Artificial-intelligence-model to optimize biocide dosing in seawater-cooled industrial process applications considering environmental, technical, energetic, and economic aspects.

This research introduces an Artificial Intelligence (AI) based model designed to concurrently optimize energy supply management, biocide dosing, and maintenance scheduling for heat exchangers. This optimization considers energetic, technical, economic, and environmental considerations. The impact of biofilm on heat exchangers is assessed, revealing a 41% reduction in thermal efficiency and a 113% increase in flow frictional resistance of the fluid compared to the initial state. Consequently, the pump's power consumption, required to maintain hydraulic conditions, rises by 9%. The newly developed AI model detects the point at which the heat exchanger's performance begins to decline due to accumulating dirt, marking day 44 of experimentation as the threshold to commence the antifouling biocide dosing. Leveraging this AI model to monitor heat exchanger efficiency represents an innovative approach to optimizing antifouling biocide dosing and reduce the environmental impact stemming from industrial plants.

Prediction of biological development effects on drag forces of ceramic hull coating using Reynolds-averaged Navier-Stokes-based solver.

Ships in service feature surfaces that exhibit biofouling, which alters the hydrodynamics of the vessels, thus affecting their normal displacement and significantly increasing their fuel consumption. The application of three types of ceramic coatings as ecological, effective and durable alternatives to commercial silicone-based marine coatings is investigated in this study. Three different ceramic glazes and two control commercial paints are analysed in an actual environment during 20 months of exposure to simulate the navigation conditions such that growth and roughness data can be obtained and then applied to computational fluid dynamics (CFD) software using an open-source Reynolds-averaged Navier-Stokes solver. The CFD results are validated under smooth hull conditions with a full-scale Kriso Container Ship (KCS) model and with different levels of hull roughness. The developed approach shows that the drag in hulls coated with conventional paint is 19% greater than that in hulls with ceramic coating.

Predicting tubular heat exchanger efficiency reduction caused by marine biofilm adhesion using CFD simulations.

A novel efficiency reduction model to tubular heat exchanger based on heat transfer losses by biofilm adhesion is proposed, which included a modified equation based on the real data-dependent time, seawater, hydrodynamics and heat transfer resistance using computational fluid dynamics (CFD). The biofilm growth model based on Verhulst model and experimental data has been obtained and simulated in a CFD software tool to analyze the tubular heat exchanger performance prediction cooled by seawater. The biofilm CFD model with appropriate fit, and the correlation coefficient (R2) values are between 0.97 and 0.99, was validated by experimental data obtained at different flow velocity. The final results of in/outlet difference temperatures were from 3.9 °C to 2.2 °C for different flow velocity with R2 > 0.97. The simulation results demonstrate that the novel CFD model is capable of predicting the efficiency losses during the development period of biofilm growth in in open-loop cooling seawater systems.

Effect of magnetic field on calcium - silica fouling and interactions in brackish water distribution systems.

Fouling growth in brackish water distribution systems (BWDS), especially calcium-silica fouling, is inevitable issue in brackish water desalination, chemical and agricultural industry, eventually threaten the cleaner production process and environment. Magnetic Field (MF) has been a greener and effective technology to control calcium carbonate fouling. However, the effects of MF on composite calcium-silica fouling are still elusive. Therefore, this paper assessed the effect of MF on calcium and silica fouling. We found that MF not only significantly reduce the calcium carbonate fouling, but also obviously decreased the silica fouling. The MF reduced the calcite fouling reached 38.2%-64.3% by changing water quality parameters to trigger the transformation rate of CaCO3 crystal from compact calcite to looser aragonite, as well as increase the unit-cell parameters and chemical bond lengths of calcite and aragonite. The MF also decreased the content of silica fouling (silica and silicate) reached 22.4-46.3% by reducing the concentration of soluble silica and accelerating the flocculation settlement to form large size solid particles in BW. Furthermore, MF broke the synergistic interactions among calcium and silica fouling. In addition, the anti-fouling ability of permanent MF was higher by 12.3-35.1% than electric MF. Overall, these findings demonstrate that MF is an effective and chemical-free technology to control calcium-silica fouling in BWDS, and provide a new perspective for sustainable application of brackish water.

CUSUM chart method for continuous monitoring of antifouling treatment of tubular heat exchangers in open-loop cooling seawater systems.

