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Training Program On Petroleum Refining Technology: Session 5: Fouling - Causes, Consequences and Mitigation
Training Program On Petroleum Refining Technology: Session 5: Fouling - Causes, Consequences and Mitigation
Petroleum Refining
Technology
Session 5: Fouling - Causes,
consequences and mitigation
Faculty: R. Mukherjee
Heat Transfer Consultant
New Delhi
Topics
Particulate fouling
Bio-fouling
Corrosion fouling (of tube material)
Precipitation (scaling) – cooling water
Chemical reaction fouling
Coking
Generally, several fouling mechanisms occur
at the same time, nearly always being mutually
reinforcing.
Fouling Mitigation, April 2008
R. Mukherjee
Particulate fouling
Accumulation of finely Frequently
divided solids superimposes on
suspended in the precipitation and
process fluid on to the facilitates certain
heat transfer surface types of chemical
In some instances, reaction fouling.
settling by gravity
prevails ->
sedimentation fouling
Fouling Mitigation, April 2008
R. Mukherjee
Bio-fouling (organic)
The attachment of Combines with or
macro-organisms superimposes on
and/or micro- precipitation and
organisms to a heat particulate fouling.
transfer surface, Degree varies with
along with the water source and
season.
adherent slimes often
generated by the Bacterial growth can
usually be controlled
latter. by chlorination.
Fouling Mitigation, April 2008
R. Mukherjee
Corrosion fouling
The heat transfer Heavy HC streams
surface itself reacts at temp’s of about
to produce 290C and higher
corrosion products cause corrosion of
which foul the CS tubes and other
surface and may components due to
promote the high-temperature
attachment of other sulfur corrosion.
foulants.
Nature of fluid
Fluid velocity – high velocity minimises
all modes but requires more pumping
power
Wall temperature affects scaling, bio-
fouling, chemical reaction rates
Tube material
Fouling Mitigation, April 2008
R. Mukherjee
The stages of fouling
Step 1 Initiation Delay, nucleation, induction,
incubation, surface conditioning
Step 2 Transport Mass transfer
Use floating-head or U-
tube design.
Use square or rotated
square layout.
Minimize dead spaces by
optimum baffle design.
Maintain high velocity –
use multiple shells in
series (case study follows)