and better agreement with the data than an existing correlation.     

三相循环流化床中沸腾传热特性

提出了一种新型蒸发沸腾传热方式,即汽液固三相循环流化床沸腾传热。实验表明:该传热方式具有强化传热和防、除垢效果;其传热系数比汽液两相流沸腾传热膜系数高1.5～2.0倍,并能长期保持传热壁面的洁净。实验中研究了不同种类的固体粒子(玻璃球、陶瓷球、钛粒和钢球)、粒子体积分率、液相流速以及加热蒸汽压力等因素对循环流化床沸腾传热的影响。     

固体颗粒对流化床多相蒸发海水淡化操作浓缩比及膜传热系数的影响

提高海水淡化操作浓缩比,不仅可以提高造水比,还可以有效降低淡化后浓海水再利用的后处理成本,故其是实现低成本零排放的关键之一。在一套循环流化床多相蒸发海水淡化实验装置上,分别采用汽-液两相及汽-液-固三相操作,考察固体颗粒对海水淡化操作浓缩比及膜传热系数的影响,并分析垢层的主要成分。实验表明：高温下CaSO4首先析出,是形成垢层的主要成分;采取汽-液两相操作,膜传热系数保持在1.75 kW·m-2·K-1左右,操作浓缩比可达到3.8左右;采取汽-液-固三相操作,固体颗粒强化传热和防除垢的作用显著,加入颗粒体积分数为4%时,在膜传热系数保持在2.3 kW·m-2·K-1左右不降低的情况下,海水淡化操作浓缩比达到5.8以上。