The work presented here is a synergistic blend between
experimentation, numerical simulations and
industrial observations into developing a novel heat exchanger
that minimises fouling while increasing the heat
transfer and lowering the pressure drop. A number of inline
tube bundle heat exchanger geometries are experimentally
and numerically studied in order to assess their
gas-side thermal, hydraulic and fouling behaviour, while
assuming that possible variations of the shape of the
inner tube surfaces will not significantly affect the study.
Three different tube shapes (namely circular, elliptic and
drop-shaped) are considered at two transverse spacings;
one of the spacings is similar to the one employed in typical
industrial heat exchangers (e.g., at the lignite utility
boilers of the Public Power Corporation of Greece,
PPC). The design methodology followed is explained
in detail and the selection of the various tube bundle
arrangements described. The heat transfer, pressure
drop and fouling characteristics of the various tube bundle
geometries are compared by means of numerical simulations
at full-scale and at the actual operating
conditions of the lignite utility boilers of PPC. This is
followed by lab-scale experiments and simulations to
give further insight into the mechanisms responsible
for the different behaviour observed. The outcome is an arrangement implementing a novel tube shape which
performs favourably well in terms of particle deposition,
heat transfer and pressure drop. This study is part of a
long-term research programme into the effects of fouling
on heat exchangers in lignite utility boilers and into
alternative techniques for process intensification and
fouling minimisation.
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