Particulate Fouling and Challenges of Metal Foam Heat Exchangers

ABSTRACT

In recent years, open-cell metal foam has gained attention for utilization for exhaust gas recirculation coolers due to its large surface area and porous structure. Theoretically, the porous foam structure would have better transfer heat through conduction and convection processes. However, the exhaust gases that enter the cooler would carry particulate matter, which may deposit within the foam structure. The existing fouling studies cannot explain the underlying mechanisms of particulate deposition thoroughly within the foam structure. This study reviews the particulate fouling of heat exchangers, particularly in the exhaust gas recirculation system. Some past approaches to investigate fouling, particle transport, and deposition in the metal foam heat exchangers for many different applications are also included. In addition, this study also includes the challenges that lie ahead in implementing the metal foam heat exchangers in the industries.     

板式换热器颗粒污垢特性的实验研究

以纳米氧化镁颗粒溶液为实验工质,进行了板式换热器颗粒污垢特性的实验研究,分析了颗粒质量浓度、颗粒粒径、流速和低温介质温度对颗粒污垢热阻的影响.结果表明:板式换热器颗粒污垢无明显诱导期存在,结垢速率和污垢热阻渐进值均随颗粒质量浓度的增大而增大,且增大幅度逐渐减小;颗粒粒径对污垢热阻的影响较明显,在相同质量浓度下,颗粒粒径越小,结垢速率越快,且污垢热阻越大;流速对污垢热阻的影响较为复杂,高流速下的结垢速率略大于低流速下,且高流速下达到稳定时的污垢热阻渐进值小于低流速下;低温介质温度对颗粒污垢热阻的影响不明显.     

Modeling and Prediction of Shell-Side Fouling in Shell-and-Tube Heat Exchangers

Fouling is a challenging, longstanding, and costly problem affecting a variety of heat transfer applications in industry. Mathematical models that aim at capturing and predicting fouling trends in shell-and-tube heat exchangers typically focus on fouling inside the tubes, while fouling on the shell side has generally been neglected. However, fouling deposition on the shell side may be significant in practice, impairing heat transfer, increasing pressure drops, and modifying flow paths. In this paper, a new model formulation is presented that enables capturing fouling on the shell side of shell-and-tube heat exchangers including the effect of occlusion of the shell-side clearances. It is demonstrated by means of an industrial case study in a crude oil refinery application. The model, implemented in an advanced simulation environment, is fitted to plant data. It is shown to capture the complex thermal and hydraulic interactions between fouling growth inside and outside of the tubes, the effect of fouling on the occlusion of the shell-side construction clearances, and to unveil the impact on shell-side flow patterns, heat transfer coefficient, pressure drops, and overall exchanger performance. The model is shown to predict the fouling behavior in a seamless dynamic simulation of both deposition and cleaning operations, with excellent results.     

Optimization of Flow Direction to Minimize Particulate Fouling of Heat Exchangers

The influence of flow direction with respect to gravity on particulate fouling of heat exchangers is investigated experimentally to determine the optimal flow direction to minimize fouling. Four orientations of flow have been investigated: horizontal flow, upward flow, downward flow, and a flow under an angle of 45°. It is observed that fouling starts at the point of stagnation irrespective of the flow direction, and also at the top of the heat exchanger tubes. Particulate fouling grows from these two points till they meet and the fouling layer covers the whole surface of the heat exchanger tube. Fouling at the upper half of the tubes is much faster than the lower half of the tubes, and the fouling rate is faster at the bottom tubes of the heat exchanger section than at the upper tubes. The best orientation for lingering particulate fouling is the downward flow, where the flow stagnation point coincides with the top point of the heat exchanger tubes and the growth of the fouling layer only starts from one point.     

污水换热器污垢生长特性试验研究

污水换热器污垢是影响污水冷热源应用的主要因素.了解污垢的形成规律是污水换热器应用与研究的基本要求.基于工程现场实验,通过热阻法测定污水换热器管程内污垢的热阻变化模型Rf(θ)=8×10-4[1-exP(-θ/188)].提出了污垢形成过程有效热阻与有效总传热系数的概念.并通过热阻模型提出了渐进型污垢形成过程的压降模型△(△p)=A-Bexp[-t/t0).为进一步的研究与应用提供了理论基础.     