A CUSUM chart method is presented as an alternative tool for continuous monitoring of an electromagnetic field-based (EMF) antifouling (AF) treatment of a heat exchanger cooled by seawater. During an initial experimental phase, biofilm growth was allowed in a heat exchanger formed of four tubes until sufficient growth had been established. In two of the tubes, continuous EMF treatment was then applied. The heat transfer resistance and heat duty (heat transfer per unit time) results showed that biofilm adhesion was reduced by the EMF treatment. EMF treatments resulted in a 35% improvement in the heat transfer resistance values. The proposed CUSUM chart method showed that the EMF treatment increased the useful life of the heat exchanger by ∼20 days. Thus, CUSUM charts proved to be an efficient tool for continuous monitoring of an AF treatment using data collected online and can also be used to reduce operation and maintenance costs.

Impact of the surface roughness of AISI 316L stainless steel on biofilm adhesion in a seawater-cooled tubular heat exchanger-condenser.

The present study evaluated biofilm growth in AISI 316L stainless steel tubes for seawater-cooled exchanger-condensers that had four different arithmetic mean surface roughness values ranging from 0.14 µm to 1.2 µm. The results of fluid frictional resistance and heat transfer resistance regarding biofilm formation in the roughest surface showed increases of 28.2% and 19.1% respectively, compared with the smoothest surface. The biofilm thickness taken at the end of the experiment showed variations of up to 74% between the smoothest and roughest surfaces. The thermal efficiency of the heat transfer process in the tube with the roughest surface was 17.4% greater than that in the tube with the smoothest surface. The results suggest that the finish of the inner surfaces of the tubes in heat exchanger-condensers is critical for improving energy efficiency and avoiding biofilm adhesion. This may be utilised to reduce biofilm adhesion and growth in the design of heat exchanger-condensers.

Mitigation of marine biofouling on tubes of open rack vaporizers using electromagnetic fields.

This study quantitatively evaluates the antifouling action of the continuous physical treatment with electromagnetic fields (EMFs) of seawater used as heat exchanger fluid in an open rack vaporizer (ORV) pilot plant to reduce the growth of biofouling on external rib-tube surfaces. The results demonstrate that the biofilm adhered on the treated rib-tubes was reduced by 33% in thickness and by 44% in dissolved solids regarding the biofilm adhered on the untreated control rib-tubes. The lower conductivity and Ca(2+) and Mg(2+) ionic content in the effluent of the treated seawater confirmed that the EMFs accelerated the process of ionic calcium nucleation and precipitation as calcium carbonate. The precipitation of ions dissolved affected the inter-molecular interactions among extracellular polymers, thereby weakening the biofouling film matrix and reducing its adhesion capacity. The drag of small particles by the flow of seawater had an erosive action and decreased the biofouling film thickness. Consequently, the antifouling methods treatment with EMFs allowed reduce the negative effect that the biofouling have for the heat transfer equipment used in the regasification process and keep the highest techno-economic operating conditions.

Influence of flow velocity on biofilm growth in a tubular heat exchanger-condenser cooled by seawater.

The influence of flow velocity (FV) on the heat transfer process in tubes made from AISI 316L stainless steel in a heat exchanger-condenser cooled by seawater was evaluated based on the characteristics of the resulting biofilm that adhered to the internal surface of the tubes at velocities of 1, 1.2, 1.6, and 3 m s(-1). The results demonstrated that at a higher FV, despite being more compact and consistent, the biofilm was thinner with a lower concentration of solids, and smoother, which favoured the heat transfer process within the equipment. However, higher velocities increase the initial cost of the refrigerating water-pumping equipment and its energy consumption cost to compensate for the greater pressure drops produced in the tube. The velocity of 1.6 m s(-1) represented the equilibrium between the advantages and disadvantages of the variables analysed for the test conditions in this study.

The effect of electromagnetic fields on biofouling in a heat exchange system using seawater.

This article discusses the antifouling action of a continuous physical treatment process comprising the application of electromagnetic fields (EMFs) to seawater used as the refrigerant fluid in a heat exchanger-condenser to maintain the initial 'clean tube' condition. The results demonstrated that the EMFs accelerated the ionic nucleation of calcium and precipitation as calcium carbonate, which weakened the growing biofilm and reduced its adhesion capacity. Consequently, EMFs induced an erosive effect that reduced biofilm formation and fouling. This treatment allowed for the maintenance of significantly lower fouling factors in the treated tubes compared to a control group of untreated tubes, thereby leading to a higher heat transfer efficiency.

