King Abdulaziz University

Mechanical Engineering Department

MEP 460
Heat Exchanger Design

Fouling of heat Exchanger

March 2018
 Fouling of heat exchangers
Introduction
Basic consideration
Effect of fouling
on heat transfer
on pressure drop
Design of HX subject to fouling
Cleanliness factor & Percent over surface
Cost of fouling
Types of fouling
Ways to minimize fouling effect

Reference: Ch.6 Kakac book, 3ed. Edition

 Symbols uses
′′ ′′
1 𝐴𝑜 𝐴𝑜 𝑅𝑓𝑖 1 𝑅𝑓𝑜
Incropera =
𝑈𝑜 ℎ𝑖 𝐴𝑖 𝜂𝑖
+
𝜂 𝑖 𝐴𝑖
+ 𝑅𝑤 𝐴𝑜 + +
ℎ𝑜 𝜂𝑜 𝜂𝑜

1 𝐴𝑜 𝐴𝑜 𝑅𝑓𝑖 1 𝑅𝑓𝑜
Kakac =
𝑈𝑜 ℎ𝑖 𝐴𝑖 𝜂𝑖
+
𝜂 𝑖 𝐴𝑖
+ 𝑅𝑤 𝐴𝑜 + +
ℎ𝑜 𝜂𝑜 𝜂𝑜

′′
𝑅𝑓𝑖 is the fouling factor for interior surface [m2.K/W]
′′
𝑅𝑓𝑜 is the fouling factor for the exterior surface [m2.K/W]

𝜂𝑜 is the outside surface overall efficiency

𝜂𝑖 is the inside surface overall efficiency

Rw is the wall thermal resistance [K/W]

ln (𝑟𝑜 𝑟𝑖 )
𝑅𝑤 =
2𝜋𝑘𝐿
Inside surface and outside surface fouling
 Definition of Uc , Ac and Uf and Af
Based on outside area
If Qc and Qf is the same, then
𝑄𝑐 = 𝑈𝑐 𝐴𝑐 Δ𝑇𝑚 Clean HX
𝑈𝑓 𝐴𝑓 = 𝑈𝑐 𝐴𝑐
𝑄𝑓 = 𝑈𝑓 𝐴𝑓 Δ𝑇𝑚 Fouled HX
𝑈𝑐 𝐴𝑐 1 ′′
1 𝐴𝑜 1 𝐴𝑓 = = 𝑈𝑐 𝐴𝑐 + 𝑅𝑓𝑡
= + 𝑈𝑓 𝑈𝑐
𝑈𝑐 ℎ𝑖 𝐴𝑖 ℎ𝑜
𝐴𝑓 ′′
′′
𝑅𝑓𝑖 𝐴𝑜 = 1 + 𝑈𝑐 𝑅𝑓𝑡
1 𝐴𝑜 ′′ 1 1 ′′ 𝐴𝑐
= + + 𝑅𝑓,𝑜 + = + 𝑅𝑓𝑡
𝑈𝑓 ℎ𝑖 𝐴𝑖 𝐴𝑖 ℎ𝑜 𝑈𝑐
𝐴𝑓 > 𝐴𝑐
2
𝑚 𝐾
𝑅𝑓′′ 𝑖𝑛
𝑊
′′ The area of fouled heat
′′
𝑅𝑓,𝑖 𝐴𝑜 ′′
𝑅𝑓,𝑡 = + 𝑅𝑓,𝑜 exchanger is greater than
𝐴𝑖
the area required for
1 1 ′′ cleaned heat exchanger
= + 𝑅𝑓𝑡
𝑈𝑓 𝑈𝑐
 Effect of fouling on heat transfer area

′′
𝑅𝑓𝑡
𝐴𝑓 ′′
= 1 + 𝑈𝑐 𝑅𝑓𝑡
𝐴𝑐

As Uc increase
the
percentage
increase of
the area will
increase
 Effect of fouling
Typical fouling resistance for
Shell and tube heat
Effect of fouling on heat transfer exchangers

For example for

liquid to liquid heat
exchange

𝑚2 𝐾
𝑅𝑓𝑡 = 7.9 ∗ 10−4
𝑊
 Effect of fouling on heat transfer

1 1 1
≈ +
𝑈𝑐 ℎ𝑖 ℎ𝑜

Assuming AoyAi
and Rwy0
1 1 ′′
= + 𝑅𝑓𝑡
𝑈𝑓 𝑈𝑐

hi=1000, ho=1000,
Rft=6.5*10-4

Uc=500, Uf=377.4

𝐴𝑓 ′′
= 1 + 𝑈𝑐 𝑅𝑓𝑡 =1.325
𝐴𝑐

Heat transfer area increase=

(Af-Ac)*100=32.5 % Heat transfer area could be doubled or more due fouling
 Relation between friction factor f
and friction coefficient Cf

friction factor f friction coefficient Cf

𝑓 = 4 𝐶𝑓

In kakac Book use of friction

coefficient with the symbol f

Replace f by f/4
 Relation between friction factor f
and friction coefficient Cf

Kakac symbols

Replace f by f/4
We get
2
𝐿 𝑢𝑚
Δ𝑃 = 𝑓 𝜌
𝐷 2
f is friction factor
which can be found
from Moody diagram
 Effect of fouling
Effect of fouling on pressure drop

• more heat exchangers are removed

from service due excessive pressure
drop than to meet heat transfer
requirements.

