Heat exchanger fouling is a commonly occurring problem in different kinds of heat exchangers. Through monitoring and reconciling plant data, smartpm provides accurate performance predictions through detailed heat exchanger modeling. Heat exchanger fouling is caused by a variety of reasons such as corrosion, precipitation, accumulation of dirt or particles, accumulation of biological material etc. Apr 18, 2016 shell and tube heat exchanger fouling factors engineers are often faced with interoffice scheduling traditions. However, calculating the remaining useful life rul of the hx. Xchanger suite is software for the rating, simulation, andor design of a wide variety of heat transfer equipment. Make an initial estimate of the overall heat transfer coefficient, u, based on the fluids involved.
An step further is the analysis of alternative cleaning schedules and their influence in the total annual cost applying techniques existing in the literature odonnell et al 2001. Below are some of the tools and information we use on a routine basis. Fouling in oil and refinery plants consumes an extra 0. Unlike other tools, ensures that the calculations are performed step by step to help in understanding the design calculations. Please note that the software can only do the basic design calculations the mechanical design. R d fouling factor or unit thermal resistance of deposit m 2 kw u d overall heat transfer coefficient of heat exchanger after fouling wm 2 k u overall heat transfer coefficient of clean heat exchanger wm 2. Depending on the kind of fouling, different kinds of solid material will accumulate on the walls of the heat exchanger fouling factor or dirt factor definition. The foulant layer imposes an additional resistance to heat transfer and the narrowing of the flow area, due to the presence of deposit, results in an increased velocity for a given volumetric flow rate. Aimed at the dairy industry, it is effective with both type a protein and type b mineral deposits found at temperatures both below and above.
Reduce protein and mineral fouling and increase heat transfer coefficient by 1020%. Calculate the required heat transfer rate, q, in btuhr from specified information about fluid flow rates and temperatures. For shell and tube heat exchanger, the common method is to use fouling factors. Plate heat exchanger calculation method alfa laval. To solve a thermal problem, we need to know several parameters. In fact, fouling has been recognised for a in fact, fouling has been recognised for a long time, and research on heat exchanger fo uling was. Online calculators to perform iterative thermal rating calculations for shell and tube heat exchangers. Examples of components that may be subject to fouling and the corresponding effects of fouling. The heat load of a heat exchanger can be derived from the following two formulas. For other types of heat exchangers, excess heat transfer area is often used.
In practice, all the thermal duty of the hot fluid fc is transferred to the cold fluid ff, thereby fulfilling the next energy balance. For a new heat exchanger the fouling factor is zero and it increases with time with increased fouling. Gasketed plate heat exchanger design software thermal. Proven dramatic results show it can help companies save thousands of hours of cleaning and millions of dollars in costs every year. Fouling in a variety of heat transfer applications, for example in. Provides typical fouling factor values for different process fluids and various cooling waters. Gasketed plate heat exchanger design free download and. Antifouling he new technology can reduce heat exchanger. Resistance which is the reciprocal of u for a clean heat exchanger.
We provide useful software and tools for some of our products. There exists many different tools used to design, size and rate heat exchangers. Ssp is our unique software developed for advanced heat exchange calculations. Fex17 the history and status of research in fouling of heat exchangers in cooling water service 1976 fex18 plate heat exchanger fouling study 1976 fex19 seawater studies of fouling on copper and its alloys 1978.
Heat exchanger surfaces reduces thermal efficiency, decreases heat flux, increases temperature on the hot side, decreases temperature on the cold side, induces underdeposit corrosion, increases use of cooling water. Dynamic fouling models are used to assess the impact. Heat exchanger fouling calculation process heat transfer. Fouling is the accumulation of unwanted material on solid surfaces. F12 improved use of fouling allowances in heat exchanger design 2002 q61 fouling of middle distillate blends 2002 f analysis of htri crude oil fouling data 2003. Keywords fouling resistance, mass flow rate, heat transfer, pressure drop, shell and tube heat exchanger.
The second type is regenerative type, in which hot and cold fluids are in the same space which contain a matrix of materials which work alternately as source for heat flow. The amount of heat to be transferred heat load the inlet and outlet temperatures on the primary and secondary sides. This tool also calculates the utility requirements for achieving the desired heat transfer. I am developing heat exchanger monitoring spreadsheet. The development of fouling depends on a number of things, 5 and 16. Chapter 5 heat exchangers faculty of engineering and. If the flow rate, specific heat and temperature difference on one side are known, the heat load can be calculated. Checalc chemical engineering calculations to assist process, plant operation and maintenance engineers. Smartpm performance monitoring, analysis, and prediction software for shellandtube heat exchanger networks supports a greater understanding of oil refinery operational performance. Fouling phenomenon and its effect on heat exchanger. Fouling and cleaning analysis of a heat exchanger network. Heat transfer and thermal design tools and software. As fouling develops the overall heat transfer coefficient will vary from point to point within the exchanger.
The required heat transfer area, the number of tubes and the shell size are. While we were working with a local engineer on a heat exchanger application, she asked why the office always specified a. The calculations are performed through a series of click buttons arranged in order. Heat exchanger fouling calculation posted in process heat transfer. Phex is an easy to use tool which demonstrates the thermal calculations of gasketed plate heat exchangers, the plate dimensions and materials can be entered. Increasing heat exchanger performance bryan research. Heat exchanger fouling and cleaning vii, july 1 6, 2007, tomar, portugal. Engineering page heat exchangers, thermal calculators and. Shell and tube heat exchanger design free download and. The software handles for example singlephase, condenser, evaporator, cascade calculations and twostage applications.
