{"id":83958,"date":"2023-04-18T00:00:00","date_gmt":"2023-04-18T00:00:00","guid":{"rendered":"https:\/\/www.corrosionpedia.com\/2023\/04\/18\/fouling-in-heat-exchangers-detection-prevention-and-removal"},"modified":"2023-04-13T15:31:44","modified_gmt":"2023-12-09T19:09:49","slug":"fouling-in-heat-exchangers-detection-prevention-and-removal","status":"publish","type":"post","link":"https:\/\/www.corrosionpedia.com\/fouling-in-heat-exchangers-detection-prevention-and-removal\/2\/7434","title":{"rendered":"Fouling in Heat Exchangers: Detection, Prevention and Removal"},"content":{"rendered":"
Heat exchangers<\/a>, which are used to transfer heat from one fluid to another, are critical equipment in various industrial processes.<\/p>\n Over time, the buildup of unwanted materials on heat exchanger surfaces, also known as fouling<\/a>, can lead to decreased heat transfer efficiency, increased energy consumption, increased pressure drop<\/a>, equipment failure and reduced production capacity.<\/p>\n This article explores the phenomenon of heat exchanger fouling in detail, from detection to prevention and removal.<\/p>\n Fouling in heat exchangers can develop due to several primary factors, including:<\/span><\/p>\n In general, the fouling found in heat exchangers can be categorized into several main types based on the main phenomena occurring.<\/span><\/p>\n Major types of fouling in heat exchangers include:<\/span><\/span><\/p>\n The fouling factor measures the extent to which fouling in a heat exchanger influences the process fluid's resistance to heat transfer. In other words, it represents how much additional thermal resistance the fouling layer adds to the heat transfer surfaces. The fouling factor is expressed in units of (m².K)\/W.<\/span><\/p>\n The fouling factor can be calculated by dividing the thermal resistance due to fouling by the heat exchanger's overall heat transfer coefficient (U). The reciprocal of the overall heat transfer coefficient is the sum of the individual resistances to heat transfer, including the resistances of the fouling layer (R<\/em>f<\/em><\/sub>), the resistance of the heat transfer surfaces (R<\/em>w<\/em><\/sub>) and the resistance of the fluid film (R<\/em>h<\/em><\/sub>, R<\/em>c<\/em><\/sub>). <\/span><\/p>\n This can be expressed mathematically as:<\/p>\n 1\/U = <\/em><\/strong>R<\/em>h <\/em><\/sub><\/strong><\/em>+ <\/strong>R<\/em>f,h<\/em><\/sub><\/strong><\/em> + <\/strong>R<\/em>w <\/em><\/sub><\/strong><\/em>+ <\/strong>R<\/em>f,c <\/em><\/sub><\/strong><\/em>+ <\/strong>R<\/em><\/strong><\/em>c<\/em><\/strong><\/em><\/sub><\/span><\/em><\/span><\/em><\/span><\/em><\/span><\/em><\/span><\/p>\n When designing heat exchangers, the fouling factor can be used to calculate the appropriate fouling allowance — the maximum amount of fouling a heat exchanger can shoulder without compromising the machine's efficiency —<\/span><\/span><\/span><\/span> and<\/span><\/span> to determine the optimal cleaning frequency and maintenance schedule. <\/span>(For more on controlling corrosion through design, read: <\/strong><\/span><\/span><\/span><\/span>How to Control Corrosion by Improving Design<\/strong><\/a>.)<\/strong><\/span><\/span><\/span> Some of the most common methods to detect fouling in heat exchangers are:<\/span><\/span><\/strong><\/p>\n Besides fouling detection, cleaning and routine maintenance activities are crucial to maintain heat exchangers' performance.<\/span><\/p>\n The following methods will help remove fouling and are beneficial to keep heat exchangers clean:<\/span><\/span><\/p>\n Fouling in heat exchangers is a very typical, common and generally inevitable challenge.<\/p>\n However, understanding the causes and types of fouling allows one to select the appropriate preventive, control and cleaning strategies to maintain the heat exchanger's efficiency and performance.<\/p>\n","protected":false},"excerpt":{"rendered":" Heat exchangers, which are used to transfer heat from one fluid to another, are critical equipment in various industrial processes. Over time, the buildup of unwanted materials on heat exchanger surfaces, also known as fouling, can lead to decreased heat transfer efficiency, increased energy consumption, increased pressure drop, equipment failure and reduced production capacity. This […]<\/p>\n","protected":false},"author":11852,"featured_media":83959,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"topic":[],"acf":[],"yoast_head":"\nCauses of Fouling in Heat Exchangers<\/span><\/h2>\n
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<\/span>Types of Heat Exchanger Foulin<\/span><\/span>g<\/span><\/h2>\n
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The Fouling Factor<\/span><\/h2>\n
<\/span><\/p>\nHow to Detect Fouling in Heat Exchangers<\/h2>\n
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How to Remove Fouling in Heat Exchangers<\/h2>\n
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Conclusion<\/h2>\n