ISSN 2249-6343 International Journal of Computer Technology and Electronics Engineering (IJCTEE) Volume 2, Issue 3, June 2012

Optimization In Thermal Design Of Surface Condenser By Changing Fouling Factor

Vijay K. Mehta,
Abstract: One of the most common operational challenges encountered with heat exchangers is fouling. Fouling is the build-up of sediments and debris on the surface area of a heat exchanger that inhibits heat transfer. Fouling will reduce heat transfer, impede fluid flow, and increase the pressure drop across the heat exchanger. As with many operational concerns, proper planning at the design stage can minimize the effects of fouling down the road. Designers use fouling factors to maximize the lifespan, runtime and efficiency of a heat exchanger by accounting for the amount of fouling an exchange will sustain over a period of time. This often results in increasing the surface area of a heat exchanger, so that fouling will not have as much of an effect.. This means that the heat exchanger must be able to function efficiently for long periods of time. Compensating for fouling by enlarging surface area allows heat exchangers to function with years of fouling. Owing to the wide utilization of heat exchangers in industrial processes, their cost minimization is an important target for both designers and users.[1]

Fouling depends on the type of heat exchanger, and the kind of fluids being transferred. Due to different designs, composition, and transfer fluid, each type of heat exchanger will suffer fouling in unique ways. The tube side of a shell and tube heat exchanger is usually easy to clean but the shell side can be more difficult to access. Plate heat exchangers can be taken apart for cleaning on both sides. Some heat exchangers can be cleaned every night when the equipment is not in use, while others can only be cleaned every few months or years. In order to reduce the amount of fouling in a heat exchanger, equipment should be cleaned as often as possible. If a plate heat exchanger were to suffer from the effects of fouling, extra plates can be added to re-gain performance if the space permits in the frame. 2. T YPES OF FOULING There are several types of fouling, each forming depending on the type of fluid and conditions. The following are some of the more common fouling mechanisms; 2.1 Crystallization Crystallization is one of the most common types of fouling. Certain salts commonly present in natural waters have a lower solubility in warm water than cold. Therefore, when cooling water is heated during the cooling process (particularly at the tube wall) these dissolved salts will crystallize on the surface in the form of scale. [Common Solution: reducing the temperature of the heat transfer surface often softens the deposits] 2.2 Sedimentation Sedimentation, the depositing of dirt, sand, rust, and other small matter is also common when fresh water is used. This can be controlled to a degree by the heat exchanger design. [Common Solution: velocity control] 2.3 Biological Biological Organic growth material occurs from chemical reactions, and can cause considerable damage when built up. [Common Solution: material selection]

Keywords: Tube Materials, Fouling factor, Heat transfer

rate, Aspen plus condenser design software, Effect of fouling factor & Heat transfer rate on surface Area.

1. INTRODUCTION : Condenser is a type of heat exchanger in which hot fluid becomes cold fluid. surface condenser is a commonly used term for a water-cooled shell and tube heat exchanger installed on the exhaust steam from a steam turbine in thermal power stations. These condensers are heat exchangers which convert steam from its gaseous to its liquid state at a pressure below atmospheric pressure where cooling water is in short Supply; an air-cooled condenser is often used. An air-cooled condenser is however significantly more expensive and cannot achieve as low a steam turbine exhaust pressure as a water-cooled surface condenser. One of the most common operational challenges encountered with heat exchangers is fouling. Fouling is the build-up of sediments and debris on the surface area of a heat exchanger that inhibits heat transfer. Fouling will reduce heat transfer, impede fluid flow, and increase the pressure drop across the heat exchanger [2]

