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Fouling is the accumulation of unwanted material on solid surfaces. The fouling materials can consist of either living organisms (
Examples of components that may be subject to fouling and the corresponding effects of fouling:
*
(Google books)
/ref> *Electrical
Scaling or precipitation fouling involves \mathsf
The calcium carbonate that forms through this reaction precipitates. Due to the temperature dependence of the reaction, and increasing volatility of CO2 with increasing temperature, the scaling is higher at the hotter outlet of the heat exchanger than at the cooler inlet.
In general, the dependence of the salt
, noselite">Coxygen">O3)2">aluminum">Al6silicon.html" ;"title="luminum.html" ;"title="oxygen.html" ;"ti ...
, noselite);
*Copper (metallic copper, cuprite, tenorite);
*Phosphates (hydroxyapatite);
*Magnetite or nickel ferrite (NiFe2O4) from extremely pure, low-iron water.
The deposition rate by precipitation is often described by the following equations:
:Transport:
:Surface crystallisation:
:Overall:
where:
: - mass of the material (per unit surface area), kg/m2
: - time, s
: - concentration of the substance in the bulk of the fluid, kg/m3
: - concentration of the substance at the interface, kg/m3
: - equilibrium concentration of the substance at the conditions of the interface, kg/m3
: -
Fouling is the accumulation of unwanted material on solid surfaces. The fouling materials can consist of either living organisms (biofouling
Biofouling or biological fouling is the accumulation of microorganisms, plants, algae, or small animals where it is not wanted on surfaces such as ship and submarine hulls, devices such as water inlets, pipework, grates, ponds, and rivers that ...
) or a non-living substance (inorganic or organic). Fouling is usually distinguished from other surface-growth phenomena in that it occurs on a surface of a component, system, or plant performing a defined and useful function and that the fouling process impedes or interferes with this function.
Other terms used in the literature to describe fouling include deposit formation, encrustation, crudding, deposition, scaling, scale formation, slagging, and sludge formation. The last six terms have a more narrow meaning than fouling within the scope of the fouling science and technology, and they also have meanings outside of this scope; therefore, they should be used with caution.
Fouling phenomena are common and diverse, ranging from fouling of ship hulls, natural surfaces in the marine environment ( marine fouling), fouling of heat-transfer components through ingredients contained in cooling water
Cooling tower and water discharge of a nuclear power plant
Water cooling is a method of heat removal from components and industrial equipment. Evaporative cooling using water is often more efficient than air cooling. Water is inexpensive and no ...
or gases, and even the development of plaque
Plaque may refer to:
Commemorations or awards
* Commemorative plaque, a plate or tablet fixed to a wall to mark an event, person, etc.
* Memorial Plaque (medallion), issued to next-of-kin of dead British military personnel after World War I
* Pla ...
or calculus
Calculus, originally called infinitesimal calculus or "the calculus of infinitesimals", is the mathematical study of continuous change, in the same way that geometry is the study of shape, and algebra is the study of generalizations of arithm ...
on teeth or deposits on solar panels on Mars, among other examples.
This article is primarily devoted to the fouling of industrial heat exchangers, although the same theory is generally applicable to other varieties of fouling. In cooling technology and other technical fields, a distinction is made between macro fouling and micro fouling. Of the two, micro fouling is the one that is usually more difficult to prevent and therefore more important.
Components subject to fouling
Examples of components that may be subject to fouling and the corresponding effects of fouling:
*Heat exchanger
A heat exchanger is a system used to transfer heat between a source and a working fluid. Heat exchangers are used in both cooling and heating processes. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contac ...
surfaces – reduces thermal efficiency, decreases heat flux, increases temperature on the hot side, decreases temperature on the cold side, induces under-deposit corrosion, increases use of cooling water;
*Piping, flow channels – reduces flow, increases pressure drop, increases upstream pressure, increases energy expenditure, may cause flow oscillations, slugging in two-phase flow, cavitation; may increase flow velocity elsewhere, may induce vibrations, may cause flow blockage;
*Ship hulls – creates additional drag, increases fuel usage, reduces maximum speed;
*Turbine
A turbine ( or ) (from the Greek , ''tyrbē'', or Latin ''turbo'', meaning vortex) is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. The work produced by a turbine can be used for generating ...
s – reduces efficiency, increases probability of failure;
*Solar panels – decreases the electrical power generated;
* Reverse osmosis membranes – increases pressure drop, increases energy expenditure, reduces flux, membrane failure (in severe cases);Siobhán Francesca E. Boerlage, "Scaling and Particulate Fouling in Membrane Filtration Systems", Taylor & Francis; 2001,(Google books)
/ref> *Electrical
heating element
A heating element converts electrical energy into heat through the process of Joule heating. Electric current through the element encounters resistance, resulting in heating of the element. Unlike the Peltier effect, this process is indepen ...
s – increases temperature of the element, increases corrosion, reduces lifespan;
*Firearm
A firearm is any type of gun designed to be readily carried and used by an individual. The term is legally defined further in different countries (see Legal definitions).
The first firearms originated in 10th-century China, when bamboo tubes ...
barrels - increases chamber pressure; hampers loading for muzzleloaders
*Nuclear fuel in pressurized water reactor
A pressurized water reactor (PWR) is a type of light-water nuclear reactor. PWRs constitute the large majority of the world's nuclear power plants (with notable exceptions being the UK, Japan and Canada). In a PWR, the primary coolant (water) i ...
s – axial offset anomaly, may need to de-rate the power plant;
*Injection/spray nozzles (e.g., a nozzle spraying a fuel into a furnace) – incorrect amount injected, malformed jet, component inefficiency, component failure;
*Venturi tube
The Venturi effect is the reduction in fluid pressure that results when a fluid flows through a constricted section (or choke) of a pipe. The Venturi effect is named after its discoverer, the 18th century Italian physicist, Giovanni Battista ...
s, orifice plate An orifice plate is a device used for measuring flow rate, for reducing pressure or for restricting flow (in the latter two cases it is often called a ').
Description
An orifice plate is a thin plate with a hole in it, which is usually placed in ...
s – inaccurate or incorrect measurement of flow rate;
*Pitot tube
A pitot ( ) tube (pitot probe) measures fluid flow velocity. It was invented by a French engineer, Henri Pitot, in the early 18th century, and was modified to its modern form in the mid-19th century by a French scientist, Henry Darcy. It ...
s in airplanes – inaccurate or incorrect indication of airplane speed;
* Spark plug electrodes in cars – engine misfiring;
*Production zone of petroleum reservoir
A petroleum reservoir or oil and gas reservoir is a subsurface accumulation of hydrocarbons contained in porous or fractured rock formations.
Such reservoirs form when kerogen (ancient plant matter) is created in surrounding rock by the presence ...
s and oil well
An oil well is a drillhole boring in Earth that is designed to bring petroleum oil hydrocarbons to the surface. Usually some natural gas is released as associated petroleum gas along with the oil. A well that is designed to produce only gas may ...
s – decreased petroleum production
The petroleum industry, also known as the oil industry or the oil patch, includes the global processes of exploration, extraction, refining, transportation (often by oil tankers and pipelines), and marketing of petroleum products. The largest ...
with time; plugging; in some cases complete stoppage of flow in a matter of days;
*Teeth – promotes tooth or gum disease, decreases aesthetics;
*Living organisms – deposition of excess minerals (e.g., calcium, iron, copper) in tissues is (sometimes controversially) linked to aging
Ageing ( BE) or aging ( AE) is the process of becoming older. The term refers mainly to humans, many other animals, and fungi, whereas for example, bacteria, perennial plants and some simple animals are potentially biologically immortal. In ...
/senescence
Senescence () or biological aging is the gradual deterioration of functional characteristics in living organisms. The word ''senescence'' can refer to either cellular senescence or to senescence of the whole organism. Organismal senescence inv ...
.
Macro fouling
Macro fouling is caused by coarse matter of either biological or inorganic origin, for example industrially producedrefuse
Waste (or wastes) are unwanted or unusable materials. Waste is any substance discarded after primary use, or is worthless, defective and of no use. A by-product, by contrast is a joint product of relatively minor economic value. A waste prod ...
. Such matter enters into the cooling water circuit through the cooling water pump
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical action, typically converted from electrical energy into hydraulic energy. Pumps can be classified into three major groups according to the method they u ...
s from sources like the open sea
The sea, connected as the world ocean or simply the ocean, is the body of salty water that covers approximately 71% of the Earth's surface. The word sea is also used to denote second-order sections of the sea, such as the Mediterranean Sea, ...
