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CHAPTER 4
4.1 INTRODUCTION
In Chapter 1 it was stated that the rate of build up of deposit on a surface could
be defined by the simple concept of the difference between the rates of deposition
and removal. In more precise mathematical terms
dm
= ~o - ~R (4.1)
dt
and #n and ~R are the deposit and removal mass flow rates per unit area of
surface respectively
The equation is a statement of the mass balance across the fluid/solid interface, i.e.
4
u, = V ~ (4.3)
If due to the fouling process d~ is reduced to d~/2 the new velocity u 2 for the same
mass flow rate is given by
V4x4
u2 - (4.4)
24 Fouling of Heat Exchangers
16V
(4.5)
~12
i.e. a fourfold increase in velocity.
d 1 16V P i . e . 8Vp
2 ad, 2 r/ ad, r/
4V .p_p_i.e4Vp
i.e. the Reynolds number has been doubled due to the presence of the deposit.
In addition the roughness of the deposit surface will be different from the clean
heat exchanger surface roughness (usually greater) which will result in a change in
the level of turbulence particularly near the surface. Greater roughness will
produce greater turbulence with its enhancement of heat transfer or a smoother
surface may reduce the level of turbulence. An alternative statement describing the
effects of fouling may be made on this basis [Bott and Walker 1971 ].
The purpose of any fouling model is to assist the designer or indeed the
operator of heat exchangers, to make an assessment of the impact of fouling on
heat exchanger performance given certain operating conditions. Ideally a
mathematical interpretation of Equation 4.6 would provide the basis for such an
assessment but the inclusion of an extensive set of conditions into one
mathematical model would be at best, difficult and even impossible.
Fig. 1.2 provided an idealised picture of the development of a deposit with time.
Other possibilities, still ideal, are possible and these are shown on Fig. 4.1. Curve
C represents the asymptotic curve of Fig. 1.2. Curve A represents a straight line
relationship of deposit thickness with time, i.e. the rate of development
GeneralModels of Fouling 25
Vl
tA
r
C
t./
o1,.i
41-.
.4.-
.m
t/t
0
r
s
Time t
Initiation
period
of the fouling layer is constant once the initiation of the process has taken place.
Curve B on the other hand, represents a falling rate of deposition once initiation
has occurred. It is possible that in effect, Curve B is essentially part of a similar
curve to C and if the process of deposition were allowed to progress sufficiently an
asymptote would be produced.
General models of the fouling process are essentially the fitting of equations to
the curves illustrated in Fig. 4.1. The curves A, B and C on Fig. 4.1 are shown to
have an initiation or induction period, but in some examples of fouling, e.g. the
deposition of wax from waxy hydrocarbons during a cooling process, the initiation
period may be so short as to be negligible. It is often extremely difficult or
impossible to predict the initiation period even with the benefit of experience, so
that most mathematical models that have been developed ignore it, i.e. fouling
begins as soon as fluid flows through the heat exchanger.
The inaccuracY in ignoring the initiation period is not likely to be great. For
severe fouling problems the initiation of fouling is usually rapid. Where the
establishment of the fouling takes longer it is usually accompanied by a modest rate
of fouling. Under these circumstances where long periods between heat exchanger
cleans are possible, the induction period represents a relatively small percentage of
the cycle. Errors in ignoring it are therefore small particularly in the light of the
other uncertainties associated with the fouling process. Typical initiation periods
may be in the range 50 - 400 hours.
26 Fouling of Heat Exchangers
The simplest model is that of Curve A in Fig. 4.1 but ignoring the induction
period and would have the form
dr
xI =-~-. t (4.7)
If the induction time (or initiation period) is t~ then the Equation 4.7 becomes
The difficulty of course in using this model is that without experimental work
dx/dt is unknown and the use of xI to determine the fouling resistance to heat
transfer is also a problem since the thermal conductivity of the foulant is not
usually known (see Chapter 2). In terms of fouling resistance Equation 4.8 would
take the form
_dR
R~ - - - ~ ( t - t~) (4.9)
x~ (4.10)
R1~= 2I
Even in this form the model is difficult to use unless dR/dt is known from
experimental determinations the conditions of which can also be applied to the
fouling problem in hand.
One of the simplest models to explain the fouling process was put forward by
Kern and Seaton [ 1959].
R~ =Rioo(1-e~ ) (4.11)
General Models of Fouling 27
where K~c'M is the rate of deposition term similar to a first order reaction
By assuming that c' and M are constant which is reasonable for a steady state
flow heat exchanger, and xI the thickness, is very much less than the tube diameter
for deposition in a tube, it is possible to integrate Equation 4.12.
