Skip to main content
SpringerLink
Log in

Accounting for local features of fouling formation on PHE heat transfer surface

  • Research Article
  • Published:
Frontiers of Chemical Science and Engineering Aims and scope Submit manuscript

Abstract

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Klemeš J J, Varbanov P S, Kapustenko P. 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

    Article  Google Scholar 

  2. Klemeš J J, Arsenyeva O, Kapustenko P, Tovazhnyanskyy L. Compact Heat Exchangers for Energy Transfer Intensification: Low Grade Heat and Fouling Mitigation. Florida: CRC Press, 2015, 41–210

    Book  Google Scholar 

  3. Malayeri M R, Müller-Steinhagen H, Watkinson A P. 11th international conference on heat exchanger fouling and cleaning—2015, Enfield, Republic of Ireland. Heat Transfer Engineering, 2017, 38(7–8): 667–668

    Article  CAS  Google Scholar 

  4. Panchal C B, Knudsen J G. Mitigation of water fouling: Technology status and challenges. Advances in Heat Transfer, 1998, 31: 431–474

    Article  CAS  Google Scholar 

  5. Li W, Webb R L. 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

    Article  CAS  Google Scholar 

  6. Kukulka D J, Smith R, Zaepfel J. Development and evaluation of vipertex enhanced heat transfer tubes for use in fouling conditions. Theoretical Foundations of Chemical Engineering, 2012, 46(6): 627–633

    Article  CAS  Google Scholar 

  7. Crittenden B D, Yang M, Dong L, Hanson R, Jones J, Kundu K, Harris J, Klochok O, Arsenyeva O, Kapustenko P. Crystallization fouling with enhanced heat transfer surfaces. Heat Transfer Engineering, 2015, 36(7–8): 741–749

    Article  CAS  Google Scholar 

  8. Wang L, Sunden B, Manglik R M. PHEs. Design, Applications and Performance. Southhampton: WIT Press, 2007, 195–196

    Google Scholar 

  9. Standards of the Tubular Exchanger Manufacturers Association. 9th ed. New York: TEMA Inc., 2007, 1028–1033

  10. Al-Janabi A, Malayeri M R, Müller-Steinhagen H. Experimental fouling investigation with electroless Ni-P coatings. International Journal of Thermal Sciences, 2010, 49(6): 1063–1071

    Article  CAS  Google Scholar 

  11. Malayeri M R, Muller-Steinhagen H. Initiation of CASO4 scale formation on heat transfer surface under pool boiling conditions. Heat Transfer Engineering, 2007, 28(3): 240–247

    Article  CAS  Google Scholar 

  12. Yang M, Young A, Niyetkaliyev A, Crittenden B. Modelling fouling induction periods. International Journal of Thermal Sciences, 2012, 51: 175–183

    Article  Google Scholar 

  13. Müller-Steinhagen H M. Cooling water fouling in heat exchangers. Advances in Heat Transfer, 1999, 33: 415–495

    Article  Google Scholar 

  14. Palmer K A, Hale W T, Such K D, Shea B R, Bollas G M. Optimal design of tests for heat exchanger fouling identification. Applied Thermal Engineering, 2016, 95: 382–393

    Article  Google Scholar 

  15. Wang F L, He Y L, Tong Z X, Tang S Z. 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

    Article  CAS  Google Scholar 

  16. Teng K H, Kazi S N, Amiri A, Habali A F, Bakar M A, Chew B T, Al-Shamma’a A, Shaw A, Solangi K H, Khan G. Calcium carbonate fouling on double-pipe heat exchanger with different heat exchanging surfaces. Powder Technology, 2017, 315: 216–226

    Article  CAS  Google Scholar 

  17. Bai X, Luo T, Cheng K, Chai F. Experimental study on fouling in the heat exchangers of surface water heat pumps. Applied Thermal Engineering, 2014, 70(1): 892–895

    Article  Google Scholar 

  18. Hasan B O, Jwair E A, Craig R A. 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

    Article  CAS  Google Scholar 

  19. Demirskiy O V, Kapustenko P O, Arsenyeva O P, Matsegora O I, Pugach Y A. Prediction of fouling tendency in PHE by data of onsite monitoring. Case study at sugar factory. Applied Thermal Engineering, 2018, 128: 1074–1081

    Article  Google Scholar 

  20. Kern D Q, Seaton R E. A theoretical analysis of thermal surface fouling. British Chemical Engineering, 1959, 4(5): 258–262

    Google Scholar 

  21. Webb R L. 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

    Article  CAS  Google Scholar 

  22. Gogenko A L, Anipko O B, Arsenyeva O P, Kapustenko P O. Accounting for fouling in plate heat exchanger design. Chemical Engineering Transactions, 2007, 12: 207–212