, river
A river is a natural flowing watercourse, usually freshwater, flowing towards an ocean, sea, lake or another river. In some cases, a river flows into the ground and becomes dry at the end of its course without reaching another body of wate ...
s or lake
A lake is an area filled with water, localized in a basin, surrounded by land, and distinct from any river or other outlet that serves to feed or drain the lake. Lakes lie on land and are not part of the ocean, although, like the much large ...
s. In closed circuits, like cooling tower
A cooling tower is a device that rejects waste heat to the atmosphere through the cooling of a coolant stream, usually a water stream to a lower temperature. Cooling towers may either use the evaporation of water to remove process heat an ...
s, the ingress of macro fouling into the cooling tower basin is possible through open canals or by the wind. Sometimes, parts of the cooling tower internals detach themselves and are carried into the cooling water circuit. Such substances can foul the surfaces of heat exchangers and may cause deterioration of the relevant heat transfer coefficient
In thermodynamics, the heat transfer coefficient or film coefficient, or film effectiveness, is the proportionality constant between the heat flux and the thermodynamic driving force for the flow of heat (i.e., the temperature difference, ). ...
. They may also create flow blockages, redistribute the flow inside the components, or cause fretting
Fretting refers to wear and sometimes corrosion damage of loaded surfaces in contact while they encounter small oscillatory movements tangential to the surface. Fretting is caused by adhesion of contact surface asperities, which are subsequent ...
damage.
; Examples:
*Manmade refuse;
*Detached internal parts of components;
*Tools and other "foreign objects" accidentally left after maintenance;
*Algae
Algae (; singular alga ) is an informal term for a large and diverse group of photosynthetic eukaryotic organisms. It is a polyphyletic grouping that includes species from multiple distinct clades. Included organisms range from unicellular mic ...
;
*Mussel
Mussel () is the common name used for members of several families of bivalve molluscs, from saltwater and Freshwater bivalve, freshwater habitats. These groups have in common a shell whose outline is elongated and asymmetrical compared with other ...
s;
*Leaves
A leaf (plural, : leaves) is any of the principal appendages of a vascular plant plant stem, stem, usually borne laterally aboveground and specialized for photosynthesis. Leaves are collectively called foliage, as in "autumn foliage", wh ...
, parts of plants up to entire trunks.
Micro fouling
As to micro fouling, distinctions are made between:T.R. Bott, "Fouling of Heat Exchangers (Chemical Engineering Monographs)", Elsevier Science, 1995. *Scaling or precipitation fouling, ascrystallization
Crystallization is the process by which solid forms, where the atoms or molecules are highly organized into a structure known as a crystal. Some ways by which crystals form are precipitating from a solution, freezing, or more rarely deposi ...
of solid salt
Salt is a mineral composed primarily of sodium chloride (NaCl), a chemical compound belonging to the larger class of salts; salt in the form of a natural crystalline mineral is known as rock salt or halite. Salt is present in vast quantitie ...
s, oxide
An oxide () is a chemical compound that contains at least one oxygen atom and one other element in its chemical formula. "Oxide" itself is the dianion of oxygen, an O2– (molecular) ion. with oxygen in the oxidation state of −2. Most of the E ...
s, and hydroxide
Hydroxide is a diatomic anion with chemical formula OH−. It consists of an oxygen and hydrogen atom held together by a single covalent bond, and carries a negative electric charge. It is an important but usually minor constituent of water. I ...
s from water solution
Solution may refer to:
* Solution (chemistry), a mixture where one substance is dissolved in another
* Solution (equation), in mathematics
** Numerical solution, in numerical analysis, approximate solutions within specified error bounds
* Soluti ...
s (e.g., calcium carbonate or calcium sulfate)
*Particulate
Particulates – also known as atmospheric aerosol particles, atmospheric particulate matter, particulate matter (PM) or suspended particulate matter (SPM) – are microscopic particles of solid or liquid matter suspended in the air. The te ...
fouling, i.e., accumulation of particles, typically colloidal
A colloid is a mixture in which one substance consisting of microscopically dispersed insoluble particles is suspended throughout another substance. Some definitions specify that the particles must be dispersed in a liquid, while others extend ...
particles, on a surface
*Corrosion fouling, i.e., in-situ growth of corrosion
Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...
deposits, for example, magnetite on carbon steel
Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states:
* no minimum content is specified or required for chromium, cobalt ...
surfaces
*Chemical reaction fouling, for example, decomposition or polymerization of organic matter on heating surfaces
*Solidification fouling - when components of the flowing fluid with a high-melting point freeze onto a subcooled surface
*Biofouling
Biofouling or biological fouling is the accumulation of microorganisms, plants, algae, or small animals where it is not wanted on surfaces such as ship and submarine hulls, devices such as water inlets, pipework, grates, ponds, and rivers that ...
, like settlements of bacteria
Bacteria (; singular: bacterium) are ubiquitous, mostly free-living organisms often consisting of one biological cell. They constitute a large domain of prokaryotic microorganisms. Typically a few micrometres in length, bacteria were among ...
and algae
*Composite fouling, whereby fouling involves more than one foulant or fouling mechanism
Precipitation fouling
Scaling or precipitation fouling involves crystallization
Crystallization is the process by which solid forms, where the atoms or molecules are highly organized into a structure known as a crystal. Some ways by which crystals form are precipitating from a solution, freezing, or more rarely deposi ...
of solid salt
Salt is a mineral composed primarily of sodium chloride (NaCl), a chemical compound belonging to the larger class of salts; salt in the form of a natural crystalline mineral is known as rock salt or halite. Salt is present in vast quantitie ...
s, oxide
An oxide () is a chemical compound that contains at least one oxygen atom and one other element in its chemical formula. "Oxide" itself is the dianion of oxygen, an O2– (molecular) ion. with oxygen in the oxidation state of −2. Most of the E ...
s, and hydroxide
Hydroxide is a diatomic anion with chemical formula OH−. It consists of an oxygen and hydrogen atom held together by a single covalent bond, and carries a negative electric charge. It is an important but usually minor constituent of water. I ...
s from solution
Solution may refer to:
* Solution (chemistry), a mixture where one substance is dissolved in another
* Solution (equation), in mathematics
** Numerical solution, in numerical analysis, approximate solutions within specified error bounds
* Soluti ...
s. These are most often water solutions, but non-aqueous precipitation fouling is also known. Precipitation fouling is a very common problem in boilers and heat exchangers operating with hard water
Hard water is water that has high mineral content (in contrast with "soft water"). Hard water is formed when water percolates through deposits of limestone, chalk or gypsum, which are largely made up of calcium and magnesium carbonates, bicarbo ...
and often results in limescale
Limescale is a hard, chalky deposit, consisting mainly of calcium carbonate (CaCO3). It often builds up inside kettles, boilers, and pipework, especially that for hot water. It is also often found as a similar deposit on the inner surfaces of old ...
.
Through changes in temperature, or solvent evaporation
Evaporation is a type of vaporization that occurs on the surface of a liquid as it changes into the gas phase. High concentration of the evaporating substance in the surrounding gas significantly slows down evaporation, such as when humidi ...
or degasification
Degassing, also known as degasification, is the removal of dissolved gases from liquids, especially water or aqueous solutions. There are numerous methods for removing gases from liquids.
Gases are removed for various reasons. Chemists remove ga ...
, the concentration of salts may exceed the saturation
Saturation, saturated, unsaturation or unsaturated may refer to:
Chemistry
* Saturation, a property of organic compounds referring to carbon-carbon bonds
**Saturated and unsaturated compounds
** Degree of unsaturation
**Saturated fat or fatty aci ...
, leading to a precipitation
In meteorology, precipitation is any product of the condensation of atmospheric water vapor that falls under gravitational pull from clouds. The main forms of precipitation include drizzle, rain, sleet, snow, ice pellets, graupel and hail. ...
of solids (usually crystals).
As an example, the equilibrium between the readily soluble calcium bicarbonate
Calcium bicarbonate, also called calcium hydrogencarbonate, has the chemical formula Ca(HCO3)2. The term does not refer to a known solid compound; it exists only in aqueous solution containing calcium (Ca2+), bicarbonate (), and carbonate () ions ...
