July 1-6, 2007 - Tomar, Portugal

Editors:   Hans Müller-Steinhagen, Institute of Technical Thermodynamics, German Aerospace Centre (DLR)
  and Institute for Thermodynamics and Thermal Engineering, University of Stuttgart, Germany
  M. Reza Malayeri, University of Stuttgart, Germany
  A. Paul Watkinson, The University of British Columbia, Canada

The articles for these proceedings are peer-reviewed.

PREFACE

Fouling of heat exchangers in processing industries is a chronic operating problem that compromises energy recovery and maybe environmental welfare. Mitigation of fouling occurrence is frequently hindered by the lack of quantitative knowledge of the dynamic effects of fouling on exchanger heat transfer and pressure drop. Maintaining clean heat transfer surfaces is of vital importance for reliable and efficient energy recovery. However, fouling in tubes or flow channels creates three major problems: (1) Loss of heat transfer, (2) Under-deposit corrosion, and (3) Pressure loss. In addition, it is responsible for the emission of many millions of tonnes of carbon dioxide as well as the use and disposal of hazardous cleaning chemicals. For instance, data from oil refineries suggest that crude oil fouling accounts for about 10% of the total CO2 footprint of these plants. Generally speaking, costs associated with heat exchanger fouling may include the following:

  • Production losses due to efficiency deterioration and to loss of production during planned or unplanned shutdowns.
  • Higher maintenance costs resulting from the removal of fouling deposits with chemicals and/or mechanical antifouling devices or the replacement of corroded or plugged equipment.
  • Increased consumption of water, electricity, fossil fuels and other resources
  • Need for excess heat transfer surface in the design of heat exchangers.
  • A reduction in the ability of the system to supply the design output
  • Increased safety hazards
  • Increased environmental hazards and emissions

The goal of the bi-yearly conferences on heat exchanger fouling has been to facilitate innovative thinking and to explore new theoretical and practical approaches to address the tremendous challenges associated with fouling of heat exchangers. In addition these conferences have successfully provided a forum for experts from industry, academia and government research centres from around the world to present their latest research and technological developments in the areas of fouling mitigation and cleaning technologies. Since 1995, seven of these conferences have been organised by Engineering Conferences International (previously United Engineering Foundation). These meetings generally involve overview presentations, technical papers, poster sessions, and panel discussions. Following the highly successful meetings in San Luis Obispo (1995), Lucca (1997), Banff (1999), Davos (2001), Santa Fé (2003), Kloster Irsee (2005), the 7th conference in this series was held in Tomar, Portugal, in July 2007. The conference attracted representatives from a wide range of universities, research institutes and companies and hence was able to provide participants with excellent technical presentations and a very conducive environment for personal discussions. In total, 92 participants attended the conference, presenting 70 papers/posters, which was the highest numbers in any meeting of this series. The next International meeting on heat exchanger fouling will be held in June or July 2009.

The following papers have been presented, and recommended for publication in the final conference proceedings after a careful refereeing and revision process. The proceedings cover various aspects of heat exchanger fouling along with updated state-of-art fouling mitigation and cleaning strategies. The present e-proceedings as well as those from the previous conferences in 2003 and 2005 can be obtained free of charge from the following homepage of Engineering Conferences International Symposium Series:

http://dc.engconfintl.org

The editors wish to thank everybody who contributed towards the conference and the conference proceedings, i.e.

  • all the authors and participants who invested substantial efforts to produce high-quality papers and to attend the conference
  • the technical referees who helped to improve the quality of these papers even further, by providing valuable and helpful comments
  • the Conference Advisory Committee and the Session Chairmen
  • Barbara Hickernell and Frank Schmidt, and their team from Engineering Conferences International, for an effective organization.

  • Mrs Elham Key Manesh, who has been responsible for the preparation and finalisation of the program and the compilation of the final proceedings.

Editors
Hans Müller-Steinhagen
Institute of Technical Thermodynamics, German Aerospace Centre (DLR)
and Institute for Thermodynamics and Thermal Engineering, University of Stuttgart, Germany

M. Reza Malayeri
University of Stuttgart (Germany)

A. Paul Watkinson
University of British Columbia (Canada)

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Cover Page, Hans Müller-Steinhagen, M. Reza Malayeri, and Paul Watkinson (Article)

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Table of Contents, Hans Müller-Steinhagen, M. Reza Malayeri, and Paul Watkinson (Article)

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Preface, Hans Müller-Steinhagen, M. Reza Malayeri, and A. Paul Watkinson (Article)

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CRUDE OIL FOULING: PETRONAS REFINERIES EXPERIENCE, M.S. Rafeen, M.F. Mohamed, M.Z. Mamot, N.A. Manan, Dr A. Shafawi, and Dr M. Ramasamy (Article)

