Effects of Temperature on Flow Fouling of Smooth and Nonwetting Surfaces

Mineral fouling (scaling) of heat transfer surfaces is a pervasive problem in heat exchangers, chemical reactors, and other equipment in energy, environmental, and process industrial applications. Many of the applications involve dynamic flow of fluids with the impurity minerals and, furthermore, operate at elevated temperature. Strategies to mitigate fouling under these conditions are of much value in industrial applications. This paper presents a comparative study of temperature-dependent mineral fouling deposition on smooth surfaces and nonwetting superhydrophobic and lubricant-infused surfaces under dynamic flow conditions. The surfaces are represented in a unified manner using the viscosity ratio of the infused material within the porous asperities on a surface to that of the flowing fluid such that the spectrum of surfaces from superhydrophobic to smooth is captured by the range of viscosity ratios from 0 to infinity. Using a forced convection experimental setup, deposition of calcium sulfate on the surfaces is quantified in terms of asymptotic fouling resistance over a range of temperature, Reynolds number, and mineral foulant supersaturation. Through a systematic set of accelerated fouling experiments, an empirical relationship for the asymptotic fouling resistance is developed in terms of Reynolds number, foulant concentration, temperature, and surface type. The empirical model is validated with a comprehensive set of experimental data from this study as well as from the literature. Optimum nonwetting surface designs for minimizing fouling resistance compared to conventional smooth surfaces are developed as a function of temperature. The results of the study offer insight into the temperature-dependent fouling of surfaces under flow conditions and a rational design of fouling-resistant nonwetting surfaces that can be readily translated to practice.