Fouling Science and Technology

719 Pages·1988·17.001 MB·English

by  T. R. Bott (auth.), L. F. Melo, T. R. Bott, C. A. Bernardo (eds.)

Fouling Science and Technology
NATO ASI Series
Advanced Science Institutes Series
A Series presenting the results af activities sponsored by the NA TO Science Committee,
which aims at the dissemination af advanced scientific and technological knowledge,
with a view to strengthening links between scientific communities.
The Series is published by an international board of publishers in conjunction with
the NATO Scientific Affairs Division
A Life Sciences Plenum Publishing Corporation
B Physics London and New York
C Mathematical Kluwer Academic Publishers
and Physical Sciences Dordrecht, Boston and London
D Behavioural and Social Sciences
E Applied Sciences
F Computer and Systems Sciences Springer-Verlag
G Ecological Sciences Berlin, Heidelberg, New York, London,
H Cell Biology Paris and Tokyo
Series E: Applied Sciences - VoL 145
Fouling Science and
Technology
edited by
L. F. Melo
University of Minho,
Braga, Portugal
T. R. Bott
University of Birmingham,
Birmingham, UK
and
c.
A. Bernardo
University of Minho,
Braga, Portugal
..
Kluwer Academic Publishers
Dordrecht / Boston / London
Published in cooperation with NATO Scientific Affairs Division
Proceedings of the NATO Advanced Study Institute on
Advances in Fouling Science and Technology,
Alvor, Algarve, Portugal
May 18-30, 1987
Library of Congress Cataloging in Publication Data
NATO Advaneed Study Instltute an Advanees In Foullng Science and
Teehnology (1987 Alvor, Portugal)
Foullng selence and teehnology / [edlted by) L.F. Melo, T.R. Bott,
e.A. Bernardo.
p. cm. -- (NATO ASI serles. Series E, Applled selences ; no.
145. )
·Publlshed In eooperatlon wlth NATO Seientifie Affalrs Division.·
Ine l udes Index.
1. Heat exeha~gers--Foul Ing. 2. Foul Ing. l. Melo, L. F. (Luis
F.), 1948- Il. Bo·tt, T. R. (Theodore Reginald), 1927-
III. Bernarde, e. A. (Carlos A.). 1946- IV. North Atlantlc
Treaty Organlzatlon. Seientifie Affalrs Division. V. TItle.
VI. Series.
TJ263.N39 1987
621.402'5--dc19 88-15079
eIP
ISBN-13: 978-94-010-7766-8 e-ISBN-13: 978-94-009-2813-8
001: 10.1007/978-94-009-2813-8
Published by Kluwer Academic Publishers,
P. O. Box 17, 3300 AA Dordrecht, The Netherlands.
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In all other countries, sold and distributed
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All Rights Reserved
© 1988 by Kluwer Academic Publishers.
Softcover reprint of the hardcover 1s t edition 1988
No part of the material protected by this copyright notice may be reproduced or utilized
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or by any information storage and retrieval system, without writlen permission from the
copyright owner.
Proceedings of the
NATO Advanced Study Institute
"Advances in Fouling Science and Technology"
held in Hotel D. Joao II, Alvor, Algarve
Portugal
from the l8th to the 30th May 1987
Organizing Committee:
Luis F. Melo (Director)
University of Minho, Braga, Portugal
Carlos A. Bernardo (Associate Director)
University of Minho, Braga, Portugal
Theodore Reginald Bott
University of Birmingham, United Kingdom
Joao de Deus ~inheiro
University of Minho, Braga, Portugal
Jens Rostrup-Nielsen
Haldor-Topsoe, Denmark
FOREWORD
The fouling of heat exchangers, reactors and catalysts remains one of
the most urgent problems facing the process industries. Over the past ten
years there has been limited research and investigation into the underlying
mechanisms which give rise to this problem.