- always prevailing in natural water - and the poorly soluble calcium carbonate, the following chemical equation may be written:
:solubility
In chemistry, solubility is the ability of a substance, the solute, to form a solution with another substance, the solvent. Insolubility is the opposite property, the inability of the solute to form such a solution.
The extent of the solubil ...
on temperature or presence of evaporation will often be the driving force for precipitation fouling. The important distinction is between salts with "normal" or "retrograde" dependence of solubility on temperature. Salts with the "normal" solubility increase their solubility with increasing temperature and thus will foul the cooling surfaces. Salts with "inverse" or "retrograde" solubility will foul the heating surfaces. An example of the temperature dependence of solubility is shown in the figure. Calcium sulfate is a common precipitation foulant of heating surfaces due to its retrograde solubility.
Precipitation fouling can also occur in the absence of heating or vaporization. For example, calcium sulfate decreases its solubility with decreasing pressure. This can lead to precipitation fouling of reservoirs and wells in oil fields, decreasing their productivity with time. Fouling of membranes in reverse osmosis
Reverse osmosis (RO) is a water purification process that uses a partially permeable membrane to separate ions, unwanted molecules and larger particles from drinking water. In reverse osmosis, an applied pressure is used to overcome osmotic pre ...
systems can occur due to differential solubility of barium sulfate in solutions of different ionic strength
The ionic strength of a solution is a measure of the concentration of ions in that solution. Ionic compounds, when dissolved in water, dissociate into ions. The total electrolyte concentration in solution will affect important properties such as ...
. Similarly, precipitation fouling can occur because of solubility changes induced by other factors, e.g., liquid flashing, liquid degassing, redox potential changes, or mixing of incompatible fluid streams.
The following lists some of the industrially common phases of precipitation fouling deposits observed in practice to form from aqueous solutions:
* Calcium carbonate (calcite
Calcite is a Carbonate minerals, carbonate mineral and the most stable Polymorphism (materials science), polymorph of calcium carbonate (CaCO3). It is a very common mineral, particularly as a component of limestone. Calcite defines hardness 3 on ...
, aragonite
Aragonite is a carbonate mineral, one of the three most common naturally occurring crystal forms of calcium carbonate, (the other forms being the minerals calcite and vaterite). It is formed by biological and physical processes, including prec ...
usually at t > ~50 °C, or rarely vaterite
Vaterite is a mineral, a polymorph of calcium carbonate ( Ca C O3). It was named after the German mineralogist Heinrich Vater. It is also known as mu- calcium carbonate (μ-CaCO3). Vaterite belongs to the hexagonal crystal system, whereas calc ...
);
*Calcium sulfate
Calcium sulfate (or calcium sulphate) is the inorganic compound with the formula CaSO4 and related hydrates. In the form of γ-anhydrite (the anhydrous form), it is used as a desiccant. One particular hydrate is better known as plaster of Pari ...
(anhydrite
Anhydrite, or anhydrous calcium sulfate, is a mineral with the chemical formula CaSO4. It is in the orthorhombic crystal system, with three directions of perfect cleavage parallel to the three planes of symmetry. It is not isomorphous with the ...
, hemihydrate
In chemistry, a hemihydrate (or semihydrate) is a hydrate whose solid contains one molecule of water of crystallization per two other molecules, or per two unit cell
In geometry, biology, mineralogy and solid state physics, a unit cell is ...
, gypsum
Gypsum is a soft sulfate mineral composed of calcium sulfate dihydrate, with the chemical formula . It is widely mined and is used as a fertilizer and as the main constituent in many forms of plaster, blackboard or sidewalk chalk, and drywall. ...
);
*Calcium oxalate
Calcium oxalate (in archaic terminology, oxalate of lime) is a calcium salt of oxalic acid with the chemical formula . It forms hydrates , where ''n'' varies from 1 to 3. Anhydrous and all hydrated forms are colorless or white. The monohydrate ...
(e.g., beerstone);
*Barium sulfate
Barium sulfate (or sulphate) is the inorganic compound with the chemical formula Ba SO4. It is a white crystalline solid that is odorless and insoluble in water. It occurs as the mineral barite, which is the main commercial source of barium an ...
(barite
Baryte, barite or barytes ( or ) is a mineral consisting of barium sulfate ( Ba S O4). Baryte is generally white or colorless, and is the main source of the element barium. The ''baryte group'' consists of baryte, celestine (strontium sulfate), ...
);
*Magnesium hydroxide
Magnesium hydroxide is the inorganic compound with the chemical formula Mg(OH)2. It occurs in nature as the mineral brucite. It is a white solid with low solubility in water (). Magnesium hydroxide is a common component of antacids, such as milk ...
(brucite
Brucite is the mineral form of magnesium hydroxide, with the chemical formula Mg( OH)2. It is a common alteration product of periclase in marble; a low-temperature hydrothermal vein mineral in metamorphosed limestones and chlorite schists; and ...
); magnesium oxide
Magnesium oxide ( Mg O), or magnesia, is a white hygroscopic solid mineral that occurs naturally as periclase and is a source of magnesium (see also oxide). It has an empirical formula of MgO and consists of a lattice of Mg2+ ions and O2− ions ...
(periclase
Periclase is a magnesium mineral that occurs naturally in contact metamorphic rocks and is a major component of most basic refractory bricks. It is a cubic form of magnesium oxide ( Mg O). In nature it usually forms a solid solution with wüstit ...
);
*Silicate
In chemistry, a silicate is any member of a family of polyatomic anions consisting of silicon and oxygen, usually with the general formula , where . The family includes orthosilicate (), metasilicate (), and pyrosilicate (, ). The name is al ...
s ( serpentine, acmite, gyrolite
Gyrolite, NaCa16(Si23Al)O60(OH)8·14H2O, is a rare silicate mineral (basic sodium calcium silicate hydrate: N-C-S-H, in cement chemist notation) belonging to the class of phyllosilicates. Gyrolite is also often associated with zeolites. It is mos ...
, gehlenite
Gehlenite, (Ca2Al lSiO7, is a sorosilicate, Al-rich endmember of the melilite complete solid solution series with akermanite.Deer et al., 1993
The type locality is in the Monzoni Mountains, Fassa Valley in Trentino in Italy, and is named after ...
, amorphous silica
Silicon dioxide, also known as silica, is an oxide of silicon with the chemical formula , most commonly found in nature as quartz and in various living organisms. In many parts of the world, silica is the major constituent of sand. Silica is one ...
, quartz
Quartz is a hard, crystalline mineral composed of silica (silicon dioxide). The atoms are linked in a continuous framework of SiO4 silicon-oxygen tetrahedra, with each oxygen being shared between two tetrahedra, giving an overall chemical form ...
, cristobalite
Cristobalite is a mineral polymorph of silica that is formed at very high temperatures. It has the same chemical formula as quartz, SiO2, but a distinct crystal structure. Both quartz and cristobalite are polymorphs with all the members of the ...
, pectolite
Pectolite is a white to gray mineral, Na Ca2 Si3 O8(O H), sodium calcium hydroxide inosilicate. It crystallizes in the triclinic system typically occurring in radiated or fibrous crystalline masses. It has a Mohs hardness of 4.5 to 5 and a specif ...
, xonotlite
Xonotlite, or eakleite, is a mineral of general formula named by the German mineralogist Karl Friedrich August Rammelsberg in 1866. The name originates from its discovery locality, Tetela de Xonotla, Puebla, Mexico. Although it was discovered i ...
);
*Aluminium oxide hydroxide
Aluminium hydroxide oxide or aluminium oxyhydroxide, AlO(OH) is found as one of two well defined crystalline phases, which are also known as the minerals boehmite and diaspore. The minerals are important constituents of the aluminium ore, bauxite ...
s ( boehmite, gibbsite
Gibbsite, Al(OH)3, is one of the mineral forms of aluminium hydroxide. It is often designated as γ-Al(OH)3 (but sometimes as α-Al(OH)3.). It is also sometimes called hydrargillite (or hydrargyllite).
Gibbsite is an important ore of aluminiu ...
, diaspore
Diaspore , also known as diasporite, empholite, kayserite, or tanatarite, is an aluminium oxide hydroxide mineral, α-AlO(OH), crystallizing in the orthorhombic system and isomorphous with goethite. It occurs sometimes as flattened crystals, bu ...