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ISSN 2249-6343 International Journal of Computer Technology and Electronics Engineering (IJCTEE) Volume 2, Issue 3, June 2012
2.4 Chemical Reaction Chemical Reaction Coking appears where hydrocarbon deposits in a high temperature application. [Common Solution: reducing the temperature between the fluid and the heat transfer surface] 2.5 Corrosion Corrosion can destroy surface areas of the heat exchangers, creating costly damage. Fouling will slow down heat transfer and damage equipment unless it is dealt with accordingly. [Common Solution: material selection] 2.6 Freezing Fouling Freezing Fouling results from overcooling at the heat transfer surface causing solidification of some of the fluid stream components. [Common Solution: reducing the temperature gradient between the fluid and the heat transfer surface.[3] 3. FOULING F ACTOR The most common way to account for the effects of fouling in a tubular heat exchanger is the application of a fouling factor. The fouling factor is a predetermined number that represents the amount of fouling a particular heat exchanger transferring a particular fluid will sustain. In the heat transfer equation the fouling factor is added to the other thermal resistances to calculate the Total Thermal Resistance which is the reciprocal of U clean (Overall Heat transfer coefficient). There is no direct calculation to determine the appropriate fouling factor to use for a given fluid in a particular application; however guidelines do exist to help determine an appropriate fouling factor. The most common compilation of fouling factors, to be used for a variety of fluid in various applications, is supplied by Tubular Exchanger Manufacturers Association (TEMA). The below table is a list of general fouling factors used for shell and tube heat exchangers and common fluids and applications [3] Table-1 Typical Fouling Factor value for different condition OF water [4]
Typical Fouling Factors [m2 K/W] Conditions Cooling Cooling Cooling Water < 50C Water <50C Water >50C v > 1 m/s Type of Water Sea Brackish Cooling tower with inhibitor Cooling tower without inhibitor City grid River mimimum River average Engine jacket Demineralized or distilled Treated Boiler Feedwater Boiler blowdown 0.00009 0.00035 0.00018 0.00053 0.00018 0.00018 0.00053 0.00018 0.00009 0.00018 0.00035 0.00009 0.00018 0.00018 0.00053 0.00018 0.00018 0.00035 0.00018 0.00009 0.00009 0.00035 0.00018 0.00053 0.00035 0.00088 0.00035 0.00035 0.0007 0.00018 0.00009 0.00018 0.00035 0.00018 0.00035 0.00035 0.0007 0.00035 0.00035 0.00035 0.00018 0.00009 0.00018 0.00035 v < 1 m/s Cooling Water >50C v > 1 m/s

Cooling Water v < 1 m/s velocity

Table-2 Typical Fouling Factor value for different fluids [4]

Several Fluids Fouling Factor Group Fluid Gasoil Tansformer Lubrication Oil Heat Transfer oil Hydraulic Quenching Oil Fuel Oil Hydrogen Engine exhaust Steam Gas & Vapour Steam with oiltraces Cooling fluid vapours with oil traces Organic solvent vapours Compressed air Natural gas Stable top products Cooling Fluid Organic heat transfer fluids Salts LPG, LNG MEA and DEA (Amines) solutions Liquid DEG and TEG (Glycols) solutions Stable side products Stable bottom products Caustics Vegetable Oils Refrigerating Liquid Rf (m2 K/W) 0.00009 0.00018 0.00018 0.00018 0.00018 0.0007 0.0009 0.00176 0.00176 0.00009 0.00018 0.00035 0.00018 0.00035 0.00018 0.00018 0.00018 0.00018 0.00009 0.00018 0.00035 0.00035 0.00018 0.00018 0.00035 0.00053 0.0002

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ISSN 2249-6343 International Journal of Computer Technology and Electronics Engineering (IJCTEE) Volume 2, Issue 3, June 2012
4. DESIGN O F SURFACE CONDENSER : There are two design of heat exchanger 4.1 Thermal Design: Its a primary design of any heat exchanger in which u optimise by changing flow rate, material etc. Also you optimise in process by design of two or three pass system on different loading in different season like as in winter less cooling load required as compare to summer. This is based on HEI codes. Turbine Condensers are designed as per HEI-standards for steam condensers (HEI means Heat Exchange Institute) Since 1933 - HEI is a non profit trade association committed to the technical advancement, promotion, understanding and education of industrial heat exchanger, vacuum system etc. HEI has developed and published Standard 4.2 Mechanical Design: Design & Construction Code: Mechanical design based on these codes. ASME Sec VIII Div I, II, III Sec III Sec I TEMA IBR IS 2825 5. MATERIAL FOR CONSTRUCTION: CS (Plain CS & Micro Alloy Steels) LAS C-Mn, C-Mo, Cr.-Mo, Cr.-Mo. Ni. - Cr. - Mo, 7. RESULTS OBTAINED FROM ASPEN P LUS SOFTWARE

Data taken from Sikalbaha 225 MW 10% Combined Cycle (Dual Fuel) Power Plant Project Bangladesh Given Data[5] Ambient Pressure 1.0130 bar Ambient Temperature 35.0 C Relative Humidity 98.0% Design Conditions at different Gas Turbine Load Steam inlet (kg/s) Cooling Water Inlet & Condensate Outlet Temperature (0C) TABLE 3. Result table produced by Aspen plus software based on given data of thermal design of surface condenser [6]
Tube Materal (SS 304) Heat Same Design Parameter for 1 to 8 Shell & another part material Trasfer Readings. Only Fouling Factor change (Carbon Steel) Rate as per Different condition of cooling water (W/m2 K) SteamFlow (kg/s) D E S I G N P A R A M E T E R Pressure (bar) Steam Inlet/Outlet (0C) Water Flow Rate (kg/s) Density of vapor (kg/m3) Density of liquid (kg/m3) Water Inlet (0C) Water Outlet (0C) 63 0.115 Reading-1 When Rf =0 Surface Area=430.95m2 Reading-1 When Rf =0.0001 Surface Area=549.30 Reading-1 When Rf =0.0002 Surface Area=637.09m2 Reading-1 When Rf =0.0003 Surface Area=648.5m2 Reading-1 When Rf =0.0004 Surface Area=706.93m2 Reading-1 When Rf =0.0005 Surface Area=757.46m2 Reading-1 When Rf =0.0006 Surface Area=815.27m2 Reading-1 When Rf =0.0007 Surface Area=823.74m2 Reading-1 When Rf=0.0008 Surface Area=917.44m2 1269 995.6