Htri offers a wide range of software solutions for heat transfer equipment used by operating companies, engineering contractors, exchanger fabricators, and related industries. This software allows to calculate fouling resistance in shell and tubes heat exchangers from historic plant data. Heat exchanger fouling factor quantifies the effect of fouling. Screwed plate heat exchanger universal hydraulik gmbh. All tools are available for free, but for a few of them there is a short registration process necessary. Pdf fouling phenomenon and its effect on heat exchanger. Fouling tendencies depends on the type of heat exchanger and the. The two most common heat exchanger design problems are those of rating and sizing. Over 90% of all heat exchangers suffer from fouling. Below are all the update history for shell and tube heat exchanger design software. Shell and tube heat exchanger step by step calculations to. I already calculated current u value with current operating conditions and i have design u value of exchangers from the spec. The maximum allowable pressure drop on the primary and secondary sides. The comprehensive software framework integrates solutions for monitoring, design and predictive maintenance of heat exchangers and their networks in a unified platform.
Will save you an incredible amount of calculation work. Determines the preliminary size for a shell and tube heat exchanger based on the process information provided. Then lets look at some commonly used heat exchanger design software tools which can help you. So then, how can i calculate fouling to see if the heat exchanger is going to be plugged or not. Heat exchanger fouling and estimation of remaining useful life. Heat exchanger network design and retrofit that take into account fouling. Sep 26, 2017 definition of the process for the calculation of heat exchangers. Costs due to overdesign, additional fuel consumption and maintenance, loss of production, etc. Hysystasc simulators in order to calculate each exchanger fouling and hen overall. Double pipe heat exchanger calculation does the thermal and hydraulic design of double pipe heat exchangers and estimate number of hairpin required. Modeling and prediction of shellside fouling in shell.
Pdhonline course m371 2 pdh shell and tube heat exchangers. Figure 2 shows the fouling resistances for cooling water inside a plate heat exchanger in comparison with fouling resistances on the tubeside inside a shell and tube heat exchanger for the same velocity. However, fouling is a selffulfilling prophecy and the selection of fouling factors or excess area must be done carefully. The calculators are quite sophisticated and, although they have been made user friendly, require sufficient knowledge of heat exchangers. Despite the fact that the screwed plate heat exchanger produce highpressure loss, they are still found in many applications. So, the calculation of the heat transfer that occurs under fouled conditions would require that the basic heat transfer equation be applied at number of points within the. Physical and transport properties of fluids p1 capacity and thermal conductivity of oils 1964 p2 physical properties of liquids status of present knowledge and importance in design methods for heat transfer and fluid flow 1971 fouling f1 the effect of. Screwed plate heat exchanger tl screwed plate heat exchanger.
The software performs advanced data reconciliation, including simulation of detailed exchanger operational data using htri shellandtube heat exchanger calculation methods and inferring fouling resistance for individual shells for shellsinseries based on dynamic fouling behavior. Predictive analytics and prescriptive maintenance of industrial heat transfer systems for energy. Hysystasc simulators in order to calculate each exchanger fouling and hen overall performance under the actual fouling situation. It results in changing the heat transfer surface and reducing the overall heat transfer rate through that surface. These tools can be used for additional information or for product configuration and selection. Calculation of fouling factors based on measured extreme temperatures also is possible by using the heat exchanger network calculator approach. The required heat transfer area, the number of tubes and the shell size are calculated. Fouling and reduced heat transfer in heat exchangers. Fouling of heat exchangers in processing industries is a chronic operating problem. Their core product xchanger suite is a very popular package for heat exchanger design. P heat load btuh m mass flow rate lbh c p specific heat btulb f.
It enables engineers to make informed decisions regarding maintenance or. The first type of a heat exchanger is called the recuperative type, in which heat are exchanged on either side of a dividing wall by fluids. The rates of heat transfer q for the same data are calculated using excel programme. Gasketed plate heat exchanger design phex is a software tool that is made to demonstrate the thermal analysis and calculations of gasketed plate heat exchangers. In fact, fouling has been recognised for a long time, and research on heat exchanger fouling was conducted as early as 1910 and the first practical application of this research was implemented in the 1920s. The fouling of heat exchangers may be defined as the accumulation of unwanted deposits on heat transfer surfaces. Provide the input data, and ssp immediately presents the product concept that meets your needs best. Anti fouling heat exchanger solutions with the university of melbourne have developed a novel anti fouling coating. Nov 22, 2017 plate heat exchanger, how it works working principle hvac industrial engineering phx heat transfer duration.
Heat exchanger fouling and estimation of remaining useful life tutpol ardsomang1, j. R d fouling factor or unit thermal resistance of deposit m 2 kw u d overall heat transfer coefficient of heat exchanger after fouling wm 2 k u overall heat transfer coefficient of clean heat exchanger wm 2 k 1 can also be expressed as. Thermal design and optimization of shell and tube heat exchanger. Shell and tube heat exchanger the traditional heat balance model is utilized based on the assumption that the amount of heat given up by the hot fluid is equal to the amount of heat received by the cold fluid, as shown in the equation 3. Thermal rating for a shell and tube heat exchanger. Shell and tube heat exchanger design software for thermal. Htris recently acquired smartpm software complements the htri fouling research program, and. During fouling, the surface of a heat exchanger wall develops another layer of solid material.
333 1616 280 1146 754 1348 360 424 520 1680 1300 121 1388 749 63 1068 903 1340 892 1292 1663 1172 69 186 486 1663 526 1543 1385 1381 1258 1584 188 1172 1118 1029 251 704 335 442 764 686 839 695 459 312 983 1029 14 573