For convenience, particularly in heat exchanger technology, the
mechanisms involved have been subdivided into different subject areas. It
is often the situation that individuals or groups of workers have concentra
ted efforts in one or two of these specialist areas and there is a need to
integrate the ideas across the whole spectrum of the subject. In addition,
topics such as adhesion and surface phenomena have not been properly taken
into account up till now in the assessment of the fouling processes. For this
reason it was considered essential that the recognised experts from around
the world, who are actively concerned with research, development and design
in the fieId, should meet and exchange ideas and experience. Such a meeting
was held at Alvor, Portugal, in May 1987, sponsored by the NATO Advanced
St~dy Institutes Programme.
In order to obtain a common basis for the work of the Advanced Study
Institute, the whole technological field was reviewed right from the basic
concepts to the frontiers of present knowledge. Each invited contributor was
asked to make an overall presentation covering his or her area of expertise.
The texts of the lectures and the discussion reports of the meeting are
collected together in 12 chapters in this volume, representing an up to date
statement of the technological position with regard to industrial fouling. The
subject matter is developed from the fundamentals through the basic mechanisms
of surface contamination to industrial applications. Reviews on the so-called
types of fouling (particulate, biological, solidification, corrosion and
chemical reaction) and on adhesion science are presented. Fouling in food
processing, although essentiaIly reaction fouling, is kept separated in view
of its significance as a subject in its own right. In the chapter dealing
with chemical reaction fouling an overview of the field is presented,
together with reviews and papers covering specific topics, including fouling
of catalysts and hot metallic surfaces. Case studies in a number of important
industrial proces ses (water treatment, furnaces, homogeneous chemical
reaction and catalysis) are discussed. The final chapter contains short re
ports of the discussion that took place as a direct result of the interest
generated during the lectures.
The editors would like to express their thanks to all the speakers and
participants for their active collaboration which has made this book pos
sible. In addition, the support of the Scientific Affairs Division of NATO,
through the A.S.I. Programme, together with the support of the Universities
of Minho and Birmingham, Junta Nacional de Investiga~ao Cientifica e Tecno
logica, Instituto Nacional de Investiga~ao Cientifica, Calouste Gulkenkian
Foundation and the Portuguese Ministry of Education is gratefully
acknowledged.
L.F. Melo
T.R. Bott
C.A. Bernardo
CONTENTS
FOREWORD v i
CHAPTER 1. FUNDAMENT ALS AND ECONOMICS
. General Fouling Problems
T.R. Bott 3
. General Thermal Fouling Models
N. Epstein 1 5
The Economics of Fouling
A.M. Pritchard 3 1
CHAPTER 2. MONITORING EQUIPMENT
Liquid Fouling Monitoring Equipment
J.M. Chenoweth 4 9
Gas-Side Fouling Monitoring Equipment
A. Tsados 6 7
Monitoring Fouling using a Novel Technique
P.G. Cousineau, G.P. Fulford and P.M. Simmons 7 7
CHAPTER 3. ADHESION
Adhesi.on and Removal of Particles - I
J. Visser 87
Adhesion and Removal of Particles - II
J. Visser 1 O 5
Aspects of Cell Adhesion
R.S. Harbron and C.A. Kent 125