, corundum
Corundum is a crystalline form of aluminium oxide () typically containing traces of iron, titanium, vanadium and chromium. It is a rock-forming mineral. It is a naturally transparent material, but can have different colors depending on the pres ...
);
* Aluminosilicate
Aluminosilicate minerals ( IMA symbol: Als) are minerals composed of aluminium, silicon, and oxygen, plus countercations. They are a major component of kaolin and other clay minerals.
Andalusite, kyanite, and sillimanite are naturall ...
s (analcite
Analcime (; ) or analcite is a white, gray, or colorless tectosilicate mineral. Analcime consists of hydrated sodium aluminium silicate in cubic crystalline form. Its chemical formula is Na Al Si2 O6· H2O. Minor amounts of potassium and calci ...
, cancrinite
Cancrinite is a complex carbonate and silicate of sodium, calcium and aluminium with the formula Na6 Ca2 O3)2.html" ;"title="carbon">C Coxygen">O3)2"> O3)2">aluminum">Al6silicon.html"_;"title="luminum.html"_;"title="oxygen.html"_;"ti_...
,_noselite.html" ;"title="Coxygen">O3)2">aluminum">Al6silicon.html" ;"title="luminum.html" ;"title="oxygen.html" ;"ti ...order of reaction
In chemistry, the rate law or rate equation for a reaction is an equation that links the initial or forward reaction rate with the concentrations or pressures of the reactants and constant parameters (normally rate coefficients and partial reacti ...
for the crystallization reaction and the overall deposition process, respectively, dimensionless
: - kinetic rate constants for the transport, the surface reaction, and the overall deposition reaction, respectively; with the dimension of m/s (when )
Particulate fouling
Fouling by particles suspended in water ("crud
In computer programming, create, read, update, and delete (CRUD) are the four basic operations of persistent storage. CRUD is also sometimes used to describe user interface conventions that facilitate viewing, searching, and changing information u ...
") or in gas progresses by a mechanism different than precipitation fouling. This process is usually most important for colloidal
A colloid is a mixture in which one substance consisting of microscopically dispersed insoluble particles is suspended throughout another substance. Some definitions specify that the particles must be dispersed in a liquid, while others extend ...
particles, i.e., particles smaller than about 1 μm in at least one dimension (but which are much larger than atomic dimensions). Particles are transported to the surface by a number of mechanisms and there they can attach themselves, e.g., by flocculation
Flocculation, in the field of chemistry, is a process by which colloidal particles come out of suspension to sediment under the form of floc or flake, either spontaneously or due to the addition of a clarifying agent. The action differs from pr ...
or coagulation
Coagulation, also known as clotting, is the process by which blood changes from a liquid to a gel, forming a blood clot. It potentially results in hemostasis, the cessation of blood loss from a damaged vessel, followed by repair. The mechanism o ...
. Note that the attachment of colloidal particles typically involves electrical forces and thus the particle behaviour defies the experience from the macroscopic world. The probability of attachment is sometimes referred to as "sticking probability
The sticking probability is the probability that molecules are trapped on surfaces and adsorb chemically. From Langmuir equation, Langmuir's adsorption isotherm, molecules cannot adsorb on surfaces when the adsorption, adsorption sites are already ...
", :
:
where and are the kinetic rate constants for deposition and transport, respectively. The value of for colloidal particles is a function of both the surface chemistry, geometry, and the local thermohydraulic conditions.
An alternative to using the sticking probability is to use a kinetic attachment rate constant, assuming the first order reaction:
:
and then the transport and attachment kinetic coefficients are combined as two processes occurring in series:
:
:
where:
* is the rate of the deposition by particles, kg m−2 s−1,
* are the kinetic rate constants for deposition, m/s,
* and are the concentration of the particle foulant at the interface and in the bulk fluid, respectively; kg m−3.
Being essentially a surface chemistry
Surface science is the study of physical and chemical phenomena that occur at the interface of two phases, including solid–liquid interfaces, solid– gas interfaces, solid–vacuum interfaces, and liquid– gas interfaces. It includes the fi ...
phenomenon, this fouling mechanism can be very sensitive to factors that affect colloidal stability, e.g., zeta potential
Zeta potential is the electrical potential at the slipping plane. This plane is the interface which separates mobile fluid from fluid that remains attached to the surface.
Zeta potential is a scientific term for electrokinetic potential in coll ...
. A maximum fouling rate is usually observed when the fouling particles and the substrate exhibit opposite electrical charge, or near the point of zero charge
The point of zero charge (pzc) is generally described as the pH at which the net charge of total particle surface (i.e. absorbent's surface) is equal to zero, which concept has been introduced in the studies dealt with colloidal flocculation to e ...
of either of them.
Particles larger than those of colloidal dimensions may also foul e.g., by sedimentation ("sedimentation fouling") or straining in small-size openings.
With time, the resulting surface deposit may harden through processes collectively known as "deposit consolidation" or, colloquially, "aging".
The common particulate fouling deposits formed from aqueous suspensions include:
* iron oxides and iron oxyhydroxides (magnetite
Magnetite is a mineral and one of the main iron ores, with the chemical formula Fe2+Fe3+2O4. It is one of the oxides of iron, and is ferrimagnetic; it is attracted to a magnet and can be magnetized to become a permanent magnet itself. With the ...
, hematite
Hematite (), also spelled as haematite, is a common iron oxide compound with the formula, Fe2O3 and is widely found in rocks and soils. Hematite crystals belong to the rhombohedral lattice system which is designated the alpha polymorph of . ...
, lepidocrocite
Lepidocrocite (γ-FeO(OH)), also called esmeraldite or hydrohematite, is an iron oxide-hydroxide mineral. Lepidocrocite has an orthorhombic crystal structure, a hardness of 5, specific gravity of 4, a submetallic luster and a yellow-brown stre ...
, maghemite
Maghemite (Fe2O3, γ-Fe2O3) is a member of the family of iron oxides. It has the same spinel ferrite structure as magnetite and is also ferrimagnetic. It is sometimes spelled as "maghaemite".
''Maghemite'' can be considered as an Fe(II)-deficie ...
, goethite
Goethite (, ) is a mineral of the diaspore group, consisting of iron(III) oxide-hydroxide, specifically the "α" polymorph. It is found in soil and other low-temperature environments such as sediment. Goethite has been well known since ancient t ...
);
*Sedimentation
Sedimentation is the deposition of sediments. It takes place when particles in suspension settle out of the fluid in which they are entrained and come to rest against a barrier. This is due to their motion through the fluid in response to the ...
fouling by silt
Silt is granular material of a size between sand and clay and composed mostly of broken grains of quartz. Silt may occur as a soil (often mixed with sand or clay) or as sediment mixed in suspension with water. Silt usually has a floury feel when ...
and other relatively coarse suspended matter.
Fouling by particles from gas aerosol
An aerosol is a suspension (chemistry), suspension of fine solid particles or liquid Drop (liquid), droplets in air or another gas. Aerosols can be natural or Human impact on the environment, anthropogenic. Examples of natural aerosols are fog o ...
s is also of industrial significance. The particles can be either solid or liquid. The common examples can be fouling by flue gas
Flue gas is the gas exiting to the atmosphere via a flue, which is a pipe or channel for conveying exhaust gases from a fireplace, oven, furnace, boiler or steam generator. Quite often, the flue gas refers to the combustion exhaust gas produc ...
es, or fouling of air-cooled components by dust in air. The mechanisms are discussed in article on aerosol deposition.
Corrosion fouling
Corrosion deposits are created in-situ by the corrosion of the substrate. They are distinguished from fouling deposits, which form from material originating ex-situ. Corrosion deposits should not be confused with fouling deposits formed by ex-situ generated corrosion products. Corrosion deposits will normally have composition related to the composition of the substrate. Also, the geometry of the metal-oxide and oxide-fluid interfaces may allow practical distinction between the corrosion and fouling deposits. An example of corrosion fouling can be formation of an iron oxide or oxyhydroxide deposit from corrosion of the carbon steel underneath. Corrosion fouling should not be confused with fouling corrosion, i.e., any of the types of corrosion that may be induced by fouling.Chemical reaction fouling
Chemical reactions may occur on contact of the chemical species in the process fluid with heat transfer surfaces. In such cases, the metallic surface sometimes acts as acatalyst
Catalysis () is the process of increasing the rate of a chemical reaction by adding a substance known as a catalyst (). Catalysts are not consumed in the reaction and remain unchanged after it. If the reaction is rapid and the catalyst recyc ...
