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Heat Exchanger

Crack Down on Heat Exchanger Fouling

Crack Down on Heat Exchanger Fouling

Written by Mike Watson, Technical and Managing Director, T.T.I.L.

Heat exchangers are the unsung heroes of many industrial processes and as such they tend to be taken for granted - nobody likes paying for what is often seen to be unnecessary maintenance. Heat exchangers provide duty for so long, that when they start to drop in efficiency, it's usually a gradual process that goes largely unnoticed - until their performance has deteriorated sufficiently to be a problem. Then it really is a problem - and one requiring urgent attention.

What aggravates the situation is the heat exchanger that has never been cleaned properly, coupled with the commercial need to keep it on-line. When the decision is made to carry out cleaning, often nobody knows what the performance of the exchanger is meant to be, either because the drawings have been lost, or no record of any improvement was made after the original cleaning.

When the exchanger finally is opened up to ascertain the extent of the fouling, it's not surprising to find it is so severe that cleaning takes a lot longer than planned. Any benefit that might have been gained by a quick traditional clean is offset by the extended cleaning duration and costs - and, of course, lost production.

If that sounds like a nightmare scenario, bear in mind that this is the sort of situation specialist cleaning companies encounter every week. Cleaning is often carried out without any firm knowledge of how much of an improvement the cleaning will give and how long its effects will last. Having to make 'finger in the wind' predictions clearly is not a satisfactory way to plan maintenance.

One of the most popular and widely-employed heat exchanger configurations in industry, is the straight or hairpin shell-and-tube exchanger. With hundreds or thousands of small-bore tubes bundled together, the extent of quite modest scaling can involve major work to return the exchanger to anything near its commissioned performance. If the outside of the bundle is heavily scaled as well, the cleaning challenge rises by an order of magnitude.

There is potential to bring about a significant improvement in heat exchanger accessibility and 'cleanability', by working more closely with the people who design heat exchangers and fabricate industrial plants.

Better design would lead to improved cleaning - where improved means faster, cleaner and safer, possibly in-situ or even on-line and with better waste containment. It would then be easier and quicker to clean exchangers back to bare metal to return them to duty and their design performance faster.

Plants are generally specified and ordered on the basis of throughput, not accessibility and ease-of-cleaning. Suppliers are happy to comply with this and therefore tend to design heat exchangers with 30-40% excess capacity to ensure that they can continue to provide duty, even when quite extensively fouled. Heat exchangers the world over are currently designed and installed with a view to using one of three systems for cleaning: chemical, pressure jetting and/or mechanical and this approach has remained unchanged for over 50 years.

When it comes to maintenance, refineries - like most of industry - tend to compete on the same basis - a 21-day shutdown is decreed because it's been done that way for maybe the last 20 years. The same cleaning methods are generally used slavishly, with high-pressure water as the cleaning medium.

Most companies look at their heat exchangers in isolation and simply try to extend their run-time, instead of having them designed or re-designed so they can be cleaned more regularly, but faster and better. BP's Coryton refinery, for instance, managed to reduce cleaning time on one shell-and-tube heat exchanger from three days to three hours by applying a different approach to cleaning it.

If a plant is optimised for cleaning, almost full production can be maintained throughout the cleaning process. Relatively minor mechanical changes, such as adding isolating valves to heat exchangers, means that each exchanger, or bank of exchangers, can be taken down and cleaned while the others remain on-line. A redesign of the exchanger so that a header can be removed, means it can then be cleaned with a different system to the standard high-pressure water jetting, in a few hours instead of several days.

At Dow Corning's silicone plant in Barry, south Wales, a tubular boiler and fire tube in the Energy Recovery Unit (ERU) required the removal of a 5mm layer of deposit in as short a time as possible to minimise lost production. Another obstacle was that the unit, which carries waste gases, takes 48 hours to cool and prepare - even with the introduction of a chilled nitrogen purge - before personnel can enter to clean it manually.

The solution involved developing a bespoke remote de-scaler, which was inserted through a small 50cm man-way. Once inside, the de-scaler expanded to fit the hot fire tube, while reaching the full length of the carbon steel tube. With cooling time and man entry eliminated, the shutdown was reduced from five days to three and there was a noticeable improvement in performance of the ERU when it came back on line.