    Google Scholar 

  23. Wen X, Miao Q, Wang J, Ju Z. A multi-resolution wavelet neural network approach for fouling resistance forecasting of a plate heat exchanger. Applied Soft Computing, 2017, 57: 177–196

    Article  Google Scholar 

  24. Epstein N. 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

    Article  CAS  Google Scholar 

  25. Epstein N. Thinking about heat transfer fouling: A 5 × 5 matrix. Heat Transfer Engineering, 1983, 4(1): 43–56

    Article  CAS  Google Scholar 

  26. Yeap B L, Wilson D I, Polley G T, Pugh S J. Mitigation of crude oil refinery heat exchanger fouling through retrofits based on thermohydraulic fouling models. Chemical Engineering Research & Design, 2004, 82(1): 53–71

    Article  CAS  Google Scholar 

  27. Epstein N. 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

    Google Scholar 

  28. Wilson D I, Watkinson A P. A study of autoxidation reaction fouling in heat exchangers. Canadian Journal of Chemical Engineering, 1996, 74(2): 236–246

    Article  CAS  Google Scholar 

  29. Yang M, Crittenden B. Fouling thresholds in bare tubes and tubes fitted with inserts. Applied Energy, 2012, 89(1): 67–73

    Article  Google Scholar 

  30. Arsenyeva O P, Crittenden B, Yang M, Kapustenko P O. Accounting for the thermal resistance of cooling water fouling in plate heat exchangers. Applied Thermal Engineering, 2013, 61(1): 53–59

    Article  Google Scholar 

  31. Quan Z, Chen Y, Ma C. Experimental study of fouling on heat transfer surface during forced convective heat transfer. Chinese Journal of Chemical Engineering, 2008, 16(4): 535–540

    Article  CAS  Google Scholar 

  32. Kapustenko P O, Arsenyeva O P, Matsegora O I, Kusakov S K, Tovazhnianskyi V I. The mathematical modelling of fouling formation along PHE heat transfer surface. Chemical Engineering Transactions, 2017, 61: 247–252

    Google Scholar 

  33. Arsenyeva O P, Tovazhnyansky L L, Kapustenko P O, Khavin G L. Optimal design of plate-and-frame heat exchangers for efficient heat recovery in process industries. Energy, 2011, 36(8): 4588–4598

    Article  Google Scholar 

  34. Arsenyeva O P, Tovazhnyanskyy L L, Kapustenko P O, Demirskiy O V. 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

    Article  CAS  Google Scholar 

  35. Stogiannis I A, Paras S V, Arsenyeva O P, Kapustenko P O. CFD modelling of hydrodynamics and heat transfer in channels of a PHE. Chemical Engineering Transactions, 2013, 35: 1285–1290

    Google Scholar 

  36. Demirskiy O V, Kapustenko P O, Khavin G L, Arsenyeva O P, Matsegora O I, Kusakov S K, Bocharnikov I. Investigation of fouling in plate heat exchangers at sugar factory. Chemical Engineering Transactions, 2016, 52: 583–588

    Google Scholar 

  37. Chernyshov D V. 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)

    Google Scholar 

Download references

Acknowledgements

This research has been supported by the EU project “Sustainable Process Integration Laboratory–SPIL,” project No. CZ.02.1.01/0.0/0.0/15_003/0000456 funded by EU “CZ Operational Programme Research, Development and Education,” Priority 1: Strengthening capacity for quality research in a collaboration agreement with National Technical University “Kharkiv Polytechnic Institute” and AO Spivdruzhnist-T LLC. Olga Arsenyeva is grateful to the Alexander von Humboldt Foundation for the financial support.

Author information

Authors and Affiliations

  1. National Technical University “Kharkiv Polytechnic Institute,”, 61002, Kharkiv, Ukraine

    Petro Kapustenko & Olga Arsenyeva

  2. Sustainable Process Integration Laboratory – SPIL, NETME Centre, Faculty of Mechanical Engineering, Brno University of Technology – VUT Brno, 616 69, Brno, Czech Republic

    Jiří Klemeš

  3. University of Paderborn, Chair of Fluid Process Engineering, Paderborn, Germany

    Olga Arsenyeva

  4. AO Spivdruzhnist-T LLC, 61002, Kharkiv, Ukraine

    Olexandr Matsegora & Oleksandr Vasilenko

Authors
  1. Petro Kapustenko
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jiří Klemeš
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Olga Arsenyeva
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Olexandr Matsegora
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Oleksandr Vasilenko
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Petro Kapustenko.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kapustenko, P., Klemeš, J., Arsenyeva, O. et al. Accounting for local features of fouling formation on PHE heat transfer surface. Front. Chem. Sci. Eng. 12, 619–629 (2018). https://doi.org/10.1007/s11705-018-1736-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11705-018-1736-5

Keywords

Search

Navigation