. For example, corrosion and polymerization
In polymer chemistry, polymerization (American English), or polymerisation (British English), is a process of reacting monomer, monomer molecules together in a chemical reaction to form polymer chains or three-dimensional networks. There are ...
occurs in cooling water for the chemical industry which has a minor content of hydrocarbons. Systems in petroleum processing are prone to polymerization of olefins or deposition of heavy fractions (asphaltene
Asphaltenes are molecular substances that are found in crude oil, along with resins, aromatic hydrocarbons, and saturates (i.e. saturated hydrocarbons such as alkanes). The word "asphaltene" was coined by Boussingault in 1837 when he noticed tha ...
s, waxes, etc.). High tube wall temperatures may lead to carbonizing
Carbonization is the conversion of organic matters like plants and dead animal remains into carbon through destructive distillation.
Complexity in carbonization
Carbonization is a pyrolytic reaction, therefore, is considered a complex process ...
of organic matter. The food industry, for example milk processing, also experiences fouling problems by chemical reactions.
Fouling through an ionic reaction with an evolution of an inorganic solid is commonly classified as precipitation fouling (not chemical reaction fouling).
Solidification fouling
Solidification fouling occurs when a component of the flowing fluid "freezes" onto a surface forming a solid fouling deposit. Examples may include solidification of wax (with a high melting point) from a hydrocarbon solution, or of molten ash (carried in a furnace exhaust gas) onto a heat exchanger surface. The surface needs to have a temperature below a certain threshold; therefore, it is said to be subcooled in respect to the solidification point of the foulant.Biofouling
Biofouling
Biofouling or biological fouling is the accumulation of microorganisms, plants, algae, or small animals where it is not wanted on surfaces such as ship and submarine hulls, devices such as water inlets, pipework, grates, ponds, and rivers that ...
or biological fouling is the undesirable accumulation of micro-organisms, algae and diatoms
A diatom (New Latin, Neo-Latin ''diatoma''), "a cutting through, a severance", from el, διάτομος, diátomos, "cut in half, divided equally" from el, διατέμνω, diatémno, "to cut in twain". is any member of a large group com ...
, plants, and animals on surfaces, such as ships and submarine hulls, or piping and reservoirs with untreated water. This can be accompanied by microbiologically influenced corrosion (MIC).
Bacteria can form biofilms or slimes. Thus the organisms can aggregate on surfaces using colloidal hydrogels of water and extracellular polymeric substances (EPS) (polysaccharide
Polysaccharides (), or polycarbohydrates, are the most abundant carbohydrates found in food. They are long chain polymeric carbohydrates composed of monosaccharide units bound together by glycosidic linkages. This carbohydrate can react with wa ...
s, lipids, nucleic acids, etc.). The biofilm structure is usually complex.
Bacterial fouling can occur under either aerobic (with oxygen dissolved in water) or anaerobic (no oxygen) conditions. In practice, aerobic bacteria prefer open systems, when both oxygen and nutrients are constantly delivered, often in warm and sunlit environments. Anaerobic fouling more often occurs in closed systems when sufficient nutrients are present. Examples may include sulfate-reducing bacteria
Sulfate-reducing microorganisms (SRM) or sulfate-reducing prokaryotes (SRP) are a group composed of sulfate-reducing bacteria (SRB) and sulfate-reducing archaea (SRA), both of which can perform anaerobic respiration utilizing sulfate () as termina ...
(or sulfur-reducing bacteria
Sulfur-reducing bacteria are microorganisms able to reduce elemental sulfur (S0) to hydrogen sulfide (H2S). These microbes use inorganic sulfur compounds as electron acceptors to sustain several activities such as respiration, conserving energy an ...
), which produce sulfide and often cause corrosion of ferrous metals (and other alloys). Sulfide-oxidizing bacteria (e.g., Acidithiobacillus
''Acidithiobacillus'' is a genus of the ''Acidithiobacillia'' in the " Pseudomonadota". The genus includes acidophilic organisms capable of iron and/or sulfur oxidation. Like all ''"Pseudomonadota"'', ''Acidithiobacillus'' spp. are Gram-negative ...
), on the other hand, can produce sulfuric acid, and can be involved in corrosion of concrete.
Zebra mussel
The zebra mussel (''Dreissena polymorpha'') is a small freshwater mussel. The species originates from the lakes of southern Russia and Ukraine, but has been accidentally introduced to numerous other areas and has become an invasive species in ma ...
s serve as an example of larger animals that have caused widespread fouling in North America.
Composite fouling
Composite fouling is common. This type of fouling involves more than one foulant or more than one fouling mechanism working simultaneously. The multiple foulants or mechanisms may interact with each other resulting in a synergistic fouling which is not a simple arithmetic sum of the individual components.Fouling on Mars
NASAMars Exploration Rover
NASA's Mars Exploration Rover (MER) mission was a robotic space mission involving two Mars rovers, ''Spirit (rover), Spirit'' and ''Opportunity (rover), Opportunity'', exploring the planet Mars. It began in 2003 with the launch of the two rover ...
s (Spirit
Spirit or spirits may refer to:
Liquor and other volatile liquids
* Spirits, a.k.a. liquor, distilled alcoholic drinks
* Spirit or tincture, an extract of plant or animal material dissolved in ethanol
* Volatile (especially flammable) liquids, ...
and Opportunity
Opportunity may refer to:
Places
* Opportunity, Montana, an unincorporated community, United States
* Opportunity, Nebraska, an unincorporated community, United States
* Opportunity, Washington, a former census-designated place, United States
* ...
) experienced (presumably) abiotic fouling of solar panels by dust particles from the Martian atmosphere. Some of the deposits subsequently spontaneously cleaned off. This illustrates the universal nature of the fouling phenomena.
Quantification of fouling
The most straightforward way to quantify fairly uniform fouling is by stating the average deposit surface loading, i.e., kg of deposit per m2 of surface area. The fouling rate will then be expressed in kg/m2s, and it is obtained by dividing the deposit surface loading by the effective operating time. The normalized fouling rate (also in kg/m2s) will additionally account for the concentration of the foulant in the process fluid (kg/kg) during preceding operations, and is useful for comparison of fouling rates between different systems. It is obtained by dividing the fouling rate by the foulant concentration. The fouling rate constant (m/s) can be obtained by dividing the normalized fouling rate by the mass density of the process fluid (kg/m3). Deposit thickness (μm) and porosity (%) are also often used for description of fouling amount. The relative reduction of diameter of piping or increase of the surface roughness can be of particular interest when the impact of fouling on pressure drop is of interest. In heat transfer equipment, where the primary concern is often the effect of fouling on heat transfer, fouling can be quantified by the increase of the resistance to the flow of heat (m2K/W) due to fouling (termed " fouling resistance"), or by development ofheat transfer coefficient
In thermodynamics, the heat transfer coefficient or film coefficient, or film effectiveness, is the proportionality constant between the heat flux and the thermodynamic driving force for the flow of heat (i.e., the temperature difference, ). ...
(W/m2K) with time.
If under-deposit or crevice corrosion
Crevice corrosion refers to corrosion occurring in occluded spaces such as interstices in which a stagnant solution is trapped and not renewed. These spaces are generally called crevices. Examples of crevices are gaps and contact areas between pa ...
is of primary concern, it is important to note non-uniformity of deposit thickness (e.g., deposit waviness
Waviness is the measurement of the more widely spaced component of surface texture. It is a broader view of roughness because it is more strictly defined as "the irregularities whose spacing is greater than the roughness sampling length". It can ...
), localized fouling, packing of confined regions with deposits, creation of occlusions, "crevices", "deposit tubercles", or sludge piles. Such deposit structures can create environment for underdeposit corrosion of the substrate material, e.g., intergranular attack, pitting
Pitting corrosion, or pitting, is a form of extremely localized corrosion that leads to the random creation of small holes in metal. The driving power for pitting corrosion is the depassivation of a small area, which becomes anodic (oxidation re ...
, stress corrosion cracking, or localized wastage. Porosity
Porosity or void fraction is a measure of the void (i.e. "empty") spaces in a material, and is a fraction of the volume of voids over the total volume, between 0 and 1, or as a percentage between 0% and 100%. Strictly speaking, some tests measure ...
and permeability of the deposits will likely influence the probability of underdeposit corrosion. Deposit composition can also be important - even minor components of the deposits can sometimes cause severe corrosion of the underlying metal (e.g., vanadium in deposits of fired boilers causing hot corrosion).