Improved cleaning cycles also mean the rate of future fouling build-up is reduced, which in turn reduces the risk of tubes corroding as a result of the exchanger being open to the atmosphere longer for cleaning.

Heat exchange surfaces therefore remain smoother and provide better heat transfer. If and when the exchanger does foul up, it's easier to clean next time around, using whichever system is preferred. This would represent a change of practice to what has been the norm since the 1980s, for instance, when what was then Mobil in the UK was one of the first refineries to decide that it would extend run-times by abandoning the annual clean and only clean every two years.

Today, typical service intervals have become stretched to three and even four years in some cases, but the apparent operational savings are actually a false economy. Shareholders are indeed happy, because they are getting longer run times, while competing refineries have little choice but to play the same game or lose millions during more frequent shutdowns. Four years down the line, however, the plant will have to come down for major cleaning and maintenance and it will experience a far higher capital replacement cost than ever before.

About the Author

Regenerative Heat Exchanger $70.1 A regenerative heat exchanger, or more commonly a regenerator, is a type of heat exchanger where the flow through the heat exchanger is cyclical and periodically changes direction. It is similar to a countercurrent heat exchanger. However, a regenerator mixes the two fluid flows while a countercurrent exchanger maintains them separated. The temperature profile remains at a nearly constant temperature, and this includes the fluid entering and exiting each end.In regenerative heat exchangers, the fluid on either side of the heat exchanger is nearly always the same fluid. The fluid is cycled through the heat exchanger, often reaching high temperatures. The fluid may go through an external processing step, and then it is flowed back through the heat exchanger in the opposite direction for further processing. Usually the application will use this process cyclically or repetitively. Thus, in regenerative heat exchangers, a fluid incoming to a process is heated using the energy contained in the fluid exiting this process. Author: Surhone, Lambert M./ Timpledon, Miriam T./ Marseken, Susan F. Binding Type: Paperback Number of Pages: 88 Publication Date: 2010/07/30 Language: English Dimensions: 6.00 x 9.00 x 0.21 inches

Medline Heat Moisture Exchanger - Exchanger, Heat/Moist, w/O Filter, No Port. Case of 50 $115.91 Manufacturer: Medline. Case of 50. Heat Moisture Exchanger: This exchanger recycles exhaled humidity from a patient on every breath. No filter or port. Angled or Straight Heat Moisture Exchangers available with or without filters and ports. Electrostati

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Fundamentals of Heat Exchanger Design $194.03 No Synopsis Available

Heat Exchanger Design Handbook $311.95 No Synopsis Available

Medline Straight Heat and Moisture Exchanger with Filter and Port - Exchanger, Heat/Moist, Filter, w/Port. Case of 50 $107.42 Manufacturer: Medline. Case of 50. Straight Heat and Moisture Exchanger with Filter and Port: Bacterial/viral efficiency = 99.99%. Electrostatic media HME treated with physiologically safe calcium chloride. Luer sampling port. Humidity output = 30.4MG/H2O

Heat Exchanger Equipment Field Manual (Paperback) $183.76 From upstream to downstream, Heat Exchangers are utilized in every stage of the petroleum value stream. An integral piece of equipment, heat exchangers are among the most confusing and problematic pieces of equipment in the petroleum processing operations. This is especially true for engineers just entering the field or seasoned engineers that must keep up with the latest methods for in-shop and in-service inspection, repair, alteration and re-rating of equipment. Heat Exchanger Equipment Field Manual provides engineers and operators with an easy to understand working manual to the recent developments in heat exchanger technology and in the diagnosis and correction of operating problems. The objective of this book is to provide the reader with sufficient information to make better logical choices in designing and operating the system. Heat Exchanger Equipment Field Manual provides an indispensable means for the determination of possible failures and for the recognition of the optimization potential of the respective heat exchanger.Step-by-step procedure on how to design, perform in-shop and in-field inspections and repairs, perform alterations and re-rate equipment Select the correct heat transfer equipment for a particular applicationApply heat transfer principles to design, select and specify heat transfer equipmentEvaluate the performance of heat transfer equipment and recommend solutions to problemsControl schemes for typical heat transfer equipment application