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CRUDE OIL FOULING IN A PILOT-SCALE PARALLEL TUBE APPARATUS, B. D. Crittenden, S. T. Kolaczkowski, T. Takemoto, and D. Z. Phillips (Article)

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PRECIPITATION AND FOULING IN HEAVY OIL–DILUENT BLENDS, E Hong and A. Paul Watkinson (Article)

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OBSERVATION OF AN ISOKINETIC TEMPERATURE AND COMPENSATION EFFECT FOR HIGH TEMPERATURE CRUDE OIL FOULING, C. A. Bennett, R. S. Kistler, K. Nangia, W. Al-Ghawas, N. Al-Hajji, and A. Al-Jemaz (Article)

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APPLYING TECHNOLOGY ADVANCEMENTS TO IMPROVE HEAT EXCHANGER ECONOMIC AND ENVIRONMENTAL PERFORMANCE IN REFINERY CRUDE PREHEAT TRAINS, Himanshu Joshi, Fred Hoeve, and Eric van der Zijden (Article)

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THE EFFECT OF FOULING ON HEAT TRANSFER, PRESSURE DROP AND THROUGHPUT IN REFINERY PREHEAT TRAINS: OPTIMISATION OF CLEANING SCHEDULES, E. M. Ishiyama, W. R. Paterson, and D. I. Wilson (Article)

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SCALE DEPOSITS IN POROUS MEDIA AND THEIR REMOVAL BY EDTA INJECTION, J. Moghadasi, H. Müller-Steinhagen, M. Jamialahmadi, and A. Sharif (Article)

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DESIGNING TWO-PHASE FLOW HEAT EXCHANGERS FOR MITIGATING FOULING, C.B. Panchal and Blazo Ljubicic (Article)

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FORMATION OF GUM AND DEPOSITS IN AN OXYGENATED NAPHTHA STREAM, Yonghua Li, Paul Watkinson, Patricio Herrera, Feridoun Fahiminia, and Morgan James (Article)

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CRYSTALLIZATION FOULING BEHAVIOUR OF URANIUM OXIDE AND ALUMNOSILICATE SCALE IN HIGH LEVEL NUCLEAR WASTE MEDIUM, Jonas Addai-Mensah, Jun Li, and Bill Wilmarth (Article)

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FREE ALKALI-INDEX FOR OPTIMIZING THE FUEL MIXTURE IN BIOMASS CO-FIRING, T.E. Blomberg (Article)

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INVESTIGATION OF THE MECHANISMS OF HEAT EXCHANGER CORROSION IN A MUNICIPAL WASTE INCINERATION PLANT BY ANALYSIS OF THE RAW GAS AND VARIATION OF OPERATING PARAMETERS, C. Deuerling, J. Maguhn, H. Nordsieck, B. Benker, R. Zimmermann, and R. Warnecke (Article)

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COSTS DUE TO UTILITY FOULING IN CHINA, Xu Zhi-Ming, ZHANG Zhong-Bin, and YANG Shan-Rang (Article)

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THE SCIENCE OF CLEANING OF DAIRY FOULING LAYERS, R. Mercadé-Prieto,; W.R. Paterson; and D.I. Wilson (Article)

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FLOW CELL STUDIES ON FOULING CAUSED BY PROTEIN -CALCIUM PHOSPHATE DEPOSITION IN TURBULENT FLOW, R. Rosmaninho, G. Rizzo, H. Muller-Steinhagen, and L. F. Melo (Article)

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FOULING IN A CENTRITHERM EVAPORATOR WITH WHEY SOLUTIONS, R. S. Jebson, H. Chen, and O. H. Campanella (Article)

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MILK PROTEIN FOULING IN A TUBULAR HEAT EXCHANGER: EFFECT OF MILK TEMPERATURE AND REYNOLDS NUMBER, D.H.G. Pelegrine, K.F. Oliveira, and M.T.M.S. Gomes (Article)

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INTERACTION OF WHEY PROTEIN WITH MODIFIED STAINLESS STEEL SURFACES, S.S. Premathilaka, M.M. Hyland, X.D. Chen, L.R. Watkins, and B. Bansal (Article)

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THE THERMO-HYDRODYNAMICS OF A CONCENTRIC OHMIC HEATER FOR PROCESSING DAIRY FLUIDS, H.J. Tham, X.D. Chen, B. Young, B. Bansal, L. Zhang, and G. Duffy (Article)

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SIMULATION OF CALCIUM PHOSPHATE DEPOSITION ON STAINLESS STEEL SURFACES: A NEW APPROACH BASED ON CELLULAR AUTOMATA, F. G. Martins, T. Campos, R. Rosmaninho, and L. F. Melo (Article)

