Composite Fouling on Heat Exchange Surface in Australian Sugar Mill Evaporator

Composite scale of amorphous silica and calcium oxalate is very intractable; it imposes a significant fraction of scale management cost in sugar mill evaporators. This work evaluates silica and calcium oxalate composite fouling using dynamic fouling-loop experiments under different operating conditions with and without sugar. A novel closed-loop setup simulating in a single run the effect of feed concentration in successive stages of evaporation cycle was used. Experiments under constant composition and varying thermal hydraulic effect were conducted. Results indicated synergistic effects for initial silica and calcium oxalate supersaturation values of 2.6 and 1.7. Sugar effects became significant for concentrations in the third effect and above. The fouling mechanism was particulate deposition of silica and calcium oxalate colloidal species strengthened by consolidation; fouling rate increased with decreasing interfacial energy barrier between the surface and foulant, assessed by zeta-potential analysis. Deposit characteristics and deposition rates were concentration and thermal hydraulics dependent. Results confirmed the need that the 5 × 5 (types × stages of fouling) matrix of Epstein needs to be expanded to a 6 × 6 matrix to include composite fouling as a type of fouling. In this study the composite fouling was a surface-controlled process for which the activation energy was similar to typical chemical bond strengths, explaining the role of consolidation in composite fouling. The results contribute to advancement of fundamental understanding of heat exchanger fouling and to development of scale control strategies for composite fouling minimization in sugar mill evaporators.