Modelling, and Optimization of Plate Type Heat Exchanger through Scaling Reduction

Abstract

Fouling in process equipment has been regarded as one of the major issues in any industry because it leads to massive loss of time, energy in the form of heat in heat transfer equipment and efficiency of the unit. Heat exchangers are of primary use in almost every industry for heat transfer applications. But with the cooling water having calcium carbonate present in it which causes scaling on heat exchanger surface, the efficiency of heat exchanger is greatly lowered because of decrease in heat transfer and cleaning is needed on a weekly basis. At ICI Soda ash plant one Plate heat exchanger is shut down for cleaning every single day and this is causing great harm to heat transfer requirement. This Project is focused on modelling of Plate heat exchanger in Aspen Exchanger Design and Rating (EDR) and optimization through manipulation of process conditions and by devising a Scale Prevention technique to reduce the cleaning requirement as this technique will mitigate the scale formation. A plate heat exchanger was designed in Aspen Exchanger Design and Rating (EDR) and then optimized it by manipulating process variables. Afterwards a scheme was devised for the process that uses scale inhibitors in water. The scale inhibitor will cause 74% inhibition and will increase the heat transfer by 20% which is lost due to fouling in heat exchanger and increases the life of heat exchanger.