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STUDY OF AN ORGANIC CRYSTALLIZATION FOULING PROBLEM, Hirofumi Inokuchi, Mitsutaka Nakamura, and Yoshio Koga (Article)

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EXPERIMENTS AND MODELLING OF CALCIUM SULPHATE PRECIPITATION UNDER SENSIBLE HEATING CONDITIONS: INITIAL FOULING AND BULK PRECIPITATION RATE STUDIES, F. Fahiminia, A. P. Watkinson, and N. Epstein (Article)

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FOULING MITIGATION WITH SYNTHETIC FIBRES IN A CASO4 SUPERSATURATED SOLUTION, M. Rost and G. G. Duffy (Article)

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A REAL TIME MONITORING MODEL OF THE CALCIUM CARBONATE FOULING INDUCTION PERIOD BASED ON THE CONDUCTANCE TITRATION, S.R. Yang, S.X. CAO, L.J. CHEN, Z.M. XU, M.L. YU, W.H. SUN, and K.L. ZHENG (Article)

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EXPERIMENTAL INVESTIGATION OF CRYSTALLIZATION FOULING ON GROOVED STAINLESS STEEL SURFACES DURING CONVECTIVE HEAT TRANSFER, A. Al-Janabi, M.R. Malayeri, and H. Müller-Steinhagen (Article)

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SURFACE TREATMENT FOR THE MITIGATION OF WHEY PROTEIN FOULING, W. Augustin, T. Geddert, and S. Scholl (Article)

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INVESTIGATION OF FOULING PROCESS FOR CONVECTIVE HEAT TRANSFER IN AN ANNULAR DUCT, Y.C. Chen, Z.H. Quan, and C.F. Ma (Article)

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EXTENDING THE INDUCTION PERIOD OF CRYSTALLIZATION FOULING THROUGH SURFACE COATING, T. Geddert, I. Bialuch, W. Augustin, and S. Scholl (Article)

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INFLUENCE OF DIFFERENT SURFACE MATERIALS ON NUCLEATION AND CRYSTAL GROWTH IN HEAT EXCHANGERS, T. Geddert, S. Kipp, W. Augustin, and S. Scholl (Article)

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BACTERIAL AND PROTEIN ADHESION ON NI-P-PTFE COATED SURFACES, Q. Zhao, C. Liu, Y. Liu, and S. Wang (Article)

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LOW FOULING CRUDE OIL PREHEATERS: SCRAP YOUR EXISTING CONVENTIONAL CRUDE OIL PREHEATERS, REPLACE THEM BY LOW FOULING HEAT EXCHANGERS AND SAVE MONEY, D.G. Klaren, E.F. de Boer, and D.W. Sullivan (Article)

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ACHIEVEMENTS AND POTENTIAL OF SELF-CLEANING HEAT EXCHANGERS USING UNTREATED NATURAL SEAWATER AS A COOLANT, D.G. Klaren and E.F. de Boer (Article)

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MODELLING OF PARTICULATE FOULING ON HEAT EXCHANGER SURFACES: INFLUENCE OF BUBBLES ON IRON OXIDE DEPOSITION., D.H. Lister and F.C. Cussac (Article)

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INTELLIGENT DISCRIMINATION MODEL TO IDENTIFY INFLUENTIAL PARAMETERS DURING CRYSTALLISATION FOULING, M.R. Malayeri and H. Müller-Steinhagen (Article)

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SIMULTANEOUS CONSIDERATION OF FLOW AND THERMAL EFFECTS OF FOULING IN CRUDE OIL PREHEAT TRAINS, G.T. Polley, A. Morales Fuentes, and D.I. Wilson (Article)

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FOULING MECHANISMS BY AB INITIO CALCULATIONS CONDENSATION REACTIONS ON THE RUTILE (101) SURFACE AND ADSORPTION OF IONS ON THE Cr2O3 SURFACES, E. Puhakka, M. Riihimäki, and R.L. Keiski (Article)

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A LAGRANGIAN PARTICLE CFD POST-PROCESSOR DEDICATED TO PARTICLE ADHESION/DEPOSITION, M. Losurdo, C. Bertrand, and H. Spliethoff (Article)

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COMPUTATION AND EVALUATION OF WALL SHEAR STRESS DISTRIBUTION AT THE LOWER SURFACE OF A RADIAL FLOW CELL, J. G. Detry, B. B. B. Jensen, C. Deroanne, and M. Sindic (Article)

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FLUID DYNAMIC GAUGING IN DUCT FLOWS – EXPERIMENTS AND CFD SIMULATIONS, T. Gu, Y.M.J. Chew, W.R. Paterson, and D.I. Wilson (Article)

