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Novel Anti-Fouling Surface Treatments For Heat Exchangers

Picture for Novel Anti-Fouling Surface Treatments For Heat Exchangers
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Product Number: 51321-16734-SG
Author: Matthew A. Nakatsuka; Sumil S. Thapa; Erika P. Brown; Andrea C. Mansfeld; Vinod P. Veedu
Publication Date: 2021
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$20.00
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Seawater-fed heat exchangers are an effective and cost-efficient method of providing cooling to power plants and refineries located in coastal regions. However, utilization of untreated and unprocessed feedwater comes with its own challenges, including erosion due to sand particle impingement, microbial marine corrosion, and the buildup of biofilms and biofouling limiting the thermal heat transfer. Current methods of mitigating such effects require extensive and costly periodic maintenance, along with significant scheduled exchanger downtime. This work proposes a novel method of addressing these unique challenges through an ultra-low surface roughness treatment that can act as a protective barrier against biofilm formation and erosion, while simultaneously improving the effective heat transfer rate. The treatment contains no biocides or heavy metals, and does not slough off over time like ship hull bottom paints, minimizing its environmental impact, and allowing it to be applied at thicknesses much less than other protective coatings. Unlike traditional coatings, this surface treatment is capable of primerless application to previously in-service exchangers in-place, allowing it to be evaluated as part of an ongoing maintenance schedule, rather than be only limited to a typical factory-applied pre-installation deployment.

Seawater-fed heat exchangers are an effective and cost-efficient method of providing cooling to power plants and refineries located in coastal regions. However, utilization of untreated and unprocessed feedwater comes with its own challenges, including erosion due to sand particle impingement, microbial marine corrosion, and the buildup of biofilms and biofouling limiting the thermal heat transfer. Current methods of mitigating such effects require extensive and costly periodic maintenance, along with significant scheduled exchanger downtime. This work proposes a novel method of addressing these unique challenges through an ultra-low surface roughness treatment that can act as a protective barrier against biofilm formation and erosion, while simultaneously improving the effective heat transfer rate. The treatment contains no biocides or heavy metals, and does not slough off over time like ship hull bottom paints, minimizing its environmental impact, and allowing it to be applied at thicknesses much less than other protective coatings. Unlike traditional coatings, this surface treatment is capable of primerless application to previously in-service exchangers in-place, allowing it to be evaluated as part of an ongoing maintenance schedule, rather than be only limited to a typical factory-applied pre-installation deployment.

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Strategies to improve the heat transfer rate and efficiency of a power plant must carefully balance a trinity of factors: the overall capital expense associated with the technology, the ongoing savings during normal plant operations, and the downtime and labor required for installation and implementation. These economic concerns have slowed the adoption of protective and/or functional surface treatments in power plant operations; traditional epoxies used to prevent biofouling and scale deposition can only be applied to brand new equipment, and the coating will limit heat transfer due to its insulating nature and applied thickness. 
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