Lasko Heat Exchanger #6101 (DS) $249.99 Infrared Quartz Element with Copper Heat Technology Heater. Multi-Function Remote Control. Digital Controls. Programmable Thermostat. 8-Hour Auto Shut-Off Timer. Built-In Safety Features: Cool-Touch Housing, Overheat Protection. 1500 Watts of Soft Comforting Warmth. 2 Heat Settings High Heat, Low Heat, Plus Auto (Thermostat Controlled). Recessed Casters for Smooth Mobility. Easy-Vacuum Filter for High Efficiency. Convenient On-Board Cord Storage. Fully Assembled ETL Listed. Save-Smart Technology. This is a Special Order item shipped directly from the manufacturer and may take up to 10 business days for delivery. This product is available online only.

Medline Angled Heat and Moisture Exchanger with Port - Exchanger, Heat/Moist, Filter, No Port. Case of 50 $104.44 Manufacturer: Medline. Case of 50. Angled Heat and Moisture Exchanger with Port: Electrostatic media HME treated with physiologically safe calcium chloride. Luer sampling port. Humidity output = 30.4MG/H2O @ VT 500ML. Resistance = 148PA @ 60LPM. VT range

Portex Thermovent 600 Heat & Moisture Exchanger, 50/cs $223.11 Features of the Portex Thermovent 600 Heat & Moisture Exchanger: Applications: Heat and passive humidification for use between patient and circuit. Can be used in anesthesia or ICU, and for some pediatric tidal volumes. Moisture Output: 27 mg H2O/L at 34°C for 500 mL tidal volume. Resistance to Flow: 2.9 cm H2O at 60 L/min. Media: Corrugated paper. Weight: 10 grams. Dead Space: 11.3 mL. Connections: 15 mm I.D. x 22 mm O.D. on patient end; 15 mm O.D. on circuit end. Latex free.

Smiths Thermovent T Heat & Moisture Exchanger, Latex Free, 50/cs $296.3 Features of the Thermovent T Heat & Moisture Exchanger: "Thermovent T" is a Heat & Moisture Exchanger (HME) which captures heat and moisture on expiration and returns it to the patient in inspiration. It is suitable for spontaneously breathing patients with a tracheostomy tube. Low profile design - Ensures maximum comfort and minimal protrusion. High performance, double paper element. An efficient heat and moisture exchanger to warm and humidify inspired air, reducing the risk of tube blockage from encrustations, with minimal resistance to flow. Lightweight - Minimizes the drag on the tracheostomy tube. Convenient oxygen delivery. Full compatibility with breathing systems.

Portex Heat and Moisture Exchanger, Standard, 40/cs $137.81 Features of the Portex Heat and Moisture Exchanger: Portex® HMEs provide efficient heat and moisture recovery. All HMEs exhibit low resistance to flow and high moisture output which helps to minimize the loss of heat and moisture in ventilated or spontaneously breathing patients. All HMEs and filters have ISO standard tapered ends to assure a consistent leak-free seal. All Portex® HMEs and filters are latex-free. Applications: Heat and passive humidification between patient and circuit with a flex tube for easier connection to endotracheal tube. HME can be used in anesthesia or ICU. Moisture Output: 30 mg H2O/L at 34°C for 500 mL tidal volume, 27 mg H2O/L at 34°C for 1000 mL tidal volume Resistance to Flow: 1.0 hPa (1.0 cm H2O) at 0.5 L/sec (30 L/min), 3.0 hPa (3.0 cm H2O) at 1.0 L/sec (60 L/min), 5.0 hPa (5.0 cm H2O) at 1.5 L/sec (90 L/min) Media: Treated open-cell foam (bacteriostatic) Weight: 13 grams Dead Space: 35 mL Connections: 15 mm I.D. x 22 mm O.D. on patient end; 15 mm O.D. on circuit end.