Mitigation of biofouling using electromagnetic fields in tubular heat exchangers-condensers cooled by seawater.

Electromagnetic field (EMF) treatment is presented as an alternative physical treatment for the mitigation of biofouling adhered to the tubes of a heat exchanger-condenser cooled by seawater. During an experimental phase, a fouling biofilm was allowed to grow until experimental variables indicated that its growth had stabilised. Subsequently, EMF treatment was applied to seawater to eliminate the biofilm and to maintain the achieved cleanliness. The results showed that EMFs precipitated ions dissolved in the seawater. As a consequence of the application of EMFs, erosion altered the intermolecular bonding of extracellular polymers, causing the destruction of the biofilm matrix and its detachment from the inner surface of the heat exchanger-condenser tubes. This detachment led to the partial removal of a mature biofilm and a partial recovery of the efficiency lost in the heat transfer process by using a physical treatment that is harmless to the marine environment.

Study of the activity of quaternary ammonium compounds in the mitigation of biofouling in heat exchangers-condensers cooled by seawater.

The effectiveness of two quaternary ammonium compounds (QACs) (non-oxidising biocides) to reduce the growth of biofilm adhering to the tubes of a heat exchanger-condenser cooled by seawater was evaluated. Their effectiveness was compared to that of a conventional oxidising biocide (sodium hypochlorite [NaOCl]) under the same testing conditions. Each biocide was applied intermittently (6 h on, 6 h off) in a first shock stage (1.5 ppm over 8 days) and a second stabilising stage (0.5 ppm over 20 days). The results showed that the antifouling effectiveness of the first of the QACs (fifth generation) was comparable to that shown by the oxidising power of NaOCl. Although the reaction time was longer than that of NaOCl, both the compounds removed the biofilm, and the tube was practically restored to its clean condition. Treatment with the second of the QACs (fourth generation) allowed for the stabilisation of biofilm growth, but not for its removal. Ecotoxicology studies classified the QACs as environmentally harmless under the testing conditions.

Combined monitor for direct and indirect measurement of biofouling.

Biofouling is one of the most important problems associated with heat exchangers, leading to a loss of thermal performance in their cycle. To maintain them in optimum working condition, biofouling must be kept under control and, to do so, instrumentation is required for its monitoring. The development of the biofouling layer can be qualitatively followed, but only during maintenance shutdown periods is it possible to attain a quantitative assessment. The CMDIMB [Combined Monitor for Direct and Indirect Measurement of Biofouling] was conceived as a means of discovering the evolution of the frictional resistance (f) and the heat transfer resistance (R(f)) of a fluid because these are variables that indirectly define the biofouling deposited in the tubes of a seawater-cooled heat exchanger. They likewise serve to directly indicate its mass and thickness according to the total solid matter adhered over time. The results obtained allowed the values of the variables taken by the CMDIMB to be extrapolated to the heat exchanger that was set up in parallel. The CMDIMB is proposed as a highly useful tool for directly and indirectly monitoring biofouling growth in heat exchangers that do not possess the necessary instrumentation to monitor this phenomenon.

Optimisation of biocide dose as a function of residual biocide in a heat exchanger pilot plant effluent.

Biofouling is one of the most serious problems facing numerous industrial processes. In the case of a heat exchanger unit, biological deposits adhering to the inside surface of its tubes reduce heat transfer and, thus, the thermal performance of the cycle. Control of this phenomenon is proving fundamental for both land and marine equipment to operate in optimum working conditions. Hence, it is necessary to apply antifouling methods capable of keeping surfaces free of any kind of biofouling. This paper reports on the behaviour resulting from use of the flow inversion method vs that obtained by using various chemical treatments. The study compares the effectiveness of certain chemical treatments (Na hypochlorite, peracetic acid and a compound formed by Na bromide + Na hypochlorite) for removing a biofouling film that has already formed on the inside surfaces of tubes in a heat exchanger pilot plant. The paper also addresses the issue of optimising the concentration of biocide dose as a function of the residual biocide in order minimise the environmental impact caused by effluent from industrial plants. The results indicate that it is possible to eliminate a biofilm formed on the inside surfaces of tubes by the use of intermittent doses of chemical treatments at low concentrations and over long application times. Furthermore, once the stabilisation phase is reached 6 d after starting the treatment, it is possible to maintain the conditions achieved using only 20% of the initial dosage.