Air-Side Fouling of Compact Heat Exchangers for Discrete Particle Size Ranges

The industrial problem of the air-side fouling of compact heat exchangers has been studied in a laboratory wind tunnel for particles in the μm to mm range. The measurements of pressure drop across the exchanger as well as the quantification and classification of the particles blocked by and passing through it were taken for discrete ranges of particle sizes. Observation showed that the blocked particles either drop to the wind tunnel floor, remain on the outside surface of the exchanger (falling to the floor once the wind velocity drops), or penetrate a short distance into it according to the relative values of fin spacing and particle size. These last are the most detrimental to exchanger performance. There is a critical particle size for which this penetration is maximal. A brief non-dimensional geometrical analysis allows one to predict this critical size range for any finned exchanger. It has been found to be between 0.5–0.7 times the diameter of the largest sphere that can be inscribed between the fins. Confirmation of this was found with a second exchanger. The addition of humid conditions within the tunnel or on the exchanger itself did not modify these values. Subtracting the pressure drop due to the clean exchanger from the total measured value confirms that the foulant acts like an extra mechanical filter in series with the exchanger. This is quite understandable given the short penetration length of the particles (up to 3 mm). Finally, the effects of a closed wind tunnel test section on the measurements for non-isothermal conditions in the exchanger are discussed.     

Effect of Geometry and Flow Conditions on Particulate Fouling in Plate Heat Exchangers

This article describes particulate fouling experiments performed on small-scale and full-scale plate heat exchangers for three different corrugation angles (30 deg, 45 deg and 60 deg). The velocity effect has been studied as well as the particle type and concentration effects. The test duration ranges between 20 and 1,500 h in order to reach asymptotic behavior. The results clearly indicate that the corrugation angle has a major influence on the asymptotic fouling resistance. Increasing the corrugation angle leads to lower values for the fouling resistance. Furthermore, for a given corrugation angle, the asymptotic fouling resistance is inversely proportional to the velocity squared. Finally, the asymptotic fouling resistance is proportional to the particle concentration. Fouling mitigation can be obtained by taking into account at the design stage the heat exchanger geometry and fluid velocity.     

A Critical Review of Basic Crystallography to Salt Crystallization Fouling in Heat Exchangers

Fouling formation on heat exchanger surfaces due to crystallization of inverse solubility salts is one of the fundamental problems in process industries. Despite numerous studies carried out in recent years, comprehensive understanding of crystallization fouling mechanism remains a challenge to chemical engineers. In this review, we first focus on the basic crystallography during deposition of calcium salts, paying attention to crystal structures and crystal forms, as well as nucleation and the subsequent crystal growth process. We then endeavor to relate a number of factors to fouling rate, which may be classified into three categories: solution composition, operating parameters, and heat exchanger surface characteristics. Each aspect is discussed from the crystallization viewpoint (science) and in terms of possible industrial applications (practice). Combining the basic knowledge of crystallography with the information from experimental investigations, several fouling mitigation methods have also been described that may reduce fouling. It is hoped that some of the ideas discussed here will provide possible economic and environmental benefits. Finally, we also try to throw some light on the future direction for research.     

Petroleum Stability and Heteroatom Species Effects in Fouling of Heat Exchangers by Asphaltenes

Petroleum stability effects on heat exchanger fouling were studied using mixtures of heavy oil containing asphaltenes, and carrier fluids consisting of a fuel oil cut with varying amounts of added aliphatic or aromatic fluid. Fouling was measured in a recirculation loop using an annular, electrically heated probe. The effects of carrier fluid composition, dissolved oxygen, and heteroatomic species additions were investigated. Insolubles formed in the mixtures, measured by hot filtration, and deposits on the probe had compositions similar to asphaltenes. Fouling rates were correlated with instability indices, and with the concentrations of suspended asphaltenes.     