Portex Heat and Moisture Exchanger with Flex Tube, 20/cs $128.35 Features of the Portex Heat and Moisture Exchanger: Portex® HMEs provide efficient heat and moisture recovery. All HMEs exhibit low resistance to flow and high moisture output which helps to minimize the loss of heat and moisture in ventilated or spontaneously breathing patients. All HMEs and filters have ISO standard tapered ends to assure a consistent leak-free seal. All Portex® HMEs and filters are latex-free. Applications: Heat and passive humidification between patient and circuit with a flex tube for easier connection to endotracheal tube. HME can be used in anesthesia or ICU. Moisture Output: 30 mg H2O/L at 34°C for 500 mL tidal volume, 27 mg H2O/L at 34°C for 1000 mL tidal volume Resistance to Flow: 1.0 hPa (1.0 cm H2O) at 0.5 L/sec (30 L/min), 3.0 hPa (3.0 cm H2O) at 1.0 L/sec (60 L/min), 5.0 hPa (5.0 cm H2O) at 1.5 L/sec (90 L/min) Media: Treated open-cell foam (bacteriostatic) Weight: 27 grams Dead Space: 70 mL Connections: 15 mm I.D. x 22 mm O.D. on patient end; 15 mm O.D.

Portex Filtered Heat and Moisture Exchanger, Standard, 40/cs $166.25 Features of the Portex Filtered Heat and Moisture Exchanger: Portex® HMEs provide efficient heat and moisture recovery. All HMEs exhibit low resistance to flow and high moisture output which helps to minimize the loss of heat and moisture in ventilated or spontaneously breathing patients. All HMEs and filters have ISO standard tapered ends to assure a consistent leak-free seal. All Portex® HMEs and filters are latex-free. Applications: Heat and passive humidification with filtration between patient and circuit. Can be used in anesthesia or ICU. Filtration Efficiency: >99.9% Moisture Output: 23 mg H2O/L at 34° C for 500 mL tidal volume, 18 mg H2O/L at 34° C for 1000 mL tidal volume Resistance to Flow: 1.0 hPa (1.0 cm H2O) at 0.5 L/sec (30 L/min), 2.5 hPa (2.5 cm H2O) at 1.0 L/sec (60 L/min), 4.0 hPa (4.0 cm H2O) at 1.5 L/sec (90 L/min) Media: Open-cell foam with electrostatically charged polypropylene Method of Filtration: Electrostatic attraction, torturous path, depth Weight: 32 grams Dead Space: 44 mL Connections: 15 mm I.D. x 22 mm O.D. on patient end; 22 mm I.D. on circuit end.

Portex Thermovent T2 Heat and Moisture Exchanger, 50/cs $251.53 Features of the Portex Thermovent T2 Heat and Moisture Exchanger: Sterile, single use heat and moisture exchanger. Provides effective humidification for spontaneously breathing patients whose upper airways are bypassed by a tracheostomy tube. Device can be used for a maximum period of 24 hours. Simple opening port allows quick and easy access for a suction catheter to aid the removal of secretions. Clear housing gives an aesthetic appearance and allows visualisation of contamination. Integrated oxygen port that can provide up to 60% oxygen concentrations to the patient via the simplest of connections. Original Portex Thermovent T paper media provides high level performance heat and moisture exchange to patient. Smooth, rounded edges aids patient comfort. CE marked. Sterile. Latex free. Moisture Output: 25mg 1-1 H2O @ 15 breath/min-1 Tidal volume 500ml Resistance to Flow:0.3 hPa (cmH2O) at gas flow rate 0.5l/sec-1 (30l/min) [0.6cm H2O 1-1 sec-1]0.7 hPa (cmH2O) at gas flow rate 1.0l/sec-1 (60l/min) [0.7cm H2O 1-1 sec-1]1.2 hPa (cmH2O) at gas flow rate 1.5l/sec-1 (90l/min) [0.9cm H2O 1-1 sec-1] Dead Space: 11ml Inspired Oxygen Concentration (%):15 breath/minTidal volume 500ml O2 l/min: 1 2 3 4 5 6 7 8 9 10 O2%: 27 33 37 42 45 47 53 54 57 60