Ni- Steel Stainless Steel. Austenitic, Ferritic, Martensitic, Duplex, Super Duplex NF Metals & Alloys Al, Cu, Brass, Bronze, Monel, Cupronickel, Titanium 6. SOFTWARE USED FOR CONDENSER DESIGN: Condenser Design on Aspen-Plus Software Compress Software PVElite LMTD Calculator. Condenser Design (Cnd) Double Pipe Heat Exchanger Design(DHex) Casketed plate Exchanger Design (PH 2.0.1).

48.84

858.4

5178.16

850.3

0.08

773.6

993

722

38.5

670.8

45.5

663.9

Code Requirement ASME Code Sec VIII Div 1 TEMA Class

596.1

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ISSN 2249-6343 International Journal of Computer Technology and Electronics Engineering (IJCTEE) Volume 2, Issue 3, June 2012
8. OVERALL SUMMARY O F R ESULT IN ALL C ASES: Table-4.0 Effect of Fouling Factor on Surface Area. Fouling Factor (m K/W) 0 0.0001 0.0002 0.0003 0.0004 0.0005 0.0006 0.0007 0.0008 0.0009 Table-5.0 Effect of Heat Transfer Rate On Surface Area

Surface Area (m) 430.95 549.3 637.09 622.3 706.93 757.46 815.27 823.74 917.44 968.9

Heat Transfer Rate (W/mK) 1269 995.6 858.4 850.3 773.6 722 670.8 663.9 596.1

Surface Area(m) 430.95 549.3 637.09 622.3 706.93 757.46 815.27 823.74 917.44

Fig.-1. Surface Area V/S Fouling Factor Fig.-2.Surface Area V/S Heat Transfer Rate

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ISSN 2249-6343 International Journal of Computer Technology and Electronics Engineering (IJCTEE) Volume 2, Issue 3, June 2012
9. CONCLUSION: Heat transfer (Q) is directly proportional to heat transfer rate (U) and Area. If the value of fouling factor increases then heat transfer rate decreases. So, more Surface area required to transfer the heat. So, when we select that type of material which has less effect of fouling then we reduce the surface area. Also select the cooling media which has low value of fouling factor at that time also reduced the surface area for heat transfer [11] ACKNOWLEDGEMENT: I would like to express my deep sense of gratitude and respect towards my faculty members of Dept. of Mechanical, Sri satya Sai Institute of Science & Technology,Sehore,for his valuable guidance right from selection of the topic. His constant encouragement and support has been the cause of my success in completing this. REFERENCES:
[1] www.sciencedirect.com, C. Caputo , Pacifico M. Pelagagge, Paolo SaliniUniversity of LAquila, Heat exchanger design based on economic optimisationAntonio [2] www.sciencedirect.com,Applied Thermal Engineering 28 (2008) 17981805, Design optimization of shell-and-tube heat exchangers, Andre L.H. Costa a,*, Eduardo M. Queiroz b [3] www.deltathx.com, Industrial Heat Exchangers [4] R.C.Sachdeva, fundamentals of Engineering Heat and Mass Transfer. 3rd edition, NEW AGE INTERNATIONAL PUBLISHERS, page.Num.497

ABOUT THE AUTHOR Mr. Mehta Vijay K. M-Tech Student (Thermal Engineering) Contact No. +919998443111 E-Mail ID:mehtavijay237@gmail.com Address: Surag para,Khetani road, Near Police line, Vadia Devali-365480, Dist.-Amreli, State-Gujarat

[5] Design data, ABENER Project: Sikalbaha 225 MW 10% Combined Cycle (Dual Fuel) Power Plant Project Bangladesh, Condenser Design. Performance for Guaranteed Balances Revision 17/11/2011 [6] Author: Jim Lang (SDSM&T, 2000), Condenser Design on Aspen-Plus Software (Heat Exchanger design with a phase change) [7] Lang, Jim. Design Procedure for Heat Exchangers on Aspen Plus Software Design Manual. June 1999. [8] Aspen plus Simulator 10.0-1. User Interface (1998). [9] KEVIN M. LUNSFORD , Bryan Research and Engineering, Inc. - Technical Papers, Increasing Heat Exchanger Performance, Bryan Research & Engineering, Inc,Bryan, Texas. [10]WOLVERINE TUBE HEAT TRANSFER DATA BOOK, ch-1_6-Fouling in Heat Exchangers. [11] HTRI design manual, Page D6.2.1 (Rev.1)

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