There is no general rule on how much deposit can be tolerated, it depends on the system. In many cases, a deposit even a few micrometers thick can be troublesome. A deposit in a millimeter-range thickness will be of concern in almost any application.
Progress of fouling with time
Deposit on a surface does not always develop steadily with time. The following fouling scenarios can be distinguished, depending on the nature of the system and the local thermohydraulic conditions at the surface: * ''Induction period
An induction period in chemical kinetics is an initial slow stage of a chemical reaction; after the induction period, the reaction accelerates. Ignoring induction periods can lead to runaway reactions.
In some catalytic reactions, a pre-catalyst n ...
'' - Sometimes, a near-nil fouling rate is observed when the surface is new or very clean. This is often observed in biofouling and precipitation fouling. After the "induction period", the fouling rate increases.
* ''"Negative" fouling'' - This can occur when fouling rate is quantified by monitoring heat transfer. Relatively small amounts of deposit can improve heat transfer, relative to clean surface, and give an appearance of "negative" fouling rate and negative total fouling amount. Negative fouling is often observed under nucleate-boiling heat-transfer conditions (deposit improves bubble nucleation) or forced-convection (if the deposit increases the surface roughness and the surface is no longer "hydraulically smooth"). After the initial period of "surface roughness control", the fouling rate usually becomes strongly positive.
* ''Linear fouling'' - The fouling rate can be steady with time. This is a common case.
* ''Falling fouling'' - In this scenario, the fouling rate decreases with time, but never drops to zero. The deposit thickness does not achieve a constant value. The progress of fouling can be often described by two numbers: the initial fouling rate (a tangent
In geometry, the tangent line (or simply tangent) to a plane curve at a given point is the straight line that "just touches" the curve at that point. Leibniz defined it as the line through a pair of infinitely close points on the curve. More ...
to the fouling curve at zero deposit loading or zero time) and the fouling rate after a long period of time (an oblique asymptote to the fouling curve).
* ''Asymptotic fouling'' - Here, the fouling rate decreases with time, until it finally reaches zero. At this point, the deposit thickness remains constant with time (a horizontal asymptote
In analytic geometry, an asymptote () of a curve is a line such that the distance between the curve and the line approaches zero as one or both of the ''x'' or ''y'' coordinates tends to infinity. In projective geometry and related context ...
). This is often the case for relatively soft or poorly adherent deposits in areas of fast flow. The asymptote is usually interpreted as the deposit loading at which the deposition rate equals the deposit removal rate.
* ''Accelerating fouling'' - In this scenario, the fouling rate increases with time; the rate of deposit buildup accelerates with time (perhaps until it becomes transport limited). Mechanistically, this scenario can develop when fouling increases the surface roughness, or when the deposit surface exhibits higher chemical propensity to fouling than the pure underlying metal.
* ''Seesaw fouling'' - Here, fouling loading generally increases with time (often assuming a generally linear or falling rate), but, when looked at in more detail, the fouling progress is periodically interrupted and takes the form of sawtooth curve. The periodic sharp variations in the apparent fouling amount often correspond to the moments of system shutdowns, startups or other transients in operation. The periodic variations are often interpreted as periodic removal of some of the deposit (perhaps deposit re-suspension due to pressure pulses, spalling due thermal stresses, or exfoliation due to redox transients). Steam blanketing has been postulated to occur between the partially spalled deposits and the heat transfer surface. However, other reasons are possible, e.g., trapping of air inside the surface deposits during shutdowns, or inaccuracy of temperature measurements during transients ("temperature streaming").
Fouling modelling
Fouling of a system can be modelled as consisting of several steps:
* Generation or ingress of the species that causes fouling ("foulant sourcing");
* Foulant transport with the stream of the process fluid (most often by advection);
* Foulant transport from the bulk of the process fluid to the fouling surface. This transport is often by molecular or turbulent-eddy diffusion, but may also occur by inertial coasting/impaction, particle interception by the surface (for particles with finite sizes), electrophoresis
Electrophoresis, from Ancient Greek ἤλεκτρον (ḗlektron, "amber") and φόρησις (phórēsis, "the act of bearing"), is the motion of dispersed particles relative to a fluid under the influence of a spatially uniform electric fie ...
, thermophoresis
Thermophoresis (also thermomigration, thermodiffusion, the Soret effect, or the Ludwig–Soret effect) is a phenomenon observed in mixtures of mobile particles where the different particle types exhibit different responses to the force of a temper ...
, diffusiophoresis
Diffusiophoresis is the spontaneous motion of colloidal particles or molecules in a fluid, induced by a concentration gradient of a different substance. In other words, it is motion of one species, A, in response to a concentration gradient in an ...
, Stefan flow (in condensation and evaporation), sedimentation
Sedimentation is the deposition of sediments. It takes place when particles in suspension settle out of the fluid in which they are entrained and come to rest against a barrier. This is due to their motion through the fluid in response to the ...
, Magnus force
The Magnus effect is an observable phenomenon commonly associated with a spinning object moving through a fluid. The path of the spinning object is deflected in a manner not present when the object is not spinning. The deflection can be expl ...
(acting on rotating particles), thermoelectric effect
The thermoelectric effect is the direct conversion of temperature differences to electric voltage and vice versa via a thermocouple. A thermoelectric device creates a voltage when there is a different temperature on each side. Conversely, when ...
, and other mechanisms.
* Induction period, i.e., a near-nil fouling rate at the initial period of fouling (observed only for some fouling mechanisms);
* Foulant crystallisation on the surface (or attachment of the colloidal particle, or chemical reaction, or bacterial growth);
* Sometimes fouling autoretardation, i.e., reduction (or potentially enhancement) of crystallisation/attachment rate due to changes in the surface conditions caused by the fouling deposit;
* Deposit dissolution (or re-entrainment of loosely attached particles);
* Deposit consolidation on the surface (e.g., through Ostwald ripening
Ostwald ripening is a phenomenon observed in solid solutions or liquid sols that describes the change of an inhomogeneous structure over time, i.e., small crystals or sol particles dissolve, and redeposit onto larger crystals or sol particles ...
or differential solubility in temperature gradient) or cementation, which account for deposit losing its porosity and becoming more tenacious with time;
* Deposit spalling, erosion wear, or exfoliation.
Deposition consists of transport to the surface and subsequent attachment. Deposit removal is either through deposit dissolution, particle re-entrainment, or deposit spalling, erosive wear, or exfoliation. Fouling results from foulant generation, foulant deposition, deposit removal, and deposit consolidation.
For the modern model of fouling involving deposition with simultaneous deposit re-entrainment and consolidation, the fouling process can be represented by the following scheme:
rate of
deposit
accumulation
=
rate of
deposition
-
rate of
re-entrainment of
unconsolidated deposit
rate of
accumulation of
unconsolidated deposit
=
rate of
deposition
-
rate of
re-entrainment of
unconsolidated deposit
-
rate of
consolidation of
unconsolidated deposit
Following the above scheme, the basic fouling equations can be written as follows (for steady-state conditions with flow, when concentration remains constant with time):
:
where:
* m is the mass loading of the deposit (consolidated and unconsolidated) on the surface (kg/m2);
* t is time (s);
* kd is the deposition rate constant (m/s);
* ρ is the fluid density (kg/m3);
* Cm - mass fraction of foulant in the fluid (kg/kg);
* λr is the re-entrainment rate constant (1/s);
* mr is the mass loading of the removable (i.e., unconsolidated) fraction of the surface deposit (kg/m2); and
* λc is the consolidation rate constant (1/s).
This system of equations can be integrated (taking that m = 0 and mr = 0 at t = 0) to the form:
:
where λ = λr + λc.
This model reproduces either linear, falling, or asymptotic fouling, depending on the relative values of k, λr, and λc. The underlying physical picture for this model is that of a two-layer deposit consisting of consolidated inner layer and loose unconsolidated outer layer. Such a bi-layer deposit is often observed in practice. The above model simplifies readily to the older model of simultaneous deposition and re-entrainment (which neglects consolidation) when λc=0. In the absence of consolidation, the asymptotic fouling is always anticipated by this older model and the fouling progress can be described as:
:
where m* is the maximum (asymptotic) mass loading of the deposit on the surface (kg/m2).