Heat Exchanger Design (2nd Edition) $324.51 Author: Fraas, Arthur P./ Fraas Binding Type: Paperback Number of Pages: 560 Publication Date: 1989/03/20 Language: English Dimensions: 8.30 x 10.90 x 1.30 inches

Heat Exchanger Design, 2nd Edition $209.63 No Synopsis Available

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Ballard Trach Heat And Moisture Exchanger, 50 per Case. Case of 50 $188.82 Manufacturer: Ballard. Case of 50. For the ambulatory, non-ventilated patient. Compliment to Qwik Clip. Features an oxygen supply port and suction access ports. Customers also search for: Discount Trach Heat And Moisture Exchanger, 50 per Case , Buy Trach

Quick Nautic Boiler B3 3012Sl 8 Gal 1200W with Heat Exchanger $576.82 Quick Nautic Boiler B3 3012SL 8 Gallon 1200W w/Heat ExchangerCasing in composite material and Tank in Aisi 316 stainless steelBenefit High quality materials. Heat exchanger with wide exchange surface. Produces hot water from the electric element that is fitted with an adjustable safety thermostat. Relief / nonreturn vale that allows discharging of the water heater in case of disuse.The features. The heat exchanger used for Quick Nautic Boiler B3 is AISI 316L stainless steel. The heat exchange capacity is notably higher than that achieved from other manufactures.. The tank is made of 1.5 mm gauge AISI 316 stainless steel welded with Argon shielding gas and hence highly resistant to corrosive agents.. The electrical heating element is made of Incoloyreg;.. The thermal insulation is high density polyurethane foam injected between the cover and tank giving excellent heat retention properties. Tank mounting brackets or wall or floormounted are stainless steel AISI 316 and are supplied as standard in each package.. Product : QUICK NAUTIC BOILER B3 3012SL 8 GAL 1200W W/HEAT EXCHANGER. Manufacturer : QUICK USA. Manufacturer Part No : FLB33012S0LVA00

Guyatone Hxm5 Heat Exchanger Overdrive Guitar Effects Pedal $249 The guyatone HXm5 Heat Exchanger Overdrive Guitar Effects Pedal uses a proprietary impedance-matching ABS Active Bypass circuit that reproduces your guitar tone with stunning accuracy. A Bypass Volume control allows HEX to operate as a pre-amp to drive your signal chain doubling the effects utility. Internal 24-volt operation allows for increased headroom and improved dynamic response making your signal the best it can be. There are three modes of operation including asymmetrical clipping that allow for a wild variety of tones from mild boost to classic distortion. Special conductive paint coating is used to improve the electrical shield and reduce noise for the rest of your effects.Proprietary impedance-matching ABS Active Bypass circuitBypass mode includes pre-amp only operationIncreased headroom and improved dynamic responseThree overdrive modes for a variety of tonesReduced noise

Portex Heat and Moisture Exchanger with Gas Sampling Port, 40/cs $121.03 Features of the Portex Heat and Moisture Exchanger: Portex® HMEs provide efficient heat and moisture recovery. All HMEs exhibit low resistance to flow and high moisture output which helps to minimize the loss of heat and moisture in ventilated or spontaneously breathing patients. All HMEs and filters have ISO standard tapered ends to assure a consistent leak-free seal. All Portex® HMEs and filters are latex-free. Applications: Heat and passive humidification between patient and circuit when gas sampling is desired. Can be used in anesthesia or ICU. Moisture Output: 30 mg H2O/L at 34°C for 500 mL tidal volume, 27 mg H2O/L at 34°C for 1000 mL tidal volume Resistance to Flow: 1.0 hPa (1.0 cm H2O) at 0.5 L/sec (30 L/min), 3.0 hPa (3.0 cm H2O) at 1.0 L/sec (60 L/min), 5.0 hPa (5.0 cm H2O) at 1.5 L/sec (90 L/min) Media: Treated open-cell foam (bacteriostatic) Weight: 13 grams Dead Space: 35 mL Connections: 15 mm I.D. x 22 mm O.D. on patient end; 15 mm O.D. on circuit end.

