Quantum Mechanics Technology
Improving heat exchanger functionality with quantum mechanics technology to achieve net zero
A heat exchanger is a device that is used to transfer heat between a process and a cooling fluid during an industrial application . The term “ thermal management ” best describes the heat exchanger function .
Relatively simplistic in design , HE ’ s operational condition can significantly impact the day-to-day energy consumption of an industrial process and its carbon footprint . Due to phenomena such as biological fouling ( aka , biofilms ), calcium carbonate deposits ( aka , scaling ) & corrosion , cause heat exchangers to increase GHG emissions and energy expenditures .
By Robert B . Bender BS , MBA , MPTD
Heat exchangers are basic devices found in large numbers in all industries including mining , chemical production , petroleum refining , metallurgical , power generation and large commercial facilities ( educational , multi-unit dwellings , manufacturing , warehousing , etc .). Typically rugged , they are over designed to compensate for potential inefficiencies to minimize excessive downtime or diminished functionality . Exchanger parameters to be considered for optimum function are exchanger size , plate surface area and importantly , cooling water flow characteristics . Unfortunately , even though sufficient design margins are anticipated , certain conditions , such as cooling water fouling ( as seen in Figure1 ), can result in increased energy draw and thus excessive GHG . The results of this degrading functionality are expressed through reduced heat transference and increased back pressure within the cooling water system . For a heat exchanger to function efficiently , it requires clean heat transfer surfaces and unimpeded cooling water flow . Fouling occurs when contaminants within the cooling water adhere and solidify on heat transfer surfaces and in flow spaces . This condition begins immediately after a clean heat exchanger is brought online . Although not immediately apparent , as formations increase in density or dimension , there is an ever-decreasing function expressed by the exchanger . Each exchanger requires a specified cooling water volume , speed , and pressure to ensure heat extraction . This is not achieved if there is impeded flow space or misdirection away from heat transfer surfaces . Obstructions reduce flow volume which causes increased back pressure across the exchanger . Furthermore , on heat transfer surfaces , the biofilms & scaling function as thermal insulators , reducing the transfer of heat from one fluid to another . Sensors will demand greater water flow from the cooling water pump as a response to a temperature and pressure rise . To compensate , the pump increases water output necessitating increased amperage draw . This increased energy is typically from a source that uses fossil fuel combustion for electrical energy production , ergo the need for more fossil fuels , and their negative impact on our environment . Even a small , incremental rise in pump demand due to foul formation can often translate to measurable increases in GHG generation ( see Figure 1 ). There is an ever-increasing decline in function ( and corresponding increase in energy draw ) that continues until an acute condition , such as total malfunction , requires an emergency disassembly . Unfortunately , due to the importance of a heat exchanger within a process system , they are not readily taken offline to clean and are typically tolerated until and when an issue arises . Figure 1 is from one of the many papers that have indicated the relationship between heat exchanger fouling and its environmental impact [ 3 , 4 ] . The paper concluded the following : “… the presence of unwanted deposits on heat transfer surfaces in power station steam condensers can increase the discharge of greenhouse gases . The extent of the increase is of course dependent upon the thickness of
16 Heat Exchanger World March 2025 www . heat-exchanger-world . com