Economic and environmental importance of fouling
Fouling is ubiquitous and generates tremendous operational losses, not unlike corrosion. For example, one estimate puts the losses due to fouling of heat exchangers in industrialized nations to be about 0.25% of their GDP
Gross domestic product (GDP) is a monetary measure of the market value of all the final goods and services produced and sold (not resold) in a specific time period by countries. Due to its complex and subjective nature this measure is ofte ...
. Another analysis estimated (for 2006) the economical loss due to boiler and turbine fouling in China utilities at 4.68 billion dollars, which is about 0.169% the country GDP .
The losses initially result from impaired heat transfer, corrosion
Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...
damage (in particular under-deposit and crevice corrosion
Crevice corrosion refers to corrosion occurring in occluded spaces such as interstices in which a stagnant solution is trapped and not renewed. These spaces are generally called crevices. Examples of crevices are gaps and contact areas between pa ...
), increased pressure drop, flow blockages, flow redistribution inside components, flow instabilities, induced vibrations (possibly leading to other problems, e.g., fatigue), fretting
Fretting refers to wear and sometimes corrosion damage of loaded surfaces in contact while they encounter small oscillatory movements tangential to the surface. Fretting is caused by adhesion of contact surface asperities, which are subsequent ...
, premature failure of electrical heating elements, and a large number of other often unanticipated problems. In addition, the ecological
Ecology () is the study of the relationships between living organisms, including humans, and their physical environment. Ecology considers organisms at the individual, population, community, ecosystem, and biosphere level. Ecology overlaps wi ...
costs should be (but typically are not) considered. The ecological costs arise from the use of biocide
A biocide is defined in the European legislation as a chemical substance or microorganism intended to destroy, deter, render harmless, or exert a controlling effect on any harmful organism. The US Environmental Protection Agency (EPA) uses a slig ...
s for the avoidance of biofouling, from the increased fuel
A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work. The concept was originally applied solely to those materials capable of releasing chemical energy but ...
input to compensate for the reduced output caused by fouling, and an increased use of cooling water in once-through cooling systems.
For example, "normal" fouling at a conventionally fired 500 MW (net electrical power) power station
A power station, also referred to as a power plant and sometimes generating station or generating plant, is an industrial facility for the generation of electric power. Power stations are generally connected to an electrical grid.
Many p ...
unit accounts for output losses of the steam turbine
A steam turbine is a machine that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft. Its modern manifestation was invented by Charles Parsons in 1884. Fabrication of a modern steam turbin ...
of 5 MW and more. In a 1,300 MW nuclear power
Nuclear power is the use of nuclear reactions to produce electricity. Nuclear power can be obtained from nuclear fission, nuclear decay and nuclear fusion reactions. Presently, the vast majority of electricity from nuclear power is produced b ...
station, typical losses could be 20 MW and up (up to 100% if the station shuts down due to fouling-induced component degradation). In seawater desalination
Desalination is a process that takes away mineral components from saline water. More generally, desalination refers to the removal of salts and minerals from a target substance, as in Soil salinity control, soil desalination, which is an issue f ...
plants, fouling may reduce the gained output ratio by two-digit percentages (the gained output ratio is an equivalent that puts the mass of generated distillate in relation to the steam used in the process). The extra electrical consumption in compressor-operated coolers is also easily in the two-digit area. In addition to the operational costs, also the capital cost
Capital costs are fixed, one-time expenses incurred on the purchase of land, buildings, construction, and equipment used in the production of goods or in the rendering of services. In other words, it is the total cost needed to bring a project to a ...
increases because the heat exchangers have to be designed in larger sizes to compensate for the heat-transfer loss due to fouling. To the output losses listed above, one needs to add the cost of down-time required to inspect, clean, and repair the components (millions of dollars per day of shutdown in lost revenue in a typical power plant), and the cost of actually doing this maintenance. Finally, fouling is often a root cause of serious degradation problems that may limit the life of components or entire plants.
Fouling control
The most fundamental and usually preferred method of controlling fouling is to prevent the ingress of the fouling species into the cooling water circuit. In steam power stations and other major industrial installations ofwater
Water (chemical formula ) is an inorganic, transparent, tasteless, odorless, and nearly colorless chemical substance, which is the main constituent of Earth's hydrosphere and the fluids of all known living organisms (in which it acts as a ...
technology
Technology is the application of knowledge to reach practical goals in a specifiable and reproducible way. The word ''technology'' may also mean the product of such an endeavor. The use of technology is widely prevalent in medicine, science, ...
, macro fouling is avoided by way of pre- filtration and cooling water debris filters. Some plants employ foreign-object exclusion program (to eliminate the possibility of salient introduction of unwanted materials, e.g., forgetting tools during maintenance). Acoustic monitoring is sometimes employed to monitor for fretting by detached parts. In the case of micro fouling, water purification is achieved with extensive methods of water treatment, microfiltration
Microfiltration is a type of physical filtration process where a contaminated fluid is passed through a special pore-sized membrane filter to separate microorganisms and suspended particles from process liquid. It is commonly used in conjunction ...
, membrane
A membrane is a selective barrier; it allows some things to pass through but stops others. Such things may be molecules, ions, or other small particles. Membranes can be generally classified into synthetic membranes and biological membranes. B ...
technology (reverse osmosis
Reverse osmosis (RO) is a water purification process that uses a partially permeable membrane to separate ions, unwanted molecules and larger particles from drinking water. In reverse osmosis, an applied pressure is used to overcome osmotic pre ...
, electrodeionization
Electrodeionization (EDI) is a water treatment technology that utilizes electricity, ion exchange membranes, and resin to deionize water and separate dissolved ions (impurities) from it. It differs from other water purification technologies in ...
) or ion-exchange resins
An ion-exchange resin or ion-exchange polymer is a resin or polymer that acts as a medium for ion exchange. It is an insoluble matrix (or support structure) normally in the form of small (0.25–1.43 mm radius) microbeads, usually white or ye ...
. The generation of the corrosion products in the water piping systems is often minimized by controlling the pH of the process fluid (typically alkalinization with ammonia
Ammonia is an inorganic compound of nitrogen and hydrogen with the formula . A stable binary hydride, and the simplest pnictogen hydride, ammonia is a colourless gas with a distinct pungent smell. Biologically, it is a common nitrogenous was ...
, morpholine, ethanolamine
Ethanolamine (2-aminoethanol, monoethanolamine, ETA, or MEA) is an organic chemical compound with the formula or . The molecule is bifunctional, containing both a primary amine and a primary alcohol. Ethanolamine is a colorless, viscous liquid w ...
or sodium phosphate
Sodium phosphate is a generic term for a variety of salts of sodium (Na+) and phosphate (PO43−). Phosphate also forms families or condensed anions including di-, tri-, tetra-, and polyphosphates. Most of these salts are known in both anhyd ...
), control of oxygen dissolved in water (for example, by addition of hydrazine
Hydrazine is an inorganic compound with the chemical formula . It is a simple pnictogen hydride, and is a colourless flammable liquid with an ammonia-like odour. Hydrazine is highly toxic unless handled in solution as, for example, hydrazine ...
), or addition of corrosion inhibitor
In chemistry, a corrosion inhibitor or anti-corrosive is a chemical compound that, when added to a liquid or gas, decreases the corrosion rate of a material, typically a metal or an alloy, that comes into contact with the fluid. The effectiveness ...
s.