Authentic Optimisation Study of the Novel Compact Heat Exchanger $116.03 No Synopsis Available

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LP4X CO2 Generator with Heat Exchanger Liquid Propane 4 Burner - 12,000 BTU: J $815.15 Safety panels to avoid burning at the torch Safe, easy to use and highly energy efficient Safe electronic pilot: no manual starting button nor continuous flame Internal electronic control to avoid excessive heating and to turn off the unit in case of tipping over Heat exchanger helps keep a cooler temperature inside the greenhouse or grow room without affecting the CO2 and humidity levels Use 6 inch ducting to exhaust heat from unit. Heat exchanger may be ducted to supply heat to living space (fan suggested) without introducing CO2 Dimensions: 16.5'' D x 20.5'' H x 9.5'' W

NG4X CO2 Generator with Heat Exchanger Natural Gas 4 Burner - 12,000 BTU: J $840.65 Safety panels to avoid burning at the torch Safe, easy to use and highly energy efficient Safe electronic pilot: no manual starting button nor continuous flame Internal electronic control to avoid excessive heating and to turn off the unit in case of tipping over Heat exchanger helps keep a cooler temperature inside the greenhouse or grow room without affecting the CO2 and humidity levels Use 6 inch ducting to exhaust heat from unit. Heat exchanger may be ducted to supply heat to living space (fan suggested) without introducing CO2 Dimensions: 16.5'' D x 20.5'' H x 9.5'' W

LP8X CO2 Generator with Heat Exchanger Liquid Propane 8 Burner - 24,000 BTU: J $917.15 Safety panels to avoid burning at the torch Safe, easy to use and highly energy efficient Safe electronic pilot: no manual starting button nor continuous flame Internal electronic control to avoid excessive heating and to turn off the unit in case of tipping over Heat exchanger helps keep a cooler temperature inside the greenhouse or grow room without affecting the CO2 and humidity levels Use 6 inch ducting to exhaust heat from unit. Heat exchanger may be ducted to supply heat to living space (fan suggested) without introducing CO2 Dimensions: 16.5'' D x 20.5'' H x 9.5'' W

NG8X CO2 Generator with Heat Exchanger Natural Gas 8 Burner - 24,000 BTU: J $959.65 Safety panels to avoid burning at the torch Safe, easy to use and highly energy efficient Safe electronic pilot: no manual starting button nor continuous flame Internal electronic control to avoid excessive heating and to turn off the unit in case of tipping over Heat exchanger helps keep a cooler temperature inside the greenhouse or grow room without affecting the CO2 and humidity levels Use 6 inch ducting to exhaust heat from unit. Heat exchanger may be ducted to supply heat to living space (fan suggested) without introducing CO2 Dimensions: 16.5'' D x 20.5'' H x 9.5'' W

Portex Heat and Moisture Exchanger with Gas Sampling Port & Flex Tube, 20/cs $139.65 Features of the Portex Heat and Moisture Exchanger: Portex® HMEs provide efficient heat and moisture recovery. All HMEs exhibit low resistance to flow and high moisture output which helps to minimize the loss of heat and moisture in ventilated or spontaneously breathing patients. All HMEs and filters have ISO standard tapered ends to assure a consistent leak-free seal. All Portex® HMEs and filters are latex-free. Applications: Heat and passive humidification between patient and circuit with a flex tube for easier connection to endotracheal tube when gas sampling is desired. Can be used in anesthesia or ICU. Moisture Output: 30 mg H2O/L at 34°C for 500 mL tidal volume, 27 mg H2O/L at 34°C for 1000 mL tidal volume Resistance to Flow: 1.0 hPa (1.0 cm H2O) at 0.5 L/sec (30 L/min), 3.0 hPa (3.0 cm H2O) at 1.0 L/sec (60 L/min), 5.0 hPa (5.0 cm H2O) at 1.5 L/sec (90 L/min) Media: Treated open-cell foam (bacteriostatic) Weight: 27 grams Dead Space: 70 mL Connections: 15 mm I.D. x 22 mm O.D. on patient end. 15 mm O.D. on circuit end. Flex Tube Connection: 15 mm I.D. on one end, 22 mm I.D. on other end.