Accounting for local features of fouling formation on PHE heat transfer surface
Petro Kapustenko1(), Jiří J. Klemeš2, Olga Arsenyeva1,3, Olexandr Matsegora4, Oleksandr Vasilenko4
1. National Technical University “Kharkiv Polytechnic Institute,” 61002 Kharkiv, Ukraine 2. Sustainable Process Integration Laboratory – SPIL, NETME Centre, Faculty of Mechanical Engineering, Brno University of Technology – VUT Brno, 616 69 Brno, Czech Republic 3. University of Paderborn, Chair of Fluid Process Engineering, Paderborn, Germany 4. AO Spivdruzhnist-T LLC, 61002 Kharkiv, Ukraine
The fouling phenomena can create significant operational problems in the industry by deteriorating heat recuperation, especially in heat exchangers with enhanced heat transfer. For a correct prediction of fouling development, the reliable fouling models must be used. The analysis of existing fouling models is presented. The chemical reaction and transport model developed earlier for a description of fouling on intensified heat transfer surfaces is used for modeling of plate heat exchanger (PHE) subjected to fouling. The mathematical model consists of a system of differential and algebraic equations. The integration of it is performed by finite difference method with developed software for personal computer. For countercurrent streams arrangement in PHE the solution of two-point boundary problem is realized on every time step. It enables to estimate local parameters of heat transfer process with fouling formation and its development in time with the growth of deposited fouling layer. Two examples of model application in cases of PHEs working at sugar factory and in district heating network are presented. The comparison with experimental data confirmed the model validity and the possibility of its application to determine the performance of PHE subjected to fouling.
. [J]. Frontiers of Chemical Science and Engineering, 2018, 12(4): 619-629.
Petro Kapustenko, Jiří J. Klemeš, Olga Arsenyeva, Olexandr Matsegora, Oleksandr Vasilenko. Accounting for local features of fouling formation on PHE heat transfer surface. Front. Chem. Sci. Eng., 2018, 12(4): 619-629.
Overall heat transfer coefficient: under clean conditions U0/(W·(м2·К)-1)
2219
2667
2685
2381
experimental with fouling Ufe/(W·(м2·К)-1)
1785
1886
1854
1641
calculated by model Ufm/(W·(м2·К)-1)
1768
1944
1871
1639
calculated by Eq. (23) Uf*/(W·(м2·К)-1)
1805
1938
1861
1638
Ratio Ufe/U0× 100%
80.41
70.72
69.01
68.81
Tab.1
Fig.3
Fig.4
Fig.5
1
J JKlemeš, P SVarbanov, PKapustenko. New developments in heat integration and intensification, including total site, waste-to-energy, supply chains and fundamental concepts. Applied Thermal Engineering, 2013, 61(1): 1–6 https://doi.org/10.1016/j.applthermaleng.2013.05.003
2
J JKlemeš, OArsenyeva, PKapustenko, LTovazhnyanskyy. Compact Heat Exchangers for Energy Transfer Intensification: Low Grade Heat and Fouling Mitigation.Florida: CRC Press, 2015, 41–210
3
M RMalayeri, H Müller-Steinhagen, A PWatkinson. 11th international conference on heat exchanger fouling and cleaning—2015, Enfield, Republic of Ireland. Heat Transfer Engineering, 2017, 38(7–8): 667–668 https://doi.org/10.1080/01457632.2016.1206390
WLi, R L Webb. Fouling characteristics of internal helical-rib roughness tubes using low-velocity cooling tower water. International Journal of Heat and Mass Transfer, 2002, 45(8): 1685–1691 https://doi.org/10.1016/S0017-9310(01)00263-0
6
D JKukulka, R Smith, JZaepfel. Development and evaluation of vipertex enhanced heat transfer tubes for use in fouling conditions. Theoretical Foundations of Chemical Engineering, 2012, 46(6): 627–633 https://doi.org/10.1134/S0040579512060152
7
B DCrittenden, MYang, L Dong, RHanson, JJones, KKundu, JHarris, OKlochok, OArsenyeva, PKapustenko. Crystallization fouling with enhanced heat transfer surfaces. Heat Transfer Engineering, 2015, 36(7–8): 741–749 https://doi.org/10.1080/01457632.2015.954960
8
LWang, B Sunden, R MManglik. PHEs. Design, applications and performance.Southhampton: WIT Press, 2007, 195–196
9
Standards of the Tubular Exchanger Manufacturers Association.9th ed. New York: TEMA Inc., 2007, 1028–1033
10
AAl-Janabi, M R Malayeri, H Müller-Steinhagen. Experimental fouling investigation with electroless Ni-P coatings. International Journal of Thermal Sciences, 2010, 49(6): 1063–1071 https://doi.org/10.1016/j.ijthermalsci.2009.05.009
11
M RMalayeri, H Muller-Steinhagen. Initiation of CASO4 scale formation on heat transfer surface under pool boiling conditions. Heat Transfer Engineering, 2007, 28(3): 240–247 https://doi.org/10.1080/01457630601066897
K APalmer, W T Hale, K D Such, B R Shea, G M Bollas. Optimal design of tests for heat exchanger fouling identification. Applied Thermal Engineering, 2016, 95: 382–393 https://doi.org/10.1016/j.applthermaleng.2015.11.043