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EVALUATION OF HEAT TRANSFER BOUNDARY CONDITIONS FOR CFD MODELING OF A 3D PLATE HEAT EXCHANGER GEOMETRY, T.M. Pääkkönen, M. Riihimäki, R. Ylönen, E. Muurinen, C.J. Simonson, and R.L. Keiski (Article)

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A SURVEY OF ALFA LAVAL’S EXPERIENCE OF FOULING PREVENTION IN PLATE HEAT EXCHANGER SYSTEMS, A. Tornqvist (Article)

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INCORPORATION OF A CONSIDERATION OF FOULING INTO THE DESIGN OF VERTICAL THERMO-SIPHON RE-BOILERS, G.T. Polley and S.J. Pugh (Article)

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OPTIMIZATION OF FLOW DIRECTION TO MINIMIZE PARTICULATE FOULING OF HEAT EXCHANGERS, M.S. Abd-Elhady, C.C.M. Rindt, and A.A. van Steenhoven (Article)

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EFFECT OF THERMAL CONTACT RESISTANCE ON THE HEAT TRANSFER IN PLATE FINNED TUBE HEAT EXCHANGERS, D. Taler (Article)

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FOULING DURING THE USE OF ‘FRESH’ WATER AS COOLANT- THE DEVELOPMENT OF A ‘USER GUIDE’, S. J. Pugh, G. F. Hewitt, and H. Müller-Steinhagen (Article)

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METALLIC MICRO HEAT EXCHANGERS: PROPERTIES, APPLICATIONS AND LONG TERM STABILITY, J.J. Brandner, W. Benzinger, U. Schygulla, S. Zimmermann, and K. Schubert (Article)

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INFLUENCE OF DIFFERENT SURFACE MATERIALS ON THE FOULING PROCESS IN A MICROSTRUCTURED HEAT EXCHANGER UNDER LAMINAR REGIME, W. Benzinger, J.J. Brandner, U. Schygulla, and K. Schubert (Article)

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TOWARDS AN UNDERSTANDING OF HOW TUBE INSERTS MITIGATE FOULING IN HEAT EXCHANGERS, B. Aquino, C. Derouin, and G.T. Polley (Article)

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HITRAN® WIRE MATRIX INSERTS IN FOULING APPLICATIONS, J.M. Ritchie, P. Droegemueller, and M.J.H. Simmons (Article)

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BIOFOULING CONTROL IN HEAT EXCHANGERS USING HIGH VOLTAGE CAPACITANCE BASED TECHNOLOGY, R. Romo, M. M. Pitts, and N. B. Handagama (Article)

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DOUBLE PERFORATED IMPINGEMENT PLATE (DPIP) IN SHELL-AND-TUBE HEAT EXCHANGER, S. S. Al-Anizi and A. M. Al-Otaibi (Article)

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SOLVING A HYDTROTREATER FEED FILTER FOULING PROBLEM, X.A. Wu and K.H. Chung (Article)

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CLEANING AND PREVENTION OF INORGANIC DEPOSITS IN PLATE HEAT EXCHANGERS USING PULSATING CURRENT, A. Pehkonen, J. Aromaa, O. Forsén, J. Virtanen, and I. Galfi (Article)

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CLEANING HIGH-SPEED MARINE SEPARATORS WITH AN ENVIRONMENTALLY-FRIENDLY CIP AGENT, Ulf Nylén, Roger Andersson, and Peter Forsberg (Article)

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AUTOMATIC TUBE CLEANING SYSTEM (ATCS) INSTALLATION IN SULFIDE RETRIEVAL MONOETHANOLAMINE TREATMENT PLANT: CASE STUDY AND FOULING GLOBAL PERSPECTIVES, Chemi Sugarmen, Udi Siboni, and Ruth Volansky (Article)

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FOULING MONITORING AND CLEANING OPTIMISATION IN A HEAT EXCHANGER NETWORK OF A CRUDE DISTILLATION UNIT, Andrea Heins, Ramón Veiga, Carlos Ruiz, and Andrés Riera (Article)

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CFD AND NEURAL NETWORK-BASED EXPERT SYSTEM FOR THE SUPERVISION OF BOILERS AND FURNACES, Hugo Calisto, Nelson Martins, and Naim Afgan (Article)

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SLAG MONITORING SYSTEM FOR COMBUSTION CHAMBERS OF STEAM BOILERS, J. Taler and D. Taler (Article)

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CLEANING MONITORING USING CONTROLLED NANO-VIBRATIONS, A. Pereira, J. Mendes, and L.F. Melo (Article)

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ELECTROCHEMICAL IMPEDANCE AND DIGITAL IMAGE METHODS TO DETECT INITIAL DEPOSITION OF MICROORGANISMS, H. Men, S. W. Mu, Z. W. Lu, Y. L. Chen, S.R. Yang, Y. P. Jia, and S. X. Cao (Article)