This topic will discuss Performance of heat exchangers , common failures and heat losses , their mechanisms and root causes
Objective
Water treatment is crucial for the effective operation of (heat exchangers, evaporators, condensers, boilers ….. etc.) Proper treatment helps save energy in several ways:
1. Prevention of Scale Formation
- Heat Exchangers and Boilers: Scaling can reduce heat transfer efficiency, forcing systems to work harder and consume more energy. Effective water treatment prevents scale formation, ensuring optimal heat exchange and reducing energy costs.
- Chillers: Scale can also hinder the efficiency of chillers. Proper treatment maintains clean surfaces for effective cooling.
2. Corrosion Control
- All Equipment: Corrosion can damage equipment, leading to leaks and inefficiencies. Water treatment techniques, such as pH adjustment and the use of corrosion inhibitors, minimize corrosion, prolonging equipment life and maintaining energy efficiency.
3. Improved Heat Transfer
- Optimized Performance: Clean water allows for better thermal conductivity. For heat exchangers and boilers, this means more efficient heat transfer, reducing the energy required to achieve desired temperatures.
4. Reduced Chemical Consumption
- Efficient Operations: By maintaining optimal water quality, treatment reduces the need for additional chemicals to combat scaling and corrosion, which can lower operating costs and energy use.
5. Lower Maintenance Needs
- Operational Efficiency: Regular water treatment decreases the frequency of maintenance and repairs, allowing systems to run more efficiently and reducing downtime, which can be costly in terms of energy and productivity.
6. Enhanced System Longevity
- Sustainability: Well-treated water can extend the life of heat exchangers, chillers, and boilers, leading to fewer replacements and associated energy costs for manufacturing and installation.
Fouling
Performance Degradation Due to Micro Fouling Layers in Large- Scale Industrial Heat Exchangers.
-This topic will discuss Performance Degradation Due to Micro Fouling Layers and degradation assessment of heat exchangers, common failures occurring in the heat exchangers and heat losses, their mechanisms and their root causes.
-This study mainly deals with the evaluation of various degradation mechanisms that heat exchangers are susceptible to with an aim of evaluating future design requirements. A heat exchanger is a heat management system that uses fluids to transfer heat from one medium to the other; the most common types of fluids being air, water, oil or specialized coolant mixtures. As part of this study, we will discuss the principal types of fouling encountered in process HE And failure analysis of heat exchangers was carried out on selected heat exchangers used industries sectors.
The principal types of fouling encountered in process HE includes:
§? particular fouling
§? corrosion fouling
§? biological fouling
§? crystallization fouling
§? chemical reaction fouling
In most cases, it is unlikely that fouling is exclusively due to a single mechanism, and in many situations one mechanism will be dominant.
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Where is Mach numbers (?? ) ranging from 0.6 to 1.6
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Asset Failure
Failure is a physical indication indicating the poor performance of the system. Different types of heat exchanger failure have been analyzed based on literature studies and have been grouped according to the type of damage and its effect on the heat exchanger’s characteristics, as follows:
§? Crack and leak: one of the most dangerous failures caused by the separation of a material in two or more pieces due to the effect of stress.
§? Blockage: a type of failure which is due to substance deposition on the pipe surface resulting in pipe blockage over time.
§? Material removal: could occur due to material removal from the pipe surface due to the flow in the fluid resulting in cracks and leaks.
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Failure mechanisms
Failure mechanisms are the different processes which can lead a system to failure. Five major mechanisms exist;
§? Fouling: the deposition of solid particles inside the pipes, causing reduction of their cross-section area eventually leading to blockage.
§? Corrosion: the gradual destruction of the material surfaces by chemical reaction with their environment which leads to material removal.
§? Erosion: mechanical abrasion of the material’s surface which produces Total Dissolved Solids (TDS) in the fluid and leads to material removal.
§? Fatigue: the structural damage of a material caused by repeated loading: thermal and mechanical stresses and leads to cracks and leaks.
§? Vibration: ?a mechanical phenomenon which creates oscillations in the material at an equilibrium point. It leads to cracks and other mechanical fractures which can result in leaks or pressure drop changes.
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Analysis Techniques
The most common techniques used to analyze the deposit and corrosion samples are:
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Solutions
§? Mechanical cleaning
§? Chemical cleaning
§? Soft, Hard Monitoring
control Treatment
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?Ahmed M
Abdelrman N