Improved Water Utilization with Plate Heat Exchangers

Cooling water costs can often be reduced by utilizing impure sources of water, such as the sea. The use of seawater generally involves a closed-cycle freshwater primary circuit, a type of cooling that, although saving on water, requires special design techniques in order to optimize the process. These techniques are discussed and examples are given of large and small installations currently in operation.     

A Risk-Based Performance Analysis of Plate-andFrame Heat Exchangers Subject to Fouling: Economics of Heat Exchanger Cleaning

Fouling is one of the major uncertainties associated with the operation and maintenance of plate-and-frame heat exchangers (PHEs) in the steel and process industries. The decision regarding periodic maintenance (i.e., cleaning) to meet the target performance level is generally based on both thermal and economic behavior of the process. In this paper, we present a cost model that includes the risk level and the scatter parameter of random fouling growth models. Two models (namely, power law and exponential fouling growth) are integrated in the model. The non-dimensional cost function of reduced time is examined by considering dimensionless cost parameters, representing additional cost due to a decrease in effectiveness, pumping power cost, anti-foulant cost, cleaning cost, additional pumping power cost of the standby unit during cleaning, and miscellaneous costs. These dimensionless cost elements are examined for a PHE operating in the steel industry. The results are presented in terms of the risk level and scatter parameter for the underlying fouling models. Furthermore, a simplified closed-form solution is also obtained to study the optimal cycle time, which represents the minimum cost of operation and maintenance of heat exchangers. It is found that the optimum dimensionless cost increased by about 21 and 14% for the power law and exponential fouling models, respectively, as the risk level decreased from 0.5 to 0.01     

Influence of the Apex Angle of Cone-Shaped Tubes on Particulate Fouling of Heat Exchangers

A two-dimensional (2D) cone shape has been added to the normal circular tubes of heat exchangers to minimize the area of stagnation and to streamline the air flow around the heat exchanger tubes. An experimental setup has been developed to study the influence of the apex angle of the cone-shaped tubes on particulate fouling of heat exchangers. Fouling experiments have been performed in which calcium carbonate particles are injected during the experiments and the deposition of particles on the tubes of the heat exchanger is monitored. Four sets of experiments have been performed, in which normal cylindrical tubes and coned tubes with an apex angle of 60°, 90°, and 120° are examined. It was found that particulate fouling ceased if the apex angle of the cone-shaped tubes is smaller than 90°. The attached cones enhance the flow around the tubes of the heat exchanger, by minimizing the stagnation area and keeping the flow attached to the tubes starting from the tip of the attached cone until separation, such that particles that deposit on the top of the tubes of the heat exchanger can be removed by the air flow.     

Performances Cost Effectiveness,and Water-Side Fouling Considerations of Enhanced Tube Heat Exchangers for Boiling Service with Tube-Side Water Flow

A case study method is employed to calculate the performance benefits and cost effectiveness of enhanced tubes for an application involving seawater on the tube side and ammonia boiling on the shell side. A porous boiling surface is used on the ammonia side, and eight basic geometries are evaluated for the water side. The analysis method selects the “optimum” enhancement dimensions for each geometry type. The optimum is de fined as the minimum material requirement for fixed heat duty and water-side pumping power. Heat exchanger size reductions of 55–67% are possible, depending on the tube-side enhancement type. The cost effectiveness of the enhanced tube designs are calculated relative to a plain tube exchanger for aluminum, copper, and titanium materials. Heat exchanger tubing cost reductions in the range of 10% are predicted for the titanium and copper tubes. Doubly enhanced aluminum tubes do not appear to provide heat exchanger cost reduction. A better application for enhanced tubes may involve increasing the UA value to provide a reduced LMTD. The reduced LMTD can be used to increase process thermodynamic efficiency, and thus offset the greater heat exchanger cost. The results of this study must be considered tentative until the water-side fouling characteristics of enhanced tubes are established.     

