1. What is Fouling Factor?

The Fouling Factor represents the additional thermal resistance caused by fouling deposits on heat transfer surfaces. It quantifies the reduction in heat transfer efficiency due to the accumulation of unwanted materials on heat exchanger surfaces.

2. How Does the Calculator Work?

The calculator uses the Fouling Factor formula:

Where:

• \( U_{dirty} \) — Overall heat transfer coefficient of fouled surface (W/m²K)
• \( U_{clean} \) — Overall heat transfer coefficient of clean surface (W/m²K)

Explanation: The formula calculates the additional thermal resistance introduced by fouling by comparing the inverse of heat transfer coefficients for clean and fouled conditions.

3. Importance of Fouling Factor Calculation

Details: Accurate fouling factor calculation is crucial for heat exchanger design, maintenance scheduling, and performance monitoring. It helps engineers account for reduced heat transfer efficiency and plan appropriate cleaning cycles.

4. Using the Calculator

Tips: Enter both U_dirty and U_clean values in W/m²K. Both values must be positive numbers greater than zero for accurate calculation.

5. Frequently Asked Questions (FAQ)

Q1: What causes fouling in heat exchangers?
A: Fouling can be caused by various factors including scaling, biological growth, corrosion products, particulate deposition, and chemical reactions on heat transfer surfaces.

Q2: What are typical fouling factor values?
A: Fouling factor values vary widely depending on the fluid, operating conditions, and fouling type, typically ranging from 0.0001 to 0.001 m²K/W.

Q3: How often should fouling factors be recalculated?
A: Fouling factors should be monitored regularly, especially after cleaning cycles or when performance degradation is observed, to maintain optimal heat exchanger efficiency.

Q4: Can negative fouling factors occur?
A: No, fouling factors should always be positive as fouling increases thermal resistance. A negative value indicates measurement error or calculation issues.

Q5: How does fouling affect heat exchanger performance?
A: Fouling reduces heat transfer efficiency, increases pressure drop, raises energy consumption, and may lead to equipment failure if not properly managed.