28 Fouling of Heat Exchangers
K~c'M(1-e-X~") (4.13)
The equation is similar to equation 4.11 in form with K~c'M a constant for a
then(--
-]t__o=KlC'M (4.14)
c'M
The asymptotic thickness xroo= (4.15)
Kern and Seaton [1959] developed the theory further using the Blasius
relationship, to make allowance for the change in flow area caused by the
deposition process.
d
and Ap = 4 ~ (4.17)
dp2 g
(4.18)
Ap~ is the pressure drop at the asymptotic value of the foulant thickness
K~c' characterises the fouling qualities of the fluid and generally will remain
K~
constant. Should practical data be available for one set of conditions, the thickness
of the asymptotic value of the fouling thickness at a different set of conditions may
be obtained from the ratio"
xI~,_ ~| ~ _ o., ~ ,
~|
(4.19)
xe.~ - [ p M~ ] g - L~,J
L/~ J 4 1
dR~=K(RI~_R~). (4.20)
dt
where K is a constant
n is an exponent
forn~l
when n= 1
(4.22)
Both Equations 4.21 and 4.22 satisfy the boundary condition xI ~ 1 and t ~ oo
Equation 4.22 is a form of Equation 4.11 proposed by Kern and Seaton [ 1959]
For constant surface coefficient of heat transfer a, the heat flux is given by
AT
q=UoAT=~ (4.25)
Assuming that the overall temperature difference remains constant with time a
combination of Equation 4.24 and 4.25 yields
dRy = K (4.26)
at +R:)"
where K is a constant
t-t dR R/ K
Integrating f ~ - f (4.27)
/=o at ~. (Rc )"
1 1
TT n+l TT n+l
= Kt (4.29)
"D "C
Attempts have been made to develop the generalised models that were devised
several decades ago. For instance Taborek et al [ 1972] took the general equation
dm
= #n - #s (4.30)
dt
removal. Despite these refinements however, these models still lei~ a great deal to
be assumed about the particular fouling problem under consideration.
The use of general models for fouling analysis has many attractions but with the
present state of knowledge and the severe limitations on the generation of suitable
data, their application to specific problems is unlikely to be significant at least in
the immediate future. The fact that the references to general models are roughly in
the period 1960 - 1975, with little published since that time is not without
significance. The recent initial work of Anjorin and Feidt [ 1992] on the analysis of
fouling using entropy concepts however, shows promise. The next two chapters
illustrate the complexities that are "hidden" in the terms ~z~and ~ As the work on
fouling develops, in the longer term, generalised relationships may assume more
importance.
The present development of general theories to the problem of fouling,
however, has the very definite advantage that it has drawn attention to the
underlying phenomena and seeks to make a logical analysis of the problem. The
undoubted worth of this approach is to emphasise the factors which need to be
considered in any development of a theory and model of any particular system.
Specific models that have been developed for particular mechanisms will be
discussed in the appropriate chapters.
REFERENCES
Anjorin, M. and Feidt, M., 1992, Entropy analysis applied to fouling - a new
criteria, in: Bohnet, M., Bott, T.R., Karabelas, A.J., Pilavachi, P.A.,
S6m6ria, R. and Vidil, R., eds. Fouling Mechanisms Theoretical and
Practical Aspects. Editions Europ6ennes Thermique et Industrie, Paris, 69 -
77.
Bott, T.R. and Walker, R.A., 1971, Fouling in heat transfer equipment. Chem.
Engr. No. 251,391 - 395.
Bott, T.R. and Walker, R.A., 1973, An approach to the prediction of fouling in
heat exchanger tubes from existing data. Trans. Inst. Chem. Engrs. 51, No.
2, 165.
Kern, D.O. and Seaton, R.E., 1959, A theoretical analysis of thermal surface
fouling. Brit. Chem. Eng. 14, No. 5, 258.
Konak, A.R., 1973. Prediction of fouling curves in heat transfer equipment. Trans.
Inst. Chem. Engrs. 51,377.
Epstein, N., 1981, in: Somerscales, E.F.C. and Knudsen, J.G. eds. Fouling of Heat
Transfer Equipment. Hemisphere Publishing Corp. Washington.
Taborek, J., Aoki, T., Ritter, R.B., Palen, J.W. and Knudsen, J.G., 1972,
Predictive methods for fouling behaviour. Chem. Eng. Prog. 68, No. 7, 69 -
78.