燃气热泵系统在过渡季节制备生活热水的性能研究

研究了燃气热泵(GHP)系统在过渡季节制备生活热水的性能特性,分析了发动机余热回收对GHP系统性能的影响。在不同环境温度(15～24℃)和进水温度(37.7～47.8℃)下,考察回收与不回收发动机余热模式对生活热水制热量■、耗气功率(P_gas)及一次能源利用率(r_PER)的影响规律。结果表明,随着环境温度的升高,P_gas减小,而■和r_{PE R}呈现递增的趋势;随着进水温度的升高,Pgas增大,而■和r_PER呈现递减的趋势。其中环境温度20～24℃与进水温度37.7～47.8℃为Q_h的不敏感区间,在环境温度为24℃和进水温度为37.7℃条件下,r_PER高达2.004。GHP系统的余热回收量分别占总制热量和发动机总余热的25.00%～30.16%和62.17%～71.56%,系统的余热利用率高。     

Detection of Fouling in a Cross-Flow Heat Exchanger Using Wavelets

Detection of fouling in a heat exchanger experiencing perfect steady-state conditions is not very difficult. But the challenge is to detect fouling when all inputs (inlet temperature of the fluids and the mass flow rates) are simultaneously varying. In this paper it has been considered that the mass flow rates can vary in a ratio of 2, and that the inlet temperatures can vary by about ±20%. This first approach is dedicated to show the feasibility of using the wavelet transform. It has been considered that getting simulated data is the best way. In fact, it is then possible to introduce an arbitrary fouling factor. Thus, in the first part of the paper the model of the heat exchanger is presented. It is developed using Simulink. The validation is carried out on an electrical heater, for which it is possible to find an analytical solution for transient states. It is also shown that steady states are accurately computed over a large range of the number of transfer units and heat capacity rate ratios. Then a brief overview of the wavelet transform is given. Then basic examples show that the wavelet transform can help to find the trend of time series. It is then applied to the analysis of the “wavelet-transformed” effectiveness of the heat exchanger. This analysis is carried out on a sliding observation window (to be able to detect fouling on-line). It is shown that fouling is detected at a very early stage.     

Characteristics Of Vertical Mantle Heat Exchangers For Solar Water Heaters

The flow structure in vertical mantle heat exchangers was investigated using a full-scale tank designed to facilitate flow visualisation. The flow structure and velocities in the mantle were measured using a particle Image Velocimetry (PIV) system. A CFD simulation model of vertical mantle heat exchangers was also developed for detailed evaluation of the heat flux distribution over the mantle surface. Both the experimental and simulation results indicate that distribution of the flow around the mantle gap is governed by buoyancy driven recirculation in the mantle. The operation of the mantle was evaluated for both high and low temperature input flows.     

广东地区太阳能-空气源热泵复合系统供暖供生活热水实验研究

构建了一种太阳能-空气源热泵复合供热系统,在广东地区冬季的晴天和全阴天进行供暖供生活热水实验测试。针对办公建筑供暖供生活热水需求,定时间段供生活热水同时进行供暖实验。实验结果表明:晴天热泵相较于全阴天工况节电1.16 kW·h,供热效果优于全阴天工况,太阳能-空气源热泵复合供热性能相较于单独的空气源热泵更有显著优势;太阳能-空气源热泵复合系统供暖供生活热水期间,复合系统COP_(sys)平均值为4.71、波动范围在4.20～5.38,空气源热泵系统COP_(hp)平均值为4.60、波动范围在4.08～5.10。     

On Minimization of the Number of Heat Exchangers in Water Networks

This article addresses the problem of minimizing the number of heat exchangers for heat recovery as well as the number of mixing and splitting junctions within water networks while maintaining the energy targets determined by the classical pinch analysis. A new systematic approach is proposed to eliminate the kink points and linearize the composite curves. This is based on a systematic strategy that indicates how to mix and split the water streams in order to modify the shape of the initial composite curves. A new graphical thermodynamic rule that avoids the deterioration of energy targets while minimizing the number of heat transfer units as well as the mixing and splitting network complexity has been formalized. This rule permits the control of the procedure of mixing and splitting on the T-H diagram in order to guarantee the pre-established targets. The proposed approach can be used for either the manual design of heat recovery within water networks or the building of a superstructure with a limited number of feasible design options.