15
F LWang, Y L He, Z X Tong, S Z Tang. Real-time fouling characteristics of a typical heat exchanger used in the waste heat recovery systems. International Journal of Heat and Mass Transfer, 2017, 104: 774–786 https://doi.org/10.1016/j.ijheatmasstransfer.2016.08.112
16
K HTeng, S N Kazi, A Amiri, A FHabali, M ABakar, B TChew, AAl-Shamma’a, AShaw, K H Solangi, G Khan. Calcium carbonate fouling on double-pipe heat exchanger with different heat exchanging surfaces. Powder Technology, 2017, 315: 216–226 https://doi.org/10.1016/j.powtec.2017.03.057
17
XBai, T Luo, KCheng, FChai. Experimental study on fouling in the heat exchangers of surface water heat pumps. Applied Thermal Engineering, 2014, 70(1): 892–895 https://doi.org/10.1016/j.applthermaleng.2014.06.009
18
B OHasan, E A Jwair, R A Craig. The effect of heat transfer enhancement on the crystallization fouling in a double pipe heat exchanger. Experimental Thermal and Fluid Science, 2017, 86: 272–280 https://doi.org/10.1016/j.expthermflusci.2017.04.015
19
O VDemirskiy, P OKapustenko, O PArsenyeva, O IMatsegora, Y APugach. Prediction of fouling tendency in PHE by data of on-site monitoring. Case study at sugar factory. Applied Thermal Engineering, 2018, 128: 1074–1081 https://doi.org/10.1016/j.applthermaleng.2017.09.087
20
D QKern, R E Seaton. A theoretical analysis of thermal surface fouling. British Chemical Engineering, 1959, 4(5): 258–262
21
R LWebb. Single-phase heat transfer, friction, and fouling characteristics of three-dimensional cone roughness in tube flow. International Journal of Heat and Mass Transfer, 2009, 52(11–12): 2624–2631 https://doi.org/10.1016/j.ijheatmasstransfer.2009.01.008
22
A LGogenko, O B Anipko, O P Arsenyeva, P O Kapustenko. Accounting for fouling in plate heat exchanger design. Chemical Engineering Transactions, 2007, 12: 207–212
23
XWen, Q Miao, JWang, ZJu. A multi-resolution wavelet neural network approach for fouling resistance forecasting of a plate heat exchanger. Applied Soft Computing, 2017, 57: 177–196 https://doi.org/10.1016/j.asoc.2017.03.043
24
NEpstein. A model of the initial chemical reaction fouling rate for flow within a heated tube, and its verification. Proceedings of 10th International Heat Trans Conference, Brighton (IChemE, Rugby, UK), 1994, 4: 225–229
B LYeap, D I Wilson, G T Polley, S J Pugh. Mitigation of crude oil refinery heat exchanger fouling through retrofits based on thermo-hydraulic fouling models. Chemical Engineering Research & Design, 2004, 82(1): 53–71 https://doi.org/10.1205/026387604772803070
27
NEpstein. Comments on “Relate crude oil fouling research to field fouling observations by Joshi et al.”. In: Proceedings of International Conference on Heat Exchanger Fouling and Cleaning-2011, 62–64
28
D IWilson, A P Watkinson. A study of autoxidation reaction fouling in heat exchangers. Canadian Journal of Chemical Engineering, 1996, 74(2): 236–246 https://doi.org/10.1002/cjce.5450740209
O PArsenyeva, BCrittenden, MYang, P O Kapustenko. Accounting for the thermal resistance of cooling water fouling in plate heat exchangers. Applied Thermal Engineering, 2013, 61(1): 53–59 https://doi.org/10.1016/j.applthermaleng.2013.02.045
31
ZQuan, Y Chen, CMa. Experimental study of fouling on heat transfer surface during forced convective heat transfer. Chinese Journal of Chemical Engineering, 2008, 16(4): 535–540 https://doi.org/10.1016/S1004-9541(08)60117-2
32
P OKapustenko, O PArsenyeva, O IMatsegora, S KKusakov, V ITovazhnianskyi. The mathematical modelling of fouling formation along PHE heat transfer surface. Chemical Engineering Transactions, 2017, 61: 247–252
33
O PArsenyeva, L LTovazhnyansky, P OKapustenko, G LKhavin. Optimal design of plate-and-frame heat exchangers for efficient heat recovery in process industries. Energy, 2011, 36(8): 4588–4598 https://doi.org/10.1016/j.energy.2011.03.022
34
O PArsenyeva, L LTovazhnyanskyy, P OKapustenko, O VDemirskiy. Heat transfer and friction factor in criss-cross flow channels of plate-and-frame heat exchangers. Theoretical Foundations of Chemical Engineering, 2012, 46(6): 634–641 https://doi.org/10.1134/S0040579512060024
35
I AStogiannis, S VParas, O PArsenyeva, P OKapustenko. CFD modelling of hydrodynamics and heat transfer in channels of a PHE. Chemical Engineering Transactions, 2013, 35: 1285–1290
36
O VDemirskiy, P OKapustenko, G LKhavin, O PArsenyeva, O IMatsegora, S KKusakov, IBocharnikov. Investigation of fouling in plate heat exchangers at sugar factory. Chemical Engineering Transactions, 2016, 52: 583–588
37
D VChernyshov. Prognosis of scaling in plate water heaters to increase reliability of their work. Dissertation for the Technical Sciences Degree. Tula: Tula State University, Russian Federation, 2002, 133–167 (in Russian)
