A Risk-Based Performance Analysis Of Plate-And-Frame Heat

Exchangers
Subject To Fouling: Economics Of Heat Exchanger Cleaning
Khan, JUR; Zubair, SM
TAYLOR FRANCIS INC, HEAT TRANSFER ENGINEERING; pp: 87-100; Vol: 25
King Fahd University of Petroleum & Minerals

http://www.kfupm.edu.sa

Summary

Fouling is one of the major uncertainties associated with the operation and
maintenance of plate-and-frame heat exchangers (PHEs) in the steel and process
industries. The decision regarding periodic maintenance (i.e., cleaning) to meet the
target performance level is generally based on both thermal and economic behavior of
the process. In this paper, we present a cost model that includes the risk level and the
scatter parameter of random fouling growth models. Two models (namely, power law
and exponential fouling growth) are integrated in the model. The non-dimensional
cost function of reduced time is examined by considering dimensionless cost
parameters, representing additional cost due to a decrease in effectiveness, pumping
power cost, anti-foulant cost, cleaning cost, additional pumping power cost of the
standby unit during cleaning, and miscellaneous costs. These dimensionless cost
elements are examined for a PHE operating in the steel industry. The results are
presented in terms of the risk level and scatter parameter for the underlying fouling
models. Furthermore, a simplified closed-form solution is also obtained to study the
optimal cycle time, which represents the minimum cost of operation and maintenance
of heat exchangers. It is found that the optimum dimensionless cost increased by
about 21 and 14% for the power law and exponential fouling models, respectively, as
the risk level decreased from 0.5 to 0.01.

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© Copyright: King Fahd University of Petroleum & Minerals;
http://www.kfupm.edu.sa
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For pre-prints please write to: smzubair@kfupm.edu.sa

© Copyright: King Fahd University of Petroleum & Minerals;

http://www.kfupm.edu.sa