For water systems at relatively low temperatures, the applied biocide
A biocide is defined in the European legislation as a chemical substance or microorganism intended to destroy, deter, render harmless, or exert a controlling effect on any harmful organism. The US Environmental Protection Agency (EPA) uses a slig ...
s may be classified as follows: inorganic
In chemistry, an inorganic compound is typically a chemical compound that lacks carbon–hydrogen bonds, that is, a compound that is not an organic compound. The study of inorganic compounds is a subfield of chemistry known as '' inorganic chemist ...
chlorine
Chlorine is a chemical element with the Symbol (chemistry), symbol Cl and atomic number 17. The second-lightest of the halogens, it appears between fluorine and bromine in the periodic table and its properties are mostly intermediate betwee ...
and bromide
A bromide ion is the negatively charged form (Br−) of the element bromine, a member of the halogens group on the periodic table. Most bromides are colorless. Bromides have many practical roles, being found in anticonvulsants, flame-retardant ...
compounds, chlorine and bromide cleaver
A cleaver is a large knife that varies in its shape but usually resembles a rectangular-bladed hatchet. It is largely used as a kitchen or butcher knife and is mostly intended for splitting up large pieces of soft bones and slashing through t ...
s, ozone
Ozone (), or trioxygen, is an inorganic molecule with the chemical formula . It is a pale blue gas with a distinctively pungent smell. It is an allotrope of oxygen that is much less stable than the diatomic allotrope , breaking down in the lo ...
and oxygen
Oxygen is the chemical element with the symbol O and atomic number 8. It is a member of the chalcogen group in the periodic table, a highly reactive nonmetal, and an oxidizing agent that readily forms oxides with most elements as wel ...
cleavers, unoxidizable biocide
A biocide is defined in the European legislation as a chemical substance or microorganism intended to destroy, deter, render harmless, or exert a controlling effect on any harmful organism. The US Environmental Protection Agency (EPA) uses a slig ...
s. One of the most important unoxidizable biocides is a mixture of chloromethyl-isothiazolinone and methyl
In organic chemistry, a methyl group is an alkyl derived from methane, containing one carbon atom bonded to three hydrogen atoms, having chemical formula . In formulas, the group is often abbreviated as Me. This hydrocarbon group occurs in many ...
-isothiazolinone. Also applied are dibrom nitrilopropionamide and quaternary ammonium compounds. For underwater ship hulls bottom paint
Bottom may refer to:
Anatomy and sex
* Bottom (BDSM), the partner in a BDSM who takes the passive, receiving, or obedient role, to that of the top or dominant
* Bottom (sex), a term used by gay couples and BDSM
* Buttocks or bottom, part of t ...
s are applied.
Chemical fouling inhibitors can reduce fouling in many systems, mainly by interfering with the crystallization, attachment, or consolidation steps of the fouling process. Examples for water systems are: chelating agent
Chelation is a type of bonding of ions and molecules to metal ions. It involves the formation or presence of two or more separate coordinate bonds between a polydentate (multiple bonded) ligand and a single central metal atom. These ligands ar ...
s (for example, EDTA
Ethylenediaminetetraacetic acid (EDTA) is an aminopolycarboxylic acid with the formula H2N(CH2CO2H)2sub>2. This white, water-soluble solid is widely used to bind to iron (Fe2+/Fe3+) and calcium ions (Ca2+), forming water-soluble complexes eve ...
), long-chain aliphatic amines or polyamines (for example, octadecylamine, helamin Chemical fouling inhibitors are products that are mixtures of fouling and corrosion inhibitors use in boiler feedwater treatment. Several of these products use aliphatic polyamines to coat the surface of pipes.
Helamin
Helamin is a boiler feedwater ...
, and other "film-forming" amines), organic phosphonic acids (for example, etidronic acid
Etidronic acid, also known as etidronate, is a non-nitrogenous bisphosphonate used as a medication, detergent, water treatment, and cosmetic.
It was patented in 1966 and approved for medical use in 1977.
Use Medical
Etidronic acid is a bisph ...
), or polyelectrolyte
Polyelectrolytes are polymers whose repeating units bear an electrolyte group. Polycations and polyanions are polyelectrolytes. These groups dissociate in aqueous solutions (water), making the polymers charged. Polyelectrolyte properties are ...
s (for example, polyacrylic acid
Poly(acrylic acid) (PAA; trade name Carbomer) is a polymer with the formula (CH2-CHCO2H)n. It is a derivative of acrylic acid (CH2=CHCO2H). In addition to the homopolymers, a variety of copolymers and crosslinked polymers, and partially deproto ...
, polymethacrylic acid, usually with a molecular weight lower than 10000). For fired boilers, aluminum or magnesium additives can lower the melting point of ash and promote creation of deposits which are easier to remove. See also process chemicals
In a scientific sense, a chemical process is a method or means of somehow changing one or more chemicals or chemical compounds. Such a chemical process can occur by itself or be caused by an outside force, and involves a chemical reaction of some ...
.
Magnetic water treatment has been a subject of controversy as to its effectiveness for fouling control since the 1950s. The prevailing opinion is that it simply "does not work". Nevertheless, some studies suggest that it may be effective under some conditions to reduce buildup of calcium carbonate deposits.A. Szkatula, M. Balanda, M. Kopec, "Magnetic treatment of industrial water. Silica activation". Eur. Phys. J.Applied Physics, 1, vol. 18, p. 41-49, 200(abstract)
/ref> On the component design level, fouling can often (but not always) be minimized by maintaining a relatively high (for example, 2 m/s) and uniform fluid velocity throughout the component. Stagnant regions need to be eliminated. Components are normally overdesigned to accommodate the fouling anticipated between cleanings. However, a significant overdesign can be a design error because it may lead to increased fouling due to reduced velocities. Periodic on-line pressure pulses or backflow can be effective if the capability is carefully incorporated at the design time. Blowdown capability is always incorporated into steam generators or evaporators to control the accumulation of non-volatile impurities that cause or aggravate fouling. Low-fouling surfaces (for example, very smooth, implanted with ions, or of low surface energy like
Teflon
Polytetrafluoroethylene (PTFE) is a synthetic fluoropolymer of tetrafluoroethylene that has numerous applications. It is one of the best-known and widely applied PFAS. The commonly known brand name of PTFE-based composition is Teflon by Chemou ...
) are an option for some applications. Modern components are typically required to be designed for ease of inspection of internals and periodic cleaning. On-line fouling monitoring systems are designed for some application so that blowing or cleaning can be applied before unpredictable shutdown is necessary or damage occurs.
Chemical or mechanical cleaning processes for the removal of deposits and scales are recommended when fouling reaches the point of impacting the system performance or an onset of significant fouling-induced degradation (e.g., by corrosion). These processes comprise pickling with acid
In computer science, ACID ( atomicity, consistency, isolation, durability) is a set of properties of database transactions intended to guarantee data validity despite errors, power failures, and other mishaps. In the context of databases, a sequ ...
s and complexing agents, cleaning with high-velocity water jets ("water lancing"), recirculating ("blasting") with metal, sponge or other balls, or propelling offline mechanical "bullet-type" tube cleaners. Whereas chemical cleaning causes environmental problems through the handling, application, storage and disposal of chemicals, the mechanical cleaning by means of circulating cleaning balls or offline "bullet-type" cleaning can be an environmentally friendlier
Environment friendly processes, or environmental-friendly processes (also referred to as eco-friendly, nature-friendly, and green), are sustainability and marketing terms referring to goods and services, laws, guidelines and policies that clai ...
alternative. In some heat-transfer applications, mechanical mitigation with dynamic scraped surface heat exchanger
The dynamic scraped surface heat exchanger (DSSHE) is a type of heat exchanger used to remove or add heat to fluids, mainly foodstuffs, but also other industrial products. They have been designed to address specific problems that impede efficient h ...
s is an option. Also ultrasonic or abrasive
An abrasive is a material, often a mineral, that is used to shape or finish a workpiece through rubbing which leads to part of the workpiece being worn away by friction. While finishing a material often means polishing it to gain a smooth, reflec ...
cleaning methods are available for many specific applications.
See also
*International Convention on the Control of Harmful Anti-fouling Systems on Ships
The International Convention on the Control of Harmful Anti-fouling Systems in Ships (AFS Convention) is a 2001 International Maritime Organization (IMO) treaty whereby states agree to prohibit the use of harmful anti-fouling paints and other an ...
* Oilfield scale inhibition
* Particle deposition
Particle deposition is the spontaneous attachment of particles to surfaces. The particles in question are normally colloidal particles, while the surfaces involved may be planar, curved, or may represent particles much larger in size than the depos ...
* Steam generator (nuclear power)
Steam generators are heat exchangers used to convert water into steam from heat produced in a nuclear reactor core. They are used in pressurized water reactors (PWR) between the primary and secondary coolant loops.
In typical PWR designs, the p ...
* Tube cleaning
Tube cleaning describes the activity of, or device for, the cleaning and maintenance
Maintenance may refer to:
Biological science
* Maintenance of an organism
* Maintenance respiration
Non-technical maintenance
* Alimony, also called ...
References
{{reflist, 30emExternal links
Crude Oil Fouling research
Fouling, Filters Hydraulic engineering Transport phenomena Water technology Water treatment