CHAPTER 4. P AR TICULATE FOULING
Particulate Fouling of Heat Transfer Surfaces:
Mechanisms and Models
N. Epstein l 4 3
Stochastic Model for the Induction Step on
Particulate Fouling
N. Vatistas 1 6 5
Fouling by Aqueous Suspensions of Kaolin and
Magnetite: Hydrodynamic and Surfaee Phenomena
Effects
L. Melo and J.D. Pinheiro 1 7 3
ix
x
• Gas Side Fouling
T.R. Bott 191
CHAPTER 5. BIOLOGICAL FOULING
• Biological Fouling: Basic Science and Models
C.A. Kent 2 O 7
• Effect of Design and Operating Variables on
Biofouling
M.M.V.P.S. Pinheiro, L.F. Melo, T.R. Bott and
J.D. Pinheiro 223
• Surface Bound Biocides - A Novel Possibility
to Prevent Biofouling
K.J. Huttinger 233
• Experimental Investigation of Marine Biofouling
and Corrosion for Tropical Seawater
C.B. Panchal 2 4 l
CHAPTER 6. CRYSTALLISATION FOULING
• Crystallisation Fouling - Basic Science and
Models
T.R. Bott 251
• Deposition of Hardness Salts
A.M. Pritchard 261
• Crystallisation of Organic Materials
T.R. Bott 275
• Fouling of Cryogenic Liquids
H. Muller-Steinhagen 281
CHAPTER 7. CHEMICAL RE ACTION FOULING
• Basic Science and Models of Reaction F ouling
B.D. Crittenden 293
• Chemical Reaction Fouling of Heat Exchangers
B.D. Crittenden 3 l 5
• Fouling from Light Hydrocarbons on Metal
Surfaces
L. Sousa Lobo 333
• Fouling of Catalysts: Industrial Examples
J .R. Rostrup-Nielsen 3 5 l
• The Fouling of Catalysts by Deposition of
Filamentous Carbon
C.A. Bernardo 369
xi
Droplets and Filaments: on the Fouling of
Metal Surfaces by Carbonaceous Material from
Hydrocarbon Gases above 850K
A.I. LaCava 39 l
Carbon Limits in Steam Reforming
J .R. Rostrup-Nielsen 4 O 5
Carbon Deposition in Steam-Cracking
J.L. Figueiredo and M.L.G.M. Pinto 425
CHAPTER 8. DESIGN AND OPERAnON OF HEAT EXCHANGERS
Basic Relationships for Heat Exchangers and
Impact of Fouling on Design
S. Kakac and A.K. Agrawal 437
. Selection of Heat Exchangers
J.M. Chenoweth 463
. General Design of Heat Exchangers for
Fouling Conditions
J.M. Chenoweth 477
Basic Concepts in Heat Exchanger Network
ModeIling
P. Fryer 495
The Fouling of Heat Exchanger Networks
P. Fryer 5 l l
Compensating tor Fouling in Heat Exchanger
Networks
E. Kotjabasakis and B. Linnhoff 529
CHAPTER 9. FOOD PROCESSING FOULING
Fouling by Milk and Dairy Product and Cleaning
of Heat Exchange Surfaces
M. Lalande and F. Rene 557
. On-Line Measurement of Fouling and Cleaning of
Industrial UHT Exchangers
G. Corrieu, M. Lalande and F. Ferret 57 5
CHAPTER 10. FOULING IN INDUSTRIAL WATER SYSTEMS
Effectiveness of Biocides
A. Marshall and T .R. Bott 5 9 l
. Case Study-Clean-up of a Coke Oven Cooling
System
A. MarshaIl, G.E. Ibbotson and T.R. Bott 6 O l
Corrision Fouling: Liquid Side
E.F .C. Somerscales 6 2 l
xii
Avoiding Fouling and Corrosion in Water Cooled
Heat Exchangers: The Expert System Approach
A.E. Faltzin, H. Garcia and A.I. LaCava 637
Fouling of Geothermal Energy Systems
S.H. Chan 649
. Geothermal Water Scaling in Heat Exchangers
S. DIkii, M. Toksoy and A.C. Giirses 669
CHAPTER Il. FOULlNG IN FURNACES
High Temperature Fouling: The Nature of Deposits
J. Howarth and T.R. Bott 679
High Temperature Gas-Side Fouling Case Study
A. Tsados and T.R. Bott 7 O l
CHAPTER 12. DISCUSSIONS
Cooling Water Fouling - Summary of Discussion
P. Watkinson 7 I 5
Debate: Food Processing Fouling
M. Lalande 7 I 9
. Cleaning of Fouled Surfaces: A Discussion
A.M. Pritchard and P.J. Fryer 721
Chemical Reaction Fouling Debate
5. Crittenden and I. Downey 727
Debate on Gas-Side Fouling
J.D. Isdale 731
INDEX 735