• In tubular heat exchangers, fouling

increase surface roughness and reduce
inside diameter and increase the outside
diameter

2
𝐿 𝑢𝑚
Pressure drop due
Δ𝑃 = 𝑓 𝜌
major losses 𝐷 2
 Effect of fouling on pressure drop
Pressure drop due major losses
Assume mass flow rate
is the same for clean
For clean case and fouled case
𝐿 𝑢𝑐2 𝑚𝑓 = 𝑚𝑐
Δ𝑝𝑐 = 𝑓𝑐 𝜌
𝑑𝑐 2
For fouled surface 𝑑𝑐2 𝑢𝑐 = 𝑑𝑓2 𝑢𝑓

𝐿 𝑢𝑓2 or
Δ𝑝𝑓 = 𝑓𝑓 𝜌 𝑢𝑓 𝑑𝑐2
𝑑𝑓 2 = 2
𝑢𝑐 𝑑𝑓
Ratio
2
Then
Δ𝑝𝑓 𝑓𝑓 𝑑𝑐 𝑢𝑓
= Δ𝑝𝑓 𝑓𝑓 𝑑𝑐
5
Δ𝑝𝑐 𝑓𝑐 𝑑𝑓 𝑢𝑐
=
Δ𝑝𝑐 𝑓𝑐 𝑑𝑓
 Effect of fouling on pressure drop
1 𝐴𝑜 𝐴𝑜 𝑅𝑓𝑖 1 𝑅𝑓𝑜
We have = + + 𝑅𝑤 𝐴𝑜 + +
𝑈𝑜 ℎ𝑖 𝐴𝑖 𝜂𝑖 𝜂𝑖 𝐴 𝑖 ℎ𝑜 𝜂𝑜 𝜂𝑜
Wall thermal resistance

𝐴𝑜 ln(𝑟𝑜 𝑟𝑖 ) 𝑑𝑜 ln 𝑑𝑜 𝑑𝑖
𝑅𝑤 𝐴𝑜 = = 2𝑘𝑓 𝑅𝑓
2𝜋𝑘𝐿 2𝑘
= ln(𝑑𝑐 𝑑𝑓 )
𝑑𝑐
For fouling of diameter df
Thermal resistance due 𝑑𝑓 = 𝑑𝑐 𝑒 (−2𝑘𝑓 𝑅𝑓 𝑑𝑐 )
to fouling (internal flow)
Fouling thickness tf
𝑑𝑐 ln(𝑑𝑐 𝑑𝑓 )
𝑅𝑓 = 2𝑘𝑓 𝑅𝑓
2𝑘𝑓 𝑡𝑓 = 0.5 𝑑𝑐 1 − exp −
𝑑𝑐
 Inside the pipe fouling
Clean pipe diameter dc
Fouled diameter df
Due to less flow area, the
velocity will increase

𝐴𝑟 𝜋𝑑𝑓2 4 𝑑𝑓2
= 2 = 2
𝐴𝑐 𝜋𝑑𝑐 4 𝑑𝑐

5
Δ𝑝𝑓 𝑓𝑓 𝑑𝑐
=
Δ𝑝𝑐 𝑓𝑐 𝑑𝑓
 Effect of fouling on pressure drop
2𝑘𝑓 𝑅𝑓
𝑡𝑓 = 0.5 𝑑𝑐 1 − exp −
𝑑𝑐

2
−4
𝑚 𝐾
𝑅𝑓 = 4 ∗ 10
𝑊
Effect of fouling on pressure drop(internal flow)
𝐴𝑟 𝜋𝑑𝑓2 4 𝑑𝑓2
𝑑𝑓 = 𝑑𝑐 𝑒 (−2𝑘𝑓 𝑅𝑓 𝑑𝑐 ) = =
𝐴𝑐 𝜋𝑑𝑐2 4 𝑑𝑐2
5
Δ𝑝𝑓 𝑓𝑓 𝑑𝑐
=
Δ𝑝𝑐 𝑓𝑐 𝑑𝑓
Typical value for fouling resistances involving use
of water
 Cleanliness Factor CF

𝐶𝐹 =
𝑈𝑓 𝑅𝑓𝑡 ∗ 104
𝑈𝑐

1 1
= + 𝑅𝑓𝑡
𝑈𝑓 𝑈𝑐

𝑈𝑐
= 1 + 𝑈𝑐 𝑅𝑓𝑡
𝑈𝑓

𝑈𝑓 1
𝐶𝐹 = =
𝑈𝑐 1 + 𝑈𝑐 𝑅𝑓𝑡

1
𝑈𝑐 𝑅𝑓𝑡 = −1
𝐶𝐹

1 − 𝐶𝐹
𝑅𝑓𝑡 =
𝑈𝑐 𝐶𝐹
 Percent Over Surface

In a shell-and-tube heat exchanger, the additional surface

can be provided either by increasing the length of tubes or
by increasing the number of tubes (hence the shell
diameter). Such a change will affect the design conditions
such as flow velocities, number of cross passes, or baffle
spacing. Therefore, the new design with the increased
surface should be related to achieve optimum conditions
Kakac, 3ed edition, ch.6
Example 6.1 continue
Example 6.1 continue
Example 6.1 continue
Example 6.1 continue
 Cost of fouling
Added cost due to fouling:

1-Increased capital expenditure

2- Increased maintenance cost
3- Loss of production
4-Energy losses

Increased of capital cost due to :

 increase of heat transfer area required

 Duplicate heat exchangers may have to be installed
in order to ensure continuous operation
 High cost materials such as titanium, stainless steel
graphite may be required.
 Types of fouling
No Type
1 Particulate Accumulation of solid particles Unburnt fuel ashes. Dust on
Fouling air cooled condenser
2 Crystallization Crystal formation of salt due Calcium and magnesium
fouling heating and cooling of a stream carbonate, silicates and
phosphates
3 Corrosion Heat transfer surface interaction Fuel sulfur and vanadium
fouling with the stream producing corrode oil fired boilers
corrosion on the surface
4 Bio-fouling Due to growth of material of Micro-organisms such as
biological origin on heat transfer bacteria, algae and molds.
surface. Or sea weed and water
weeds
5 Chemical Chemical reaction within the Polymerization and cracking
reaction fouling stream and coking of hydrocarbons

In practice fouling can take place due to several types or may

complement each others
 1- Particulate/Sedimentation Fouling:

Sedimentation occurs when particles (e.g. dirt, sand or rust) in the

solution settle and deposit on the heat transfer surface. Like scale, these
deposits may be difficult to remove mechanically depending on their
nature.
 2- Scaling/Crystallization Fouling:

Scaling is the most common type of fouling and is commonly associated with
inverse solubility salts such as calcium carbonate (CaCO3) found in
water. Reverse solubility salts become less solute as the temperature
increases and thus deposit on the heat exchanger surface. Scale is difficult to
remove mechanically and chemical cleaning may be required.

http://www.hcheattransfer.com/fouling1.html
 3- Corrosion Fouling:

Results from a chemical reaction which involves the heat exchanger surface
material. Many metals such as copper and aluminum form adherent oxide
coatings which serve to passivate the surface and prevent further
corrosion. Metal oxides which are corrosion products exhibit quite a low thermal
conductivity and even relatively thin coatings of oxides may significantly affect
heat exchanger performance.
 4- Biological Fouling:

Occurs when biological organisms grow on heat transfer surfaces. It is a

common fouling mechanism where untreated water is used as the
coolant. Problems range from algae to other microbes such as barnacles and
zebra mussels. During seasons when these microbes are said to bloom, colonies
several millimeters deep may grow across the surface within hours, impeding
circulation near the surface wall and impacting heat transfer.
 5- Chemical Fouling:

Fouling from chemical reactions in the fluid stream which result in the deposition of
material on the heat exchanger surface. This type of fouling is common for
chemically sensitive materials when the fluid is heated to temperatures near its
decomposition (degradation) temperature. Coking of hydrocarbon material on the
heat transfer surface is also a common chemical fouling problem
 Freezing Fouling:

Occurs when a portion of the hot stream is cooled to near the freezing point of one
of its components. An example in refineries is when paraffin solidifies from a
cooled petroleum product. Another example is freezing of polymer products on the
heat exchanger surface.
 Ways to Minimize fouling effects
Fouling tendencies depends on the type of heat exchanger and the
fluids. During the design stage certain considerations may help minimize
fouling experienced in the field:

•If possible, allocate the more fouling fluid to the tube side
•Design for a fouling fluid velocity of 5 ft/sec on the tube
side and 3 ft/sec on the shell side
•Try to keep the fluid velocity constant
•Allow for easy access for cleaning
•In water service, ensure the tube wall temperature is not
too high to create salt deposits or render treatment
chemicals ineffective
